group presenation caterpillar
DESCRIPTION
Corrosion Prevention Products for CaterpillarTRANSCRIPT
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Group Presentation
USA, India – 3 Units, Italy, France, Thailand – Manufacturing and exports
to 25 countries globally
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About Us
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! RDM RustX USA
! 12 Years old in USA ! More than 500 customers
nationwide ! All in house manufacturing of
products
! RustX HI Tech International – Largest and oldest manufacturer of Polymers inPunjab India ! 8 Group Companies in India ! Existence since 1983
! Tecnoprimaf RustX Italy
! Bucher RustX France
! Tech Store RustX Thailand
! Mercamer RustX Finland
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q RDM RustX USA – 60,000 sq ft q Manufactures VCI packaging rolls,
bags, sheets and custom printing available
q Slits VCI papers into rolls and sheets
q Holds stocks of various oil grades
q 800 employees globally q 10000+ customers globally q 30+ Oem’s q 20+ customers in steel mills q Patents and trademarks in various
product technologies q Reach, ROHS approved q Presence in 25 countries globally
RDM RUSTX LA, USA
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! Other plants ! Italy 65000 sq ft ! Thailand 25000 sq ft ! France 25000 sq ft ! Finland warehouse 80,000
sq ft
Global Sites
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North India Plant 150,000 sq ft – 30 year old facility
Delhi Plant 50,000 sq ft, 3 years old Mumbai Plant 65,000 sq ft – 8 years old
Corporate Office Space – Upcoming by Nov 2014
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q Jaz Manak q Chairman – RDM RustX USA
q Sid Sareen –Director Technical q Honors degree holder in Polymer and Chemical Engineering Australia, EE – Harvard - USA
q Mukul Sareen – Director Business Development
q C.Knoop, Australia – Technical Assistance and Chemical Suppliers
Promoters
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Our Values
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Integrity Flexibility
Respect Innovation
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Clients
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Steel Mills
POSCO
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Claas Renault–Supplying for packaging and vendors for
over 10 Years
Tractors
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New Holland – Spare parts, exports of CBU,
SKD, CKD
Mahindra – 25,000 tractors per month
SONALIKA - Spare parts, CBU, SKD, CKD, Lubricants
and Washing Medias
Messey Ferguson– Simpsons – Packaging for
engines and parts Same Deutz– Complete
Packaging Solutions
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Trucks
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Volvo – Supplier for parts, engines, bodies and sole vendor in many units across India
Eicher – Supplier to all major vendors for rustxoils, packaging and lubricants
Mahindra Navistar – Suppliers to parts manufacturers for exports from India to USA
TATA – suppliers to various divisions making parts, vendors and for exports
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Bikes
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Suzuki – All CKD and SKD exports packed and supervised
Yamaha – All CKD and SKD exports packed and supervised
Bajaj– All vendors apply RustX oils before
despatch
Honda– All CKD and SKD exports packed
and supervised
Ducati– All parts packed in India are exported to Italy in
RustX
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q Volvo Eicher Power Train= 100% Share q Suzuki Maruti Cars = 100% Share q Slumberger = Major share in some countries q JCB = Major share in some countries q Caterpillar Aus, India and others = 100% Share q Honda MSI = 100% Share q Suzuki Motorcycle = 100% Share q CLAAS Renault I Ltd. = 100% Share q Yamaha I Ltd = 100% Share q New Holland I Ltd = 100% Share q Mahindra & Mahindra = 100% Share q Mahindra Navistar Project = 100% Share q Volvo E Commercial = 100 % Share q International Tractors Ltd = 100% Share q Tata Auto Components I Ltd. = 100% of TACO Vendors q Ashok Leyland
Business Share with OEM’S
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AQUAFLUSH
VCI Anti Corrosion products & Industrial Lubricants
Automotive Lubricants
Industrial Cleaning Agents Moisture Control Desiccants
Brands
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Rust-X provides a TOTAL solution VS
Multiple Suppliers causing Incompatibility
Solutions
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Metalworking
Washing
Aquaflush
Rust Prevention
VCI Packaging
Industrial Lubricants
RP Oils Aerosols
Plastics, Papers etc Desiccants
Rust Removal
Neutrasafe Neutralizer
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Packaging in VCI
VCI Works By q Evaporation & De-activation of
moisture
q Multi-molecuar film onto the metal q Altering the pH q Passivating the electron flow
Proprietary VCI Technology
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Fe2O3 Fe3O4 Fe Fe Fe Fe Fe
SMP Technology Speedy Moisture Passivation
q 30 second formula vs 12 hours of competition to make pH of packaging alkaline (live test available)
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q The Myth q VCI works like a sponge to absorb moisture q VCI is harmful to environment q VCI is carcinogenic
q Truth q VCI reacts with moisture to form a bond that is non reactive with Iron q RustX products are Reach approved and ROHS compliant q RustX products are recyclable
Lets squash the MYTH
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Trademark and Patents
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Papers Plastics VCI Emitters
ROHS Compliant
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ECO RUSTX
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¨ Reach approved VCI products ¨ Ecologically and biologically
friendly corrosion prevention chemicals
¨ Non carcinogenic chemicals ¨ Easy disposal ¨ Minimal consumption
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Equipment
3 Layers vs 1 Layer Plant
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Sources of Corrosion
CORROSION
VENDOR SUPPLIES
DURING MANUFACTURING
DURING STORAGE & EXPORTS
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¨ Corrosion during Supplies ¨ Improper Packaging & protection ¤ Carefree attitude –
¤ Responsibility till gate syndrome
¤ Cost Issues ¤ Concealment of corrosion –
¤ paints, coatings, grinding, rust preventives etc.
