search - november 2010

Search November 2010 Ad Name: Omron Pg. 5

Search November 2010 Ad Name: Allied Pg. 6

Search November 2010 Ad Name: Pedilite Pg. 7

Search November 2010 Ad Name: Allied Pg. 6

www.eibc.in

Regd Office : KolkataTel: +91 33-4013 9200Email: [email protected]

Mumbai Office :Tel: +91 22-4093 9200Email: [email protected]

Ahmedabad Office :Tel: +91 79-3002 7490Email: [email protected]

Bangalore Office :Tel: +91 80-2227 9295Email: [email protected]

Bhubneshwar Office :Tel: +91 674-3246 544Email: [email protected]

EAST INDIA BEARING CO. (P) LTD.

Largest Bearing Distributor in India

APartnerAsCloseTo YouAsYouAre.

Also at : Delhi, Surat, Jamnagar, Bellary, Gandhidham & Durgapur

N O V E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 25

EDITORIAL

Archana [email protected]

o, we are not debating the fact that we need to be practical in life. This expression is to define and describe this edition. Practical, easy-to-imbibe tips & tricks from shop floor to strategies is the essence of this edition.

The Industry Update on Hydraulics & Pneumatics is the case in point. Like the Hose Vs Tube article, which talks about the constant debate over whether hydraulic hoses should be used in hydraulic equipment or if

hydraulic tubing is the best option? It is complete with instructions to select the appropriate hydraulic pump. The hydraulics rebuild story talks about rebuilding of hydraulics equipment – which involves replacing the necessary parts that would enable it to last long and function like a new one – and how important it is for a user to decipher whether to spend money on rebuilding an equipment rather than purchasing a new one.

Staying with the practical and application-oriented flavour of this edition, the Easy Steps to Maintain Hydraulic Equipment is every maintenance engineer’s delight! Then again, the green technology benefit that Parallel Hydraulic Hybrids offer is a pragmatic green technology option that is highly viable. An in-depth analysis on the same is a must read.

Graduating from being practical to gauging ‘What’s Next In Hydraulics,’ provides insights into how the hydraulics segment has been at the threshold of progress over the years. It sums up with yet again some ‘must follow’ practical tips on the most common hydraulics equipment handling mistakes.

And since hydraulics is here, can we miss not talking about pneumatics? Taking the green angle to the industry, this article discusses conservation of energy by improving the efficiency of pneumatic systems. The article provides numerous opportunities for savings as a result of a high leak load, intermittent demand and tubing size reduction. As is the norm of this issue, it concludes with the best practices in these areas to ensure huge returns from pneumatic equipment, be it money or energy.

And saving the best for the last, a section on Smart Manufacturing, which is a prelude of sorts for our MEGA 13th anniversary issue come January, is what the future beholds. Smart manufacturing will deliver an extraordinary shift in the competitive landscape of Indian manufacturing. Flexible factories and IT-optimised future factories will transform manufacturing processes. It will also allow manufacturers to customise products to suit individual needs. This most dramatic, and competitively vital, smart manufacturing will neither be incremental nor show gradual changes, but it will demonstrate game-changing, market-disruptive innovations in products and processes.

In a nutshell, to strengthen our global competitiveness quotient, we must invest in applied research and innovation centres for smart manufacturing, and gear up to grab the top slot in the profoundly changed market realities, which this decade promises to bring.

So here’s summing the issue for you. Read it, relish it and implement it in your businesses…that will be the most practical thing to do!

LET’S BE PRACTICAL

N

Printed by Mohan Gajria and published & edited by Lakshmi Narasimhan on behalf of Infomedia 18 Limited and printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J. K. Sawant Marg, Dadar (W), Mumbai - 400 028.

SEARCH - The Industrial Sourcebook is registered with the Registrar of Newspapers of India under No. 67827/98. Views and opinions expressed in this publication are not necessarily those of Infomedia 18 Limited. Infomedia 18 Limited reserves the right to use the information published herein in any manner whatsoever. While every effort has been made to ensure accuracy of the information published in this edition, neither Infomedia 18 Ltd nor any of its employees accept any responsibility for any errors or omission. Further, Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. No part of this publication may be reproduced in any form without the written permission of the publisher. All rights reserved.

Executive EditorArchana Tiwari-Nayudu

Features EditorPrerna Sharma

Senior Features WriterSumedha Mahorey

Senior CorrespondentShivani Mody (Bengaluru)

Features WriterSandeep Pai, Sudhir Muddana, Purna Parmar, KTP Radhika Jinoy (Delhi)

CorrespondentGeetha Jayaraman (Delhi)

Copy DeskMarcilin Madathil

Products DeskMichael Anthony

Infomedia 18 Limited, Special Interest Publications Division, ‘A’ Wing, Ruby House, J. K. Sawant Marg, Dadar (W), Mumbai - 400 028, India

Tel: +91-22-30245000, Fax: +91-22-30034499 [email protected]

EDITORIAL

DESIGN & PRODUCTIONAssistant Art Director

Varuna Naik

Design TeamSanjay Dalvi, Uttam Rane

Production DeskDnyaneshwar Goythale, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Akshata Rane,

Ravikumar Potdar, Sanjay Shelar, Abhay Borkar

Marketing & BrandingJagruti Shah, Ganesh Mahale, Prachi Mutha, Avinash Bhakre, Shibani Gharat

BUSINESS OFFICESAhmedabad (Shashin): Tel: 079-39826432 Fax: 079-39826464 [email protected]

Bengaluru (Mahadev B): Tel: 080-30010900 Fax: 080-30010999 [email protected] Chennai (Hari): Tel: 044-39864200 Fax: 044-39864250 [email protected]

Cochin (Robin): Tel: 0484-4054380 Fax: 0484-4054370 [email protected] (Prakash): Tel: 0422-3092600 Fax: 0422-3092666 [email protected]

Hyderabad (Kalyan): Tel: 040-30647600 Fax: 040-30647676 [email protected] (Ameya): Tel: 0731-3074876 Fax: 0731-3074882 [email protected]

Jaipur (Durgesh): Tel: 0141- 3007414 Fax: 0141-2213728 [email protected] Kolkata (Deb Ranjan): Tel: 033-2265 8637 Fax: 033-2265 2964 [email protected]

Ludhiana (Jasmeet): Tel: 0161-3026198 Fax: 0161-3026198 [email protected] (Rahul): Tel: 022-30034640 Fax: 022-30034499 [email protected]

New Delhi (Jhuma/Mukesh): Tel: 011-66303278 Fax: 011-23327884 [email protected] (Rohit): Tel: 020-66031234 Fax: 020-66010486 [email protected]

Surat (Sunil): Tel: 0261-2630181 Fax: 0261-2630974 [email protected] (Samarth): Tel: 0265-3926500 Fax: 0265-2356013 [email protected]

CIRCULATION/SUBSCRIPTIONSunder Thiyagarajan, General Manager

[email protected], [email protected]

Ringier Trade Media Ltd

CHINA: 1001 Tower 3, Donghai Plaza, 1486 Nanjing Road, West, Shanghai 200040, China

Tel: +86-21 6289 – 5533 Ext. 368, Fax: +86-21 6247 – 4855 [email protected]

HONG KONG: Unit 401-5, 4/F, New Victory House, 93-103 Wing Lok Street, Sheung Wan, Hong Kong

Tel: +852 2369 – 8788 Ext. 19, Fax: +852 2369 – 5919 [email protected]

TAIWAN: Room 3, Fl. 12, No. 303, Chung Ming S. Rd., Taichung, Taiwan

Tel: +886-4 2329 – 7318 Ext. 16, Fax: +886-4 2310 – 7167 [email protected]

OVERSEAS CONTACT

CORPORATEAssociate Vice President

Sudhanva Jategaonkar

• Monthly Issue Price: Rs 100 • Annual Subscription: Rs 799

26 SEARCH - THE INDUSTRIAL SOURCEBOOK | N O V E M B E R 2 0 1 0

‘Hydraulics Capabilities Improve ShopfloorProductivity’SHYAM KAMBEYANDA, President – APAC, Hydraulics Group, Eaton Corporation

MANUFACTURING ZONE

CONTENTS

Pg 54

SMART MANUFACTURING | Pg 100

A Blueprint to

GenX Manufacturing

VIEW FROM THE TOP

Aptly responding to fast changing global consumers’ demands with the right set of variety and quality is any manufacturers dream in this cut-throat competitive era. The use of smart manufacturing practices enables a manufacturer to plan and prepare beforehand with the use of the right set of technology, planning and design tools making him flexible to cater to the ever-evolving volatile markets.

106 National Manufacturing Investment Zones Propelling Manufacturing Growth

38 NATIONAL NEWSLatest In The Indian Manufacturing

25 EDITORIALLet’s Be Practical

48 WORLD NEWSSnapshot Of Latest Global Happenings In Manufacturing Domain

TECHNOLOGY TRENDS116 Technology Update Cutting Edge Solutions

NEWS ANALYSIS44 Metal Industry Illuminating With Radiant Prospects

RENEWABLE MILESTONES120 Offshore Wind Farm Attaining Remarkable Feat In Offshore Power Generation

APPLICATION ZONE124 Mechatronic Systems Smart Solutions To Complex Problems

EQUIPMENT BUYING GUIDE130 Energy-efficient Motors Embracing The Green Solution

DESIGN INNOVATION136 Global Design And Manufacturing Partnerships Collaborating For Success

VIEW POINT112 Energy Security The Future Is Green


PRODUCT UPDATE

CONTENTSSPECIALS IN THIS ISSUE

233 PRODUCT INQUIRY FORM For Product Inquiries Showcased In This Issue, Fill In The Form And Send It Back To Us

248 PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

255 ADVERTISEMENT INQUIRY FORM Get In Touch With Supplier Of Products You Wish To Buy

260 ADVERTISERS’ LIST Advertisers’ List In Chronological Order

PRODUCT UPDATE168 Hydraulics Latest Products In Hydraulics

184 Industrial Paints & Polishes Latest Products In Industrial Paints & Polishes

192 New Launches Latest Products In The Offing

202 General Products Rolling Out The Best-in-class

SMART STRATEGIES141 Industrial Equipment Segment

Challenged, Transformed & Poised For Growth

SME ADVANTAGE154 Technological Innovation Road To Perpetual Growth

FACTORY FUNDAMENTALS146 Drive & Control Integrating Safety Into Workplace

CURTAIN RAISER160 Engineering Expo Pune 2010 The Euphoria Begins

REPORT164 Electronica + Productronica INDIA 2010 Charging Up For Growth

166 National Seminar On Challenges In Transmission & Distribution Driving Efficiency Through Automation

240 International Products Showcasing Product In A Global Arena

PREVIEW144 HiTech Material Handling Show Inspiring Innovations152 ENGINEERING EXPO Engineering Expo Ahmedabad 2010-11 Flying High With Bright Prospects

INDUSTRY UPDATEHydraulics & Pneumatics

62 Parallel Hydraulic Hybrid Systems Gaining A ‘Green’ Edge

69 Hydraulic Equipment: Hose Vs. Tube Taking The Right Call

74 Hydraulic Rebuilds Hauling Monetary Gains

INSIGHTS & OUTLOOKIndustrial Paints & Polishes

90 Paints & Polishes ‘Coated’ With Vibrant

Opportunities

96 IR Heating Technology Offering Innovative Solutions For

Paint Drying & Curing

Details on pg.203, 213, 223

78 Pneumatic Systems Compressing Energy Consumption

82 Trends & Toolkit Gauging What’s Next In Hydraulics

87 Case Study Eaton Hydraulic Motor - Speeding

Operations, Maximising Output

88 TIPS & TRICKS

NATIONAL NEWS


ndia has an ambitious plan to reach a nuclear power capacity of

63,000 MW by 2032. This is said to be done by setting up 16 indigenous Pressurised Heavy Water Reactors (PHWR) each, including 10 based on reprocessed uranium. “Of the total target of 63,000 MW, about 40,000 MW will be generated through light water reactors (LWR) with cooperation from the overseas,” said SK Jain, CMD,

NPCIL. He also said that by 2032, India would export 220 MW, 540 MW and 700 MW PHWRs. Beyond 2032, large capacity addition would be taken up by setting up metallic fuel fast breeder reactors (FBRs) and introduction of reactors based on Thorium-232 and Uranium-233 fuel cycle. According to Jain, currently, India is in a position to set up its export model 220 MW PHWR in friendly countries.

“Countries with existing nuclear power projects and

expansion plans have to face key challenges such as continued efforts in achieving enhanced safety and reliability in the existing and future nuclear power projects,” he said. Other challenges include retaining skilled human resource, management of spent fuel and radioactive waste and maintaining confidence in nuclear non-proliferation. “In order to meet this target, the industry will have to gear up,” said S Thakur, Executive Director, NPCIL.

FDI Equity Inflows (Month-wise) During The Financial Year 2010-11:

Note:(i) *Includes inflows under NRI Schemes of RBI, stock swapped and advances

pending for issue of shares.(ii) Cumulative country-wise FDI equity inflows

(from April 2000 to July 2010) – Annex-‘A’.(iii) %age worked out in US$ terms & FDI inflows received through FIPB/SIA+

RBI’s Automatic Route+ acquisition of existing shares only.

Share Of Top Investing Countries FDI Equity Inflows: (Financial Year-wise):

Amount Rupees in crores (US$ in million)

Source: Department of Industrial Policy & Promotion,Ministry of Commerce and Industry, Govt. of India

Country 2010-11(April-July

10)

% age to total Inflows

(in terms of US $)Mauritius 11,541 42%Singapore 4,416 9%U.S.A. 2,713 8%U.K. 1,101 5%Netherlands 2,091 4%Japan 2,210 4%Cyprus 630 3%Germany 220 2%France 1,125 2%U.A.E. 834 1%Total FDI Inflows *

34,777 -

Financial Year 2010-11(April-March ) Amount of FDI inflows*

(In Rs. Crore)

(In US$ mn)

April 2010 9,854 2,214

May 2010 10,135 2,213

June 2010 6,429 1,380

July 2010 8,359 1,785

2010-11 (Up to July 10) # 34,777 7,592

2009-10 (Up to July 09) 51,256 10,532

% age growth over last year (-) 32.15 % (-) 27.91 %

Sector 2010-11 (April -July

2010)

% age to total Inflows

(In terms of US$)

Services Sector 4,948 21%Computer Software & Hardware

1,882 9%

Telecommunications 4,692 8%Housing & Real Estate 1,902 7%Construction Activities 1,183 7%Power 3,119 5%Automobile Industry * 412 4%Metallurgical Industries 2,619 3%Petroleum & Natural Gas 985 2%Chemicals 471 2%

Note: Cumulative Sector- wise FDI equity inflows (from April 2000 to July 2010) - Annex-‘B’.* Earlier data has been revised, due to some figures interchange with the respective sectors.

Sectors Attracting Highest FDI Equity Inflows: (Financial Year-wise):

Amount Rupees in crores (US$ in million)

lthough India’s m a n u f a c t u r i n g sector is expanding, the pace of growth

was considerably slower than that in preceding months.

This is predominantly due to the dip in new orders and output. This is underlined by the fact that the HSBC Markit Purchasing Managers’ Index (PMI) slid to 55.1 in September, from 57.2 in the August survey, which marks the lowest reading since November last year. Frederic Neumann, Co-Head, Asian Economics Research, HSBC, said, “The manufacturing sector is showing signs of cooling

after a red hot pace earlier in the year.” Stating the reasons for this dip, he added, “Capacity

constraints may be partly responsible for this, in addition to the fading fiscal stimulus.” According to the PMI survey, input cost inflation accelerated to its highest in four months, as raw material prices rose, while output costs, though on an upward trend, remained tempered due to strong competition for new business. While indexes for both new orders and output signalled a sustained expansion in new business and improvement in economic conditions, they were also among the biggest losers, with each falling below 60 for the first time since last year.

AManufacturing sector expands at slow pace

IIndia targeting 63,000 MW nuclear power capacity by 2032

ith the India-European Union Free Trade Agreement (FTA)

round the corner, European nations are seeking to eliminate import duties in the auto sector. Large EU manufacturers are facing fall in demand for automobiles. This is prompting them to look at growing markets like India. However, imports of completely built units attract heavy duties in

India (60 per cent customs duty), while auto components face about 50 per cent duty of the overall tariff (10 per cent customs). Although the elimination of import duties will bring more companies to the country, India is unlikely to give in as it looks forward to safeguard potential long-term investments, and build a world-class local industry.

Jyotiraditya Scindia, Minister of State for Commerce, said,

“We take into consideration the interests of all our stakeholders while taking policy decisions. The same will be done for the auto sector’s fears regarding the Indo-EU FTA.”

According to SIAM, if import duties are reduced then there is a risk that global automakers may slow down investments on manufacturing capacities in India, as they may find importing from Europe a more viable option.

WEU to push for auto duty cuts under free trade pact

# Figures are provisional, subject to reconciliation with RBI, Mumbai.

There will be a contraction in margin due to rising input costs and strong competitions. However, it is difficult to pass on the input

cost to the customers.

REVATI KASTURE,Head - CARE Research Credit

Analysis & Research

NATIONAL NEWS


EVENTS In India

ccording to global c o n s u l t a n c y Deloitte, the Indian renewable energy

sector is expected to witness increased deal-making activities in the coming months. Kalpana Jain, Senior Director, Deloitte India said, “This trend will continue to move forward. The increased interest is not only a necessity to acquire technologies, but has also been on account of attractive valuations after the global financial meltdown.”

India has seen an estimated 14 deals worth $1.1 billion in

the green energy space for the year ended June 2010. According to Jain, there is renewed impetus in the renewable energy sector, especially in the solar energy segment. “The solar sector is expected to see increased participation and collaboration, especially in the technology and manufacturing space,” she explained. Thus, companies will get an opportunity to bring forward their projects and help in the overall energy requirements of the country.

AIndian renewable energy sector to see more deals

overnment of India has decided to make investments worth `1,40,000

crore in the next three years, to allocate power projects of total capacity of 28,000 MW.

India is targeting to increase the contribution of the manufacturing sector in its GDP from 15 per cent to 25 per cent by 2022. As power plays an important role in the performance of the

manufacturing sector, the decision of the government will be a good move towards the growth of the manufacturing sector. Power Finance Corporation, the state-owned company facilitating the development of ultra mega power projects (UMPPs) of 4,000 MW each, has identified seven locations across the country where these projects would come up. “There are about seven more UMPPs to

be developed over a period of time,” said an official from the Power Ministry. Four such projects have already been awarded to successful companies in international competitive bidding while three have been allotted to private developers. These projects will help provide enough power at lower rates to manufacturing companies, thereby increasing their productivity.

GGovt to allot power projects worth `1.4 lakh crore

India’s premier industrial trade fair on products and technologies from machine tools, hydraulics & pneumatics, process machinery & eqpt, automation instrumentation, packaging & auxiliaries, IT products, electrical & electronics, material handling, safety eqpt.For further details contact:Tel: 022 3003 4649/4651Fax: 022 30034499Email: [email protected]: www.engg-expo.com

MaharashtraNovember 19-22, 2010

Auto Cluster Exhibition Ctr, Chinchwad

PUNE

Tamil NaduMarch 11-13, 2011

Chennai Trade Centre

CHENNAI

GujaratDecember 10-13, 2010

Gujarat University Exhibition Hall

AHMEDABAD

Madhya PradeshJanuary 7-10, 2011

Maharaja Shivajirao School Grd, Chimanbaug

INDORE

ith rising domestic market and a strong young talent pool, the growing

economy brings many opportunities for manufacturing. In this scenario, there is a huge requirement for new product development that empowers engineers with the latest technology to innovate. One such tool is the ‘NI LabVIEW 2010’, launched recently by National Instruments, in Bengaluru. The product will help engineers through user-defined, software-based approach for developing test, control and embedded

applications. Jayaram Pillai, MD-India, Russia & Arabia, National Instruments, said, “Engineers today need to be exposed to

real industry problems and get more Indianised in terms of product capability. With our presence, we have evolved the India LabVIEW Sphere, a powerful India-ready LabVIEW ecosystem committed to serving the engineers and scientists community in the country.” LabVIEW 2010 delivers time savings with new features such as off-the-shelf compiler technologies that execute code an average of 20 per cent faster and a comprehensive marketplace for evaluating and purchasing add-on toolkits for easily integrating custom functionality into the platform.

WNI empowers engineers to innovate

The solar sector is expected to see increased participation and collaboration, especially in the technology and

manufacturing space.

KALPANA JAIN,Senior Director, Deloitte India

Trends such as mobile computing, cloud computing, improving education systems, entrepreneurship will together play an important role in development of future products.

JAYARAM PILLAI,MD-India, Russia &

Arabia, National Instruments

INDIA LABVIEW CONFERENCE 2010 Focus: Launch of LabVIEW 2010 and showcase the India LabVIEW Sphere When: November 11, 2010 Where: Essex Farms, DelhiTel: +91 11 42658282Fax: +91 11 42658282E-mail: [email protected]

WIRE & CABLE INDIA 2010 Focus: Wire & cable industry When: November 18-20, 2010 Where: Bombay Exhibition Centre, MumbaiTel: 011 2697 1745E-mail: [email protected]

IPVS - INDUSTRIAL PUMPS, VALVES AND SYSTEMS Focus: Industrial pumps, valves and systems When: December 9-11, 2010 Where: Chennai Trade Centre,Hall 3, Tamil Nadu Tel: + 044 - 22316033, 044 - 22315551 Fax: + 91 22 24102805Email: [email protected] / [email protected]

NATIONAL NEWS


wing to the constant demand from sectors like automobile and

consumer durables, domestic steel consumption has seen a rise of 9.8 per cent to 29.82 MT in the first half of the current fiscal, compared to the same period last year, which was 27.15 MT. However, domestic production rose only by 4.9 per cent to 30.63 MT in the reporting period, as against 29.21 MT last year.

It was observed that despite

the domestic production surpassing consumption, the April-September period saw imports rising by 32.6 per cent to 4.4 MT, as compared to the same period last year. This has increased domestic availability and put pressure on local prices. On the other hand, steel exports declined by 4.2 per cent in the reporting period to 1.47 MT.

In September, steel consumption rose by 4.1 per cent to 4.72 MT, as against 4.53 MT a year-ago. Production

during the month rose by 10.8 per cent to 5.38 MT, which is over 4.85 MT in the corresponding period last year. “Steel producers started building inventories in view of rising demand after the end of monsoon season. Also, there was recovery in demand in European and Western markets,” said a steel sector expert. Imports declined by 35.3 per cent to 3.64 lakh tonne during the month, while exports grew by 28.6 per cent to 1.75 lakh tonne.

HANNOVER MILANO FAIRS INDIA Focus: Concurrent trade shows on material handling & logistics; motion, drives & automation; building automation; energy & surface technologyWhen: December 15-18, 2010Where: Bombay Exhibition Centre, Mumbai Tel: +91 22 40050681/82Fax: +91 22 40050683Email: [email protected]

EA WATER EXPO Focus: Water and Wastewater ManagementWhen: January 06-08, 2011Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(11)-29531288Fax: +(91)-(11)-29531291

BLECH INDIA 2011 Focus: Technology exhibition for sheet metal workingWhen: April 14 - 17, 2011Where: Inter Ads - Brooks Exhibitions (India), Haryana Tel: +91 (0) 124 452 4200Fax: +91 (0) 124 452 4234Email: [email protected]

EVENTS In India

ince world’s major economies have still not fully recovered from

the economic slowdown, there has been a dip in the inflow of foreign direct investment (FDI) to India. This dip has occurred for the third consecutive month. For the April-August period of 2010-11, FDI inflows declined by 35 per cent to approximately

$8.92 billion as compared to $13.8 billion in the same period last year. Although there has been a smart recovery in the domestic economy and a rebound in exports, overseas investments have shown a slackening trend in the current fiscal. DK Joshi, Chief Economist, Crisil, says, “This is not a good news for the Indian economy. This reflects that global economic

recovery is still fragile and some impact of that would be reflected in the FDI.” The sectors that attract maximum foreign investments, include services, telecommunication, construction activities, software & hardware, and manufacturing domain. As this trend continues, industries will need to search for alternative methods and strategies to sustain growth.

SFDI inflows down by 60 per cent in August

OIndia’s steel consumption up by 9.8 per cent

i t h u r b a n p o p u l a t i o n increasing by 3-3.5 per cent per

annum, the per capita waste generation is rising by 1.3 per cent every year. Economic growth, urbanisation and industrialisation has resulted in increased generation of municipal solid wastes as well as hazardous wastes. Realising the need for sound management of waste, CII-Godrej Green Business Centre recently organised ‘Waste Management Summit

2010’, seeking solutions for a sustainable future. The summit focussed on current challenges, possible solutions and capacity building requirements of the

waste management and recycling sector in India.

Ram N Agnihotri, Chairman, Waste Management Summit 2010 and VP & National Head

- Hazardous Waste Management, Ramky Enviro Engineers, pointed out, “If proper disposal and management options are not applied, the impact of wastes will be enormous. Thus, effective waste management through waste minimisation, recycling, cleaner technologies and proper handling is of paramount importance.”

WCII organises waste management summit

Effective waste management through waste minimisation, recycling, cleaner technologies and proper handling is of paramount importance to protect the

environment.

RAM N AGNIHOTRI, VP & National Head - Hazardous Waste

Management, Ramky Enviro Engineers

MaharashtraFebruary 17-19, 2011

NSE Ground, Goregaon

MUMBAI

One of the largest advanced design and manufacturing events in India featuring machine tools, hydraulics & pneumatics, process machinery & equipment, packaging & auxiliaries, it products, electrical & electronics with a special focus on automation & instrumentation, material handling

For further details contact:Tel: 022 3003 4650Fax: 022 30034499Email: [email protected]

Concurrent Shows

METAL INDUSTRY


etals comprise an important component in a wide range of key sectors such as chemical, engineering, agriculture, a u t o m o b i l e s ,

infrastructure, electronics and other manufacturing sectors. Hence, the metal segment plays a major role in the growth or dip of a country’s economy as proved by the financial meltdown in the recent past. While the global financial crisis hit the American and European metal market, expanding domestic demand and readjusting industrial structure in the Asian countries, especially in China and India, cushioned the crisis. Today, as the manufacturing industry – the main

consumer of metals – is constantly exploring new initiatives, the metallurgy market in the Asia-Pacific region is all set to witnessa new era.

METAL MARKET SCENARIO A recent report by Frost & Sullivan indicates that Asia accounts for nearly 56 per cent of the total world crude steel production. “India is the primary producers’ market in the ferrous industry, which is oligopolistic and dominated by two large integrated producers – the Steel Authority of India (SAIL) in the public sector and Tata Iron and Steel Company (TISCO) in the private sector,” the report states. Non-ferrous industry also reports strong growth.

With the rising demand for aluminium in India, the aluminium industry is flourishing at an enviable pace. In fact, the production is currently surpassing the demand. “In steel sector, amidst the turmoil, China and India were among the countries that stood

The metal industry in Asia is growing at a rapid pace owning to the surge in demand from the automotive and the infrastructure sectors. However, the highly disintegrated non-ferrous metal industry is yet to exploit the plentiful of opportunities that have emerged post recession.

Illuminating with radiant prospects, the industry is sure to gain growth momentum with increased emphasis on recycling.

M KTP RADHIKA JINOY

ILLUMINATING WITHRADIANT PROSPECTS

In metal industry, one of the key concerns is the sharp rise in prices of raw materials like iron ore and coking coal, which is likely to dent the

profitability of majority players.

NARESH KHANDELWAL,Director, Rajdhani Iron Products

METAL INDUSTRY


apart with positive growth at a time when the world was reeling under demand pressure. The global downturn and the subsequent recovery have accentuated the importance of China and India in the global steel industry. This clearly demonstrates both countries’ strong domestic consumption story. The current year appears to be promising for the steel industry,” says Naresh Khandelwal, Director, Rajdhani Iron Products. Adding to this, Vinod Shankar, Consultant, Manufacturing & Process Consulting Practice, Frost & Sullivan, South Asia & Middle East, says, “The Indian subcontinent and several other parts of Asia are rich in enormous reserves of metals and minerals such as iron ore, bauxite, etc. This, along with their close geographical proximity to the Middle East, makes Asia one of the most favoured destinations for metal producers.”

DRIVING FACTORSReports show that India’s per capita consumption of steel is around 48 kg, while that of aluminium and copper is around 0.8 kg and 0.4 kg, respectively. However, with the economy booming, per capita consumption of key metals has been increasing. In addition, low penetration of key metals clearly indicates high growth potential and an opportunity for investors to exploit the untapped market. “Factors such as government policies, consolidation, favourable conditions, increasing demand and consumption, etc, directly influence the domestic metal industry,” says Shankar.

He further adds, “It is noted that up to 100 per cent foreign direct investment (FDI) is allowed under the automatic route for mining of metal ores in India. FDI policies have made global leaders like Arcelor-Mittal and POSCO evince interest in setting up plants in India. Moreover, the government’s thrust on infrastructure is expected to boost steel demand and 46 per cent of total planned allocations has been earmarked towards infrastructure development in the Union Budget (2010-11).”

This is not all. Good prospects for the metal industry are reinforced by strong domestic consumption. “Even though the growth in real estate and housing sector marked a decline in 2009, the same was more than compensated by sustained progress in other sectors such as

infrastructure, manufacturing and automobile. The first four months of 2010 has seen a significant increase in steel demand led by strong boom in key end-user segments like automobile, infrastructure and consumer goods. Not only have

capacity utilisations improved, steel prices have almost doubled over the last one year,” says Khandelwal.

The domestic consumption of aluminium is dominated by industries like power, infrastructure, transportation, etc. Due to the ever-increasing demand from the construction, electrical, automobiles and packaging industry, the production of aluminium is currently growing. The total aluminium production in India was around 1.35 tonne last year.

Also, mergers and acquisitions are intensifying competition among domestic players in the market. This is also forcing them to innovate and improve their efficiency in order to sustain competition. For example, Tata’s Corus deal and Tangshan Iron and Steel Company’s deals with two smaller rivals has aggravated the market pressure in the past.

THE DOWNSIDEDespite the positive outlook, the metal market is fraught with some bottlenecks. The industry is highly fragmented in the downstream sector of secondary producers both in China and India. The highly disintegrated non-ferrous metals industry in Asia is yet to exploit its full potential.

Another concern is the raw material price increase. “In metal industry, one of the key concerns is the sharp rise in prices of raw materials like iron ore and coking coal, which is likely to dent the profitability of majority players.

Also, in India, regular and uninterrupted supplies of iron ore might be at risk considering the current wave of curbs implemented on illegal mining activities in key ore-producing areas like Orissa,

Karnataka and Jharkhand,” says Khandelwal. Delay in executing greenfield projects also pose a threat to domestic metal industry. Large greenfield projects have not been able to take off, owing to tough regulatory environment in terms of land acquisition,

forest clearance, relief and rehabilitation procedures and most importantly grant of iron ore mining leases. To add to the woes, poor transportation infrastructure (railways, road as well as ports) also increases the cost, thereby affecting the bottom line.

Remote locations of mineral deposits, protectionist tendencies by other economies,

lack of adoption of latest technologies & scientific mining techniques, etc, pose a threat to the industry players. With rapid increase in the consumption pattern of metals, recycling has become crucial to meet the expected metal demand. Metal recycling is environmentally benign and requires less capital and energy for production. However, the recycling industry in Asia is yet to gear up fully to meet this demand, and is highly reliant on importing metal scrap because of its unorganised scrap metal sector.

TAPPING LUCRATIVE OPPORTUNITIESBooming automotive and infrastructure sectors are likely to drive the future demand for steel. Besides, heavy engineering and machine tools industries are the main dealers of metals. Currently, these industries are witnessing phenomenal growth resulting in increasing metal consumption. India is one of the low-cost producers of steel, alumina and aluminium. This presents huge investment opportunities for integrated steel, copper & aluminium plants, and recycling plants for secondary aluminium. As the per capita metal consumption of the Asian countries is projected to increase in the future, the metal industry is all set to maintain its sheen in the long-term.

With rapid increase in the consumption pattern of metals, recycling has become crucial to meet the expected metal demand. Metal recycling is environmentally benign and requires less capital and energy for production. However, the recycling industry in Asia is yet to gear up fully to meet this demand, and is highly reliant on importing metal scrap because of its unorganised scrap

metal sector.

MANUFACTURING ZONE: Smart Manufacturing

Getting It Right The First Time

on pg. 100

WORLD NEWS


a m p e n i n g speculations of revival of mergers and accusations

(M&A) in the steel industry, Lakshmi Narayan Mittal, Chairman & CEO, ArcelorMittal, has recently said that the consolidation in the steel industry worldwide is almost complete.

“There is not much room left for consolidation, except in China,” he added, while speaking at the World Steel Association conference in Tokyo. This statement comes as a

disappointment for the Indian steel companies who are on a constant lookout for merger opportunities with big players.

Despite a pick up in global M&As, steel production has seen only a few large deals since Mittal took over Arcelor in 2006. The fragmented steel

industry is in a disadvantageous position with regard to price talks with iron ore miners,

producers of key steelmaking material, because three big miners, Vale, Rio Tinto and BHP Billiton dominate the market.

Apart from ArcelorMittal, Shoji Muneoka, President, Nippon Steel, also agreed that companies do not see a

pressing need for i n d u s t r y r e a l i g n m e n t . While majority of players in the steel industry agree with Mittal, South Korea’s POSCO, world’s third-

biggest steel producer said that it would aggressively pursue M&As to drive growth.

FABTECH 2010Focus: Metal forming, fabricating, finishing and welding When: November 2- 4, 2010 Where: Georgia World Congress Centre, 285 Andrew young Intl. Blvd. NW, Atlanta GA 30313 Tel: 040- 22340000 Fax: 404-223-4211

Tooltec ExpoFocus: Tools & Tooling EquipmentWhen: November 4-6, 2010Where: Prague Exhibition Grounds, Prague,Czech RepublicTel: + (420)-(220)-103111Fax: + (420)-(233)-379450

American Manufacturing Strategies Summit Focus: Manufacturing and Machinery When: November 11-12, 2010 Where: Hilton Chicago - Indian Lakes, Chicago, ILTel: 1 416 214 1144 Fax: 1 416 214 3403

AME International Lean Conference 2010Focus: Lean management, Manufacturing, Continuous improvement, When: November 15- 19, 2010Where: Baltimore Convention Center, 1 W Pratt St, Baltimore, MD 21201 USTel: 410-837-4636 / 1-800-282-6632 Fax: 410-659-8398

SHEET METALEXFocus: Manufacturing and MachineryWhen: November 24-27, 2010Where: Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, ThailandTel: + (66)-(2)-6867299Fax: + (66)-(2)-6867288

EVENTS Abroad

DGlobal steel consolidation nearing completion

utomation major, ABB has decided to invest in robot training facility

based in Milton Keynes, the UK’s largest dedicated industrial robotic technology training school.

Nigel Platt, Manager, UK Sales and Marketing-Robotics, ABB, said, “With the current upturn in the UK manufacturing sector, the time is right to

ensure the present and future of engineers; moreover, operators are trained to leverage on the potential growth opportunities that robotics can bring. This requires them to be equipped with the skills needed to ensure the best levels of performance from their installed robots.”

New additions to the training centre include two IRB 360 FlexPicker robots, widely used

in the fast moving consumer goods (FMCG) industry for picking and packing applications. This dedicated dual cell will assist trainees in gaining a better understanding of picking and packing ‘on the fly’ by introducing them to a host of latest programming software and options such as the latest ABB vision software, product distribution techniques and conveyor tracking features.

ARobot training centre to meet UK manufacturing growth

wo years ago, Giga Watt (GW)-scale production facilities were considered a

big deal. With more companies reaching the GW range, the next step is to reach multi-GW capacities.

Taking an initiative in this direction, Neo Solar Power has recently announced that construction on the world’s largest solar cell facility, a plant that will cost $837 million and produce 3.4 GW of cells per

year is underway. The first phase of the plant will be 400 MW in size.

The company has 620 MW of capacity operating in North Taiwan. The company will scale these facilities up to 800 MW by the end of the year.

By most accounts, 2010 will be a big year for solar installations. The consultancy iSuppli predicts that about 13.6 GW of photovoltaics (PV) will be installed this year. Despite the scaling back of incentives in

a few big European markets, iSuppli projects installations to be over 20 GW in 2011. As a result of unexpectedly high demand in the second half of this year, it is increasingly difficult to find panels. Silicon prices are rising as well. Companies like Neo Solar are ramping up quickly to ensure a steady supply of cells and modules during these high growth years. Some analysts are already worrying about supply constraints into 2012.

TWorld’s Largest Solar Cell Manufacturing Plant Underway

Achieving resource security has been a primary driver behind M&A deals in steel industry. Further, geographical expansion, increased marketshare and an improved cost structure

have been governing these transactions.


WORLD NEWS

Machine Tool IndonesiaFocus: Tools & Tooling EquipmentWhen: December 1-4, 2010Where: Jakarta International Expo (JIExpo), Jakarta, IndonesiaTel: + (44)-(20)-78402100Fax: + (44)-(20)-78402111

Tire Technology Expo 2011Focus: Tire design and manufacturingWhen: February 15-17, 2011Where: Cologne, GermanyTel: +44 (0) 1306 743744Fax: +44 (0) 1306 742525

ProMat 2011Focus: Manufacturing, Engineering, Material Handling, Supply Chain, Logistics, DistributionWhen: March 21- 24, 2011Where: McCormick Place South, Chicago, IL USTel: 800-345-1815Fax: 704-676-1190

Hannover Messe 2011Focus: Industrial automation, Motion, drive & automation, energy, power plant technology, etc.When: April 4-8, 2011Where: Hannover, Germany Tel: +49 511 89-31146Fax: +49 511 89-31149E-mail: [email protected]

National Manufacturing Week (NMW)Focus: Mechanical or industrial engineering When: May 24-27, 2011Where: Melbourne Convention & Exhibition Centre, 2 Clarendon Street, Melbourne, VIC 3006 AUTel: 02 9422 8921 Fax: +61 (02) 9993 8342

EVENTS Abroad

ollowing the marked downshift seen in the previous month,

the recovery of the UK manufacturing sector continued to slow in September, as growth of output lost further momentum and the rate of increase in new orders

improved only slightly. The seasonally adjusted

Markit/CIPS UK Manufacturing PMI fell to a 10-month low of 53.4 in September, down from a revised figure of 53.7 in August. Rob Dobson, Senior Economist, Markit, and Author, the UK Manufacturing PMI, said, “September saw the

weakest expansion of UK manufacturing for a year, but some reassurance can be gained from the fact that growth has merely slowed from an exceptionally strong rate in the first half of 2010.The sector has now also recouped over 30 per cent of its recession losses.”

FUK manufacturing recovery slows down in September

all Street economists are portending that the global economy

will withstand the US slowdown. Just three years since America began to take the world into its deepest recession in seven decades, Goldman Sachs Group, Credit Suisse Holdings and BofA Merrill Lynch Global Research are forecasting that worldwide growth will slow down from 0.2 percentage point to 4.6 per cent in 2011, even as expansion in the US falls to 1.8 per cent from 2.6 per cent. “The world has already become partially decoupled,” says Nobel laureate Joseph Stiglitz, Professor, Columbia University, New York.

Manufacturing in China accelerated for a second

consecutive month in September, and industrial production in India jumped 13.8 per cent in July from a year earlier, more than twice the pace observed in June.

David Lubin, Chief Economist, Citigroup, London, estimates that emerging economies will account for about 60 per cent of global

expansion this year and the next, up from about 25 per cent a decade ago. “Direct transmission from the US slowdown to other economies through exports is not large

enough to spread the US demand problem globally,” commented Dominic Wilson and Stacy Carlson, Economists, Goldman Sachs.

“If the growth slowed 2 per cent, the drag on the BRIC countries of Brazil, Russia, India and China would be about 0.1 per cent. Developed economies including the UK, Germany and Japan also have limited exposure. A fall of almost

35 per cent is more thantwice as large as the worst declines in the rest of thegroup of 10 industrial nations,” said Wilson.

WGlobal economy may shrug off US slump

Direct transmission from the US slowdown to other economies through exports is not large enough to spread

the US demand problem globally.

DOMINIC WILSON &STACY CARLSON,

Economists, Goldman Sachs

ind power could meet about a fifth of the world’s electricity demand

within 20 years, environmental watchdog Greenpeace predicted in its recent report.

Steve Sawyer, secretary general, global wind energy council said, “The global market for wind power grew at an average of 41.7 per cent in 2009, beating average

annual growth of 28.6 per cent over the past 13 years.” The report’s ‘advanced scenario’ projects the world’s combined installed wind turbines would produce 2,600 terawatt hours (TWh) of electricity by 2020, equal to 11.5-12.3 per cent of the total power demand. The report also says that by 2030, wind energy would produce 5,400 TWh-18.8 to 21.8 per cent of

the world’s power supply. The more conservative “reference” scenario based on figures from the UN’s International Energy Agency saw wind power triple in the next decade to cover up to 4.8 per cent of electricity. The ‘moderate’ scenario based on current industry figures would see wind power meet up to 9.5 per cent of the world’s power demand by 2020, the report says.

WWind could provide 20 per cent of world power by 2020

PRESIDENT – APAC, HYDRAULICS GROUP, EATON CORP

INDIAN MANUFACTURING LANDSCAPE IN THE YEARS TO COMEToday, India is on the driver’s seat. It can control the direction it will take. The opportunity in manufacturing is slated to be more skill-intensive and the industry leaders foresee India as well-poised to take advantage of this. This is benefiting the job market as several firms are on the hiring mode.

The country has steadily developed its manufacturing excellence. There is an increase in efficiency of the industry and it emerged leaner, fitter and more productive over the years. From power generation to construction of several modern roads to aerospace, every sector has a huge impetus. India is now recognised as an automobile manufacturing hub for its pioneering efforts in adopting modern technology and for allowing the entry of foreign players. The construction and agriculture markets are accelerating. The Road Transport and Highways Ministry has proposed priority sector status to road development, allowing private highway developers more funds from banks.

With India’s rich talent pool, young population and the current generation’s determination to break open in the international market, I am quite hopeful that the current Indian manufacturing sector, with its structured and new lean look, will stand up and deliver to the expectations in the next five years.

FACTORS THAT WILL MAKE INDIA WORLD’S FUTURE FACTORYThe world is a big space and there are many players, not one. It is important for India to ensure that its primary focus is to fulfill the needs of the domestic market. Then only it can focus on augmenting the global market. India should continue to focus on delivering quality products and ensure high quality jobs. This will ensure our long-term advantage. India is and will continue to be the future factory of the world.

“The hydraulics industry is making rapid strides towards augumenting efficiency and performance of its products. Hydraulics always has been the best choice for high power density applications, but new designs, materials and manufacturing technologies are extending that advantage like never before,” avers Shyam Kambeyanda, President – APAC, Hydraulics Group, Eaton Corporation, during an exclusive interaction withPrerna Sharma. Excerpts…

HYDRAULICS CAPABILITIESIMPROVE SHOPFLOOR

PRODUCTIVITY

SEARCH - THE INDUSTRIAL SOURCEBOOK | N O V E M B E R 2 0 1 054



SUCCESS STRATEGIES THAT CAN SET COMPANIES APART FROM THE RESTIt is important for companies to test their systems and processes regularly. This will help set a foundation to outgrow end-markets. A strong foundation – unified around a common vision, mission, business system and core values – gives the right direction and sets a company apart fromthe rest.

At Eaton, we do this through Eaton Business System (EBS). The Eaton Business System is a collection of all standardised best practices that we deploy and that we teach every employee about. It is the way we run our business. There are aspects of each of our businesses that are unique, but where they are not unique and can be standardised, we try to find the best practice or process. EBS is at the heart of our strategy for becoming a premier diversified industrial organisation.

A GREAT LEADER, ACCORDING TO YOUA great leader is a person who sets a vision that continues to hold. People like JRD Tata, GD Birla, JC Mahindra and KC Mahindra have set a vision and direction that other people shared and followed.

In India, Mahatma Gandhi was among the greatest leaders. He has formed and led a great team, which shared his vision. His vision was not only to achieve freedom but achieve it in the right way – by maintaining religious harmony and following non-violence. Whatever were the circumstances, he did not waver from his belief.

This vision resonates with Eaton’s values-based business model. We believe in ‘Doing business right’. We have been living it for years, as it is central to our vision to become the most admired company in our marketspace.

REASONS BEHIND SHIFT FROM DEVELOPED COUNTRIES TO DEVELOPING REGIONSBRIC countries were engines of global growth even before the acronym was coined in 2001. China and India have a long history of being strong players in the world economy. In the 18th century, India was the second-largest economy contributing more than 20 per cent of total world output.After 1991 economic reforms, India has begun to steadily re-integrate into the

global economy. Brazil’s booming agricultural sector,

Russia’s vast natural resources, China’s and India’s accelerating growth provide great opportunities for growth. The most important growth factor in these economies is the focus on progress and people. The diverse population provides a competitive advantage. Other factors also include stable government and opening economies. It is true that the focus has shifted to BRIC, but we should not forget the West. The key is to focus on all. That is what precisely Eaton’s strategy is.

PERFECT INGREDIENTS TO SUCCEED IN THIS GLOBAL MARKETPLACEThere are three major factors for our success in the global market – manufacturing excellence, leadership in technology and being a learning organisation. Protecting and improving the environment through innovation are among Eaton’s highest priorities. Eaton’s businesses offer a wide range of products & services that help our customers conserve energy and manage power for greater efficiency.

CONTRIBUTION OF HYDRAULICS & PNEUMATICS TOWARDS IMPROVING PRODUCTIVITY ON THE SHOPFLOORHydraulics capabilities contribute immensely towards improving productivity on the shopfloor. Metal forging or metal cutting requires precision and hydraulics provides the precision. Hydraulics products help in achieving fast-paced actions, handling heavier loads, ensuring consistencies, achieving high degree of accuracies & tolerances, artificial intelligence, controllability, higher efficiencies, and importantly, lower fatigue levels among workforce. Thus, it has a significant impact on a manufacturing set-up with cost-effectiveness, better quality of products and faster deliveries.

LATEST TRENDS SHAPING UP IN THE SEGMENTThe hydraulics industry is making rapid strides towards augumenting efficiency and performance of its products. Hydraulics always has been the best choice for high power-density applications, but new designs, materials, and manufacturing technologies are extending that advantage

like never before. But, good as they are, these new components are destined to form a smaller piece of the overall hydraulics industry pie. The real action in the coming years is going to be focussed not on components, but rather on integrated system solutions that marry hydraulics & electronics in increasingly innovative ways. In hydraulics, the latest trends point to applications in electronics, high pressure systems, compactness and systems without foundations. Customers are looking for the best usage of space, better power density, energy-efficiency and hydraulics aid in achieving these objectives.

Another upcoming trend is the marriage of hydraulics & electronics that will deliver smarter products, that combines the intelligence of electronics with the power density of hydraulics to enable all of these applications and many more that have not ever been thought of yet.

HYDRAULICS MARKET IN INDIA VIS-À-VIS OTHER COUNTRIESThere are high expectations from India. India is making investments in infrastructure like dams, roads, airports, power generation and connectivity. We see many of the significant sectors showing positive growth like manufacturing, automotive, power and aerospace. We supply to all these segments. Eaton’s India operations play a leading role in driving the company’s manufacturing capabilities and professional services in the region. India not only offers a huge market opportunity in itself, but it also serves as a strategic location to enhance Eaton’s global competitiveness.

THE CRUCIAL IMPORTANCE OF DESIGN IN SELECTING SUITABLE HYDRAULICS EQUIPMENTDesign plays a crucial role in selecting hydraulics equipment. Understanding customers’ and users’ needs and translating them into machine design, integrating them to a system solution, achieving the optimum cost, energy efficiencies are the key elements of designing a product. Besides product design and developments, application engineering plays a vital role for the right selection of the products & components.

Eaton’s engineering centre in India offers unmatched design capabilities for all the



businesses across the globe and hydraulics design team is one of the largest. This gives Eaton the strength and capability to develop machine-specific adopted products. One of our recent successes has been to design a hitch valve, which meets the Indian application conditions.

PARAMETERS THAT NEED TO BE KEPT IN MIND WHILE SELECTING SUITABLE HYDRAULIC EQUIPMENTMajor things to look for while selecting suitable hydraulics equipment for a particular application are the capacity/flow, pressure, torque, power/energy consumption, envelope size/footprint, noise level, emission norms and system cleanliness.

Eaton provides the hydraulic equipment to meet customers’ most demanding standards for performance, safety, reliability and comfort. Eaton is one of the few companies, which has the capability to offer system solutions for all market segments. The products are highly engineered items and meet all the specifications, norms and the mentioned requirements.

NEW AGE ENERGY-EFFICIENT EQUIPMENT Hydraulics have won wide acceptance for factory and mobile applications. Traditional strengths of this key technology are centered around power, strength, durability and control. All hydraulics equipment essentially need to fit into the prescribed energy efficiency norms by default. The end users/OEMs/consultants need highly energy-efficient machines, so that the running cost of power is kept low and consequently the total cost of ownership comes down.

Eaton is answering this need of mobile hydraulics through the development of new smart electro-hydraulic technologies that shrink the footprint of hydraulics systems, improve their performance and energy efficiency and reduce emissions. These technologies provide equipment manufacturers greater design flexibility to achieve the goal that every customer desires: More function, less fuel. Our hydraulics products provide high durability, low noise vibration and harshness (NVH) levels, and newer technologies like hydro-electric applications are making systems more intelligent besides reducing overall costs.

We also think that cost-effective utilisation of renewable energy resources like wind, hydropower and ocean wave power will depend on even more sophisticated hydraulics systems to capture, transmit and control the energy these systems generate.

FUTURE EXPANSION PLANSWe will continue to concentrate on our existing customers as well as look for new customer base and emerging market segments, we also aim at our business, both organically and inorganically.

It is important for companies to test their systems and processes regularly. This will help set a foundation to outgrow end-markets. A strong foundation – unified around a common vision, mission, business system and core values – gives the right direction and sets

a company apart from the rest.


PARALLEL HYDRAULIC HYBRID SYSTEMS

PARALLEL HYDRAULIC HYBRID SYSTEMS: Gaining A ‘Green’ Edge ............................................62

HYDRAULIC EQUIPMENT: HOSE VS. TUBE: Taking The Right Call .............................................69

HYDRAULIC REBUILDS: Hauling Monetary Gains ..........................................................................74

PNEUMATIC SYSTEMS: Compressing Energy Consumption ..........................................................78

TRENDS & TOOLKIT: Gauging What’s Next In Hydraulics .............................................................82

CASE STUDY: Eaton Hydraulic Motor - Speeding Operations, Maximising Output ........................87

TIPS & TRICKS ..................................................................................................................................88



ydraulic hybrid technology has so far been aimed at delivery and refuse trucks, primarily to reduce fuel consumption. For the refuse industry, hydraulic

hybrids hold key advantages, particularly in terms of power density. Two major delineations exist for hybrid systems namely hydraulic vs. electric and parallel vs. series. To be more specific, hydraulic and electric hybrid technology refers to the energy transfer and storage means of a particular design. The terms parallel and series speak of the arrangement of hybrid components with respect to traditional driveline

components. Each offers distinct advantages and operating characteristics.

Electric hybrids are common in today’s marketplace and are assumed to be widely understood. In contrast, the concept of a hydraulic hybrid may be a relatively new one. Generally speaking, hydraulic hybrids have the same types of components as electric hybrids. Hydraulic pumps and motors replace electric generators and motors. Accumulators supplant batteries, and

Hydraulics offers a distinct advantage in the hybrid landscape due to superior power density as compared to competing technologies. When a hydraulic hybrid is a parallel system that supplements a conventional drive train, a fleet owner realises additional advantages over

a series hybrid system that replaces the drive train. The benefits include customisation of performance characteristics, retrofitting the hybrid onto an existing vehicle and increased mission reliability, thereby giving parallel hydraulic hybrid system a green edge.

H

GAINING A ‘GREEN’ EDGE

Engine Transmission Drive Shaft Drive Axle

Parallel Hybrid

Figure 1: Parallel hybrid block diagram

Engine Series Hybrid Drive Axle

Figure 2: Series hybrid block diagram



hoses substitute the wires. Each approach has advantages and disadvantages for a given duty cycle.

Parallel hybrid systems supplement the conventional drive train of the vehicle (Fig 1). A parallel hybrid selectively adds and absorbs energy to the driveline during acceleration and braking respectively. A parallel hybrid vehicle can continue to function with degraded performance even if the hybrid system is not functional.

Series hybrids replace the conventional drive train and encompass the entire need of power transmission and energy management for the vehicle (Fig 2). Fuel savings are largely due to engine management in addition to brake energy regeneration.

Although a series hybrid can offer more fuel savings through increased engine management, a parallel hybrid offers several advantages of its own, including options to improve vehicle acceleration, the ability to easily retrofit to existing vehicles, and greater vehicle mission reliability. For hydraulic hybrids, which are not traditionally used as drive systems for on-highway vehicles, an early advantage with vehicle mission reliability is important to spread adoption into the refuse industry.

THE HYDRAULICS ADVANTAGE Parallel hydraulic hybrid systems save fuel by assisting the launch of a vehicle with kinetic energy recovered during braking. In conventional on-highway vehicles, kinetic energy is wasted during the braking process in the form of heat generated from brake pad friction. Hydraulic hybrids offer a distinct advantage over electric hybrids as regenerative braking systems due to superior power density. This advantage is highlighted in severe duty cycles such as refuse trucks, where the power demands for braking and launch are extreme. Parallel hydraulic hybrids can return up to 70 per cent of braking energy and offer a 15-30 per cent improvement in fuel economy in refuse trucks, based on duty cycle.

Hydraulic hybrids display power density advantage and use a bladder or piston accumulator to store vehicle kinetic energy, which can accept high oil flow in order to

quickly store and release kinetic energy (Fig 3). Electric hybrid systems are limited by the capacity to capture energy during a braking event. The area between the curves

represents lost energy capture potential, resulting in lower realised fuel savings. Additionally, if an electric hybrid is placed between the engine and transmission, energy and performance will be lessened by shift interruptions. The power density advantage of hydraulics may be lessened with larger electric motor configurations, but the resulting size, cost and weight become impractical for the application.

PARALLEL HYBRID BENEFITS The first advantage offered by a parallel hybrid over a series system is the option to improve vehicle acceleration over a baseline vehicle. The second is the retrofit capability and last but not the least reliability impact. Vehicle Acceleration OptionsA parallel hybrid can be configured on a vehicle in different ways for optimising vehicle performance and fuel savings for the end-user. Three distinct options for vehicle acceleration are as follows: Hybrid powered launch: The first vehicle acceleration option with a parallel hybrid is

a hybrid powered launch. In this option, the vehicle releases available hybrid energy preferentially and uses engine torque as needed to match the acceleration of a baseline vehicle. The baseline launch curve is a standard reference point for both parallel and series hybrids in order to maintain vehicle performance with reduced fuel consumption and emissions. For a series hybrid, the desired vehicle performance determination becomes the design target for the system and is weighed against system cost as the design is established. For a parallel system, the hybrid

powered launch requires a torque limit signal to the engine, so that baseline acceleration performance is matched. This limit is sent until the hybrid indicates a

transition, as it begins to near the end of available stored energy. Fuel savings occur entirely during vehicle launch with this option. Tandem launch: The second mode offered by a parallel hybrid is a tandem launch, which releases hybrid energy in tandem with the engine power. In tandem mode, no torque limit command is issued by the hybrid. Without a limit, both the engine and hybrid will operate independently to launch the vehicle based on input from the driver. This mode increases the vehicle acceleration rate from its baseline performance, and saves fuel through the reduced work being performed by the engine as well as the reduced vehicle cycle time. Tandem launch is natural for parallel hybrids since both the engine and hybrid are connected independently to provide torque during acceleration. A parallel hybrid has the capability to meet baseline vehicle acceleration, or an increased level of acceleration without the need to change component hardware.

The US has roughly 1,50,000 refuse trucks supporting garbage and recycling collection routes. A typical refuse truck weighs 30,000 kg (65,000 lbs), services 1,000 households per day, travels 190 km (120 miles) per day, 250 days per year. These trucks typically consume between 34,000 and 45,000 litre (9,000 and 12,000 gallons) of diesel each year. To reduce the high yearly fuel consumption and realise the objective of low-fuel economy, refuse vehicles are ideal candidates for hybridisation.

400

350

300

250

200

150

100

50

0

0 5 10 15 20 25

Continuous Power Comparison

Pow

er C

apac

ity (k

W)

Vehicle Speed (kph)

Hydraulic HybridElectric Hybrid

Figure 3: Example of electric and hydraulic power capacity



For series hybrids, the vehicle acceleration capacity is determined by the core design of the system. This is true because the hybrid has the single direct connection to the wheels to provide acceleration torque. Increased acceleration capability from a baseline vehicle would most likely add cost to the series hybrid, especially if the acceleration increase required a corresponding increase in hybrid component size. However, any increase in the design would need to be weighed

against the value delivered to the application. This evaluation would be difficult within the refuse industry due to disparity of duty cycle characterisation. The number of fleet owners who desire increased acceleration capability is not clear, so the added expense to a series system may not make sense. However, the option of improved acceleration is available for no additional cost with parallel hybrids. Reduced baseline acceleration capacity: A third option exists to reduce the baseline vehicle acceleration capacity and further increase fuel savings enabled by the benefits of a hydraulic hybrid. With this option, reduced baseline capacity is offset by torque from the parallel hybrid during launch. Baseline vehicle acceleration is achieved with both the engine and hybrid, but fuel savings and emissions reductions are realised through improved subsystem efficiencies in addition to brake regeneration from the hybrid. The parallel hybrid vehicle may exhibit reduced performance if the hybrid is not active. In addition to smaller-sized diesel

engines, compressed natural gas (CNG) or liquified natural gas (LNG) engines may also be considered. Typically, the use of CNG or LNG engines involves significant acceleration performance compromises. However, the addition of a parallel hydraulic hybrid would return acceleration characteristics inline with non-hybrid diesel drivelines.

RETROFIT CAPABILITY Parallel hybrids may be installed to new or existing vehicles due to modular system

design. In other words, a parallel hybrid can be integrated into a vehicle without extensive alterations to the vehicle or required design changes from other major vehicle subsystems. A parallel hybrid is connected to the vehicle’s drive train between the transmission and the differential (Fig 4).

Most class-8 vehicles have a mid-bearing, which is replaced with the installation of the parallel hydraulic hybrid. The primary design

requirements for installation of a parallel hybrid are space on the chassis and bracketry to support the system. Controls requirement includes the electrical connections, a hybrid display in the cab, and an engine software flash to acknowledge the hybrid as a subsystem. Independence of

a parallel hybrid simplifies design and reduces operational effects from other vehicle subsystems.

RELIABILITY IMPACT Under this comes various aspects pertaining to reliability that include:Reliability lifecycle: The reliability of a vehicle is often characterised using the bath-tub curve model (Fig 5). The bath-tub curve plots the instantaneous failure rate of a vehicle throughout its lifecycle. Two key customer wants are illustrated by this model; high reliability or conversely low unreliability, and long product life.

Unreliability, from the customer’s perspective, is the area under the curve during the early and useful life periods. Failures during this period may involve unplanned maintenance, unavailability of equipment and mission unreliability. Of these, the customer is most sensitive to mission unreliability. For a refuse truck, mission unreliability is the probability of not being able to complete a scheduled route during the course of a work day. The consequence of a mission critical failure is often expensive and requires vehicle towing, rescheduling of other equipment, and potential for discontinuity of service.

Life is illustrated by the location of the end-of-life period, or the duration of the useful life. Failures during this period maybe considered as planned maintenance (i.e. overhauls), numerous unplanned maintenance actions, and may warrant decommissioning of equipment based on repair cost. It is desired, for major sub-systems such as driveline components, to avoid premature end-of-life failures. That is to say, for a particular component to reach end-of-life significantly prior to the desired

or expected life of the equipment.

In either case, useful life or end-of-life, it is always beneficial for the customer to lower the failure rate of equipment and it is especially important to lower the probability of mission critical failures. Parallel hybrid architecture positively impacts

both these metrics by reducing the average overall operating stress on mission critical components, and by minimising the impact of hybrid-related mission critical failure modes through hybrid system diagnostics. Reduced stress on driveline components: A parallel hydraulic hybrid system can

Figure 4: Parallel Hybrid Architecture

Parallel hydraulic hybrid systems supplement a vehicle’s drive train while a series system replaces it. Although a series hybrid has the potential for additional fuel savings through engine management, a parallel hybrid can improve vehicle acceleration, retrofit to existing trucks,

and reduce end-user risks of vehicle downtime.



significantly reduce brake power and heat generation, engine power output, and torque converter and transmission power throughput. Simulations indicate that a typical truck running the environmental protection agency (EPA) refuse duty cycle in the US will reduce brake power and heat generation 61 per cent, engine power output 18 per cent, and torque converter and transmission throughput 17 per cent (Fig 6).

Knowing that failure rates of equipment can be characterised generally