Vendor Supplies
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¨ Corrosion in Vendors Manufacturing process
¨ Shipping in open bins ¨ No use of Rust Preventives ¨ Lack of packaging knowledge ¨ Poor handling by transporter ¨ Exposure to rainfall ¨ RESPONSIBILITY TO GATE syndrome
Incoming parts
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Corrosion During Manufacturing
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Water based
washing process.
Coolants after
machining
Moisture retention
after casting
Leak testing under water
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Corrosion After machining or washing
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q Lack of knowledge of packaging q Poor Storage Facilities q Exposure to Rainfall or Acidic
Environments q Irregularity of storage periods q Under-designed Packaging Solution q Cost based decisions by suppliers
_________________________________ q Non Sea-Worthy Products q Pressure on reducing packaging costs q Knowledge issues q Water based washing q LCL Conisgnments subjected to
Rainfall
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1 Layer Plant
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q Conventional Plant q Single Layer Structure
q Less Tacky film due to lower impregnation of tacky additives
q Lower VCI Dosage q Lower Elongation due to
lesser take up q Lower production capcity q Higher Water Vapour
Emission Rates q Higher Oxygen
Transmission Rates q Higher blow holes and
puncture points
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Click to edit + ̀Container Rain
• Where is your container on the ship? • What is happening inside the container?
RUST-X
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Permeability
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Container Rain
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q Co Ex Plant q Outer Layer
q High quantity of strengthening polymers
q High corona treatment for better printing adhesion
q Middle Layer q High moisture and oxygen
barrier polymers that also give better strength and elongation
q VCI Additives for appropriate bleeding to the inner layer
q Inner Layer q VCI Additives in high proportion q High tacky additives
Co Ex Plant
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q Construction of Tuff Film q Outer layer – Moisture
Resistant film with printable surface
q Middle layer – High Density Barrier H20 & O2
q Inner Layer – VCI Film
q More VCI concentrated on the inside and can only MIGRATE towards the wrapped component
CoEx vs 1 Layer Film
Laye
r 1 La
yer 2
- B
arrie
r
Laye
r 3
q Adhesive is non controlled and bleeds more on one side
q VCI film is single Layered
q VCI can migrate to both the sides as there is no High Density barrier
1- Layer film Co Ex film
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Pores
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1 Layer cast film has higher permeability of moisture and oxygen compared
to a CO Extruded film
1 layer Co-EX Films
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Complete Knock Down (CKD)
Semi Knock Down (SKD)
Complete Build Unit (CBU)
Engine Packaging Solutions
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All CKD, SKD, CBU packed by RustX Oils, VCI Packaging, Desiccants , Emitters
CKD Packaging at Suzuki
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Heavy Equipment engines in RustX VCI, Oils and Desiccants and Emitters
Engines
VCI SMP Action starts within 1-5 minutes V/S 12 Hours of nearest competitors of placing the engine on pallet (2400% improvement).
Neutralizes the shop floor humidity stuck in the packaging very quick
Can be checked using Red Litmus Solution
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Long Block Dry Packing
Step 1 Step 2 (Wrap with VCI non Woven sheet) Step 3
Step 4 (Place in VCI Pallet Bag) Step 5
5 years Corrosion Prevention
Dry Packaging
Elimination of oiling and
washing process before painting
No Oil yet excellent protection
Step 8 ( Raincoat Bag) Global Team
Step 6 ( Desiccants + Emitter Combo)
Step 7 ( Heat Sealing)
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q Aluminum Foil Packaging for Heavy machines
q Spray RP Oil on the non painted parts
q Add Desiccants and Emitters q Heat Sealing q Vacuuming
Aluminum Barrier Film
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q Only manufacturers in the world to provide Aluminum Foil with VCI in the inner layer
q No extra VCI film or papers required before using Aluminum Film
q Saves at least 30% cost and time.
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Shrink Packaging
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q Shrink Packaging for Heavy machines and equipment's
q Spray RP Oil on the non painted parts
q Add Desiccants and Emitters q Heat Shrinking q No Vacuuming Required
q Only manufacturers in the world to provide 3 Layer shrink with outer white and inner blue with VCI
q No extra VCI film or papers required before using Aluminum Film
q Saves at least 30% cost and time.
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q Step 1 Dress the poly bag to individual fitment
Crankshaft Packaging
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q Place the bottom fitment ( 1st Layer ) and dress the VCI bag over the fitment
q Place 3 parts in to the given slot ( Refer the images ) q Seal the VCI bag properly
Step 2
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• Put the another fitment dressed with poly bag & Dress the common VCI bag from out side
• Repeat the same up to 3rd Layer • Seal the VCI bag properly
Step 3
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q Strap the complete pallet with Pet strap
Step 4
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q Place raincoat cover and ready for export
Step 6
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For open storages
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q TUFFPAULIN - HIGH STRENGTH UV PROOF COVERS
Tuffpaulin
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q Heavy equipment packaging
Tuffpaulin
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Castings
Forgings
Sheet Metal Parts
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q Process q Place VCI Bag in pallet q Place support separators of Styrofoam, wood or corrugation covered with plastic q Place components after oiling with RustX VCI Oil q Heat seal the bag
Forgings / Castings Master Packaging
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q Advantages q No individual packing of big parts q Dry to touch oils , so no cleaning required before assembly q Engine oil compatible rust prevention products – No contamination q Saves time of packaging and un-packaging
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q Forgings and castings packed in VCI Paper or VCI Plastics
q Placed in VCI Master bags q Place desiccants and
emitters in pallet q Heat the Master VCI bag
Other Packaging's
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q Provides long term corrosion prevention of upto 5 years
q For parts requiring custom packaging, custom vci bags with or without zip available
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Rust Removers
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q Observe the rust being removed and extracted into the liquid by the q Changing colour of the liquid from transparent to yellowish brown q 5-15 minutes required to convert complete corrosion
Rust Remover used on Castings
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q 2mm thick steel after
Rust Remover
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q 2mm thick steel before
Rust Remover
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q No effect on Copper only the rust is removed within 3-4 minutes
Rust Remover
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q 6 month old component q Rust Removed in 3 minutes
Sheet Metal
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q Holographic packaging for spares
Spare Parts
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Steel Mills
Coil Packaging Automated
Coil Packaging Manual
Sheet Packaging Manual
Steel Rods Packaging
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Automated Coil Packing using VCI Stretch
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1. Cross Linked Polymers for Higher Tensile Strength
Advantages of RUSTX Films
2. Highly tacky stretch films for higher adhesion
Fe
4.) Co – Extrusion Film for better elongation and strength
Layer 1
Layer 2 - Barrier
Layer 3
3. Patented SMP VCI Technology for upto 5 years protection
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Demonstrable Proprietary technology provides higher strength in low gauge films
q Type of Polymers used distinguish a film q Cross Linking increase functional strength q A film made on a Co Ex plant is 30% stronger than
made on 1 layer plant or cast line q Better polymers with lower MFI are used to
strengthen a film
q VCI additive in the inner film maintain a ph of 8-9 inside the packaging
q Tackiness on both outer and inner enable better adhesion of the film layers
q High elongation up to 900% results in lesser tearing at the edges.
Specialty of RustX Films
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Multi Colour Printing
q RustX films can be printed to upto 6 colours on roto gravuere machines
q All printing is done free of cost
q I.E. make your brand visible to many people
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q Moisture during transportation – 100% RH with Temp of 45 - 48 C
q Breathing of the Packaging – Changes in Temperature & Volume of Air
q Removal Of Oil from the surface by absorption
q Absorption of Humidity or water retention by Interleaving Paper
q Rainfall during transportation
q Improper Storage Conditions
Causes of Rust
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q Snow causing seepage of water inside the coils
q Poor tacky adhesives can lead to gaps
q Poor VCI is a major cause of non neutral environment in packaging
q Rain Water, water at ports or sea can seep through the edge of protectors
Only a good quality tacky stretch can result in tightly
wrapped coil
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Causes of Rust
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q Poor Stretch wrapping causing moisture to go inside packaging
Causes of Rust
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Navy and Army
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q VCI Shrink Packaging with outer white and inner VCI Shrink
Aircraft and Marine Preservation
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q VCI Zipper pouches in LDPE and Aluminum Bags
q Ammunition without VCI protection
Ammunition Packaging
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Cutting Oils
Rust Preventive Coolant Additives
Lubricants
Chemicals
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q Water based cutting oil 5% in concentration to be used in CNC/VMC/HMC Machines
q 6-12 months tank life q Biocides present for good bacteria to eat bad bacteria to keep tank foul free q Rust Preventives added for upto 7-15 days corrosion prevention after
machining q More lubricity (oil viscosity 50cst) for better surface finish q Low cost per gallon and cost per component
Cutting Oil
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q Water based washing
q 3% conc in water
q Millipore values less than 2
q Heating may or may not be required
q No corrosion for upto 5 days after washing
q Non flammable
q Biologically friendly
Aquaflush
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Batch Cleaning
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RPA4500
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q Neutrasafe
q Neutral rust remover
q Non Acidic
q Safe for eco and bio
q Patented product
q Converts rust to metal in 5-10 minutes
q No mechanical action required
Rust Removers
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q Observe the rust being removed and extracted into the liquid by the q Changing colour of the liquid from transparent to yellowish brown q 5-15 minutes required to convert complete corrosion
Rust Remover used on Castings
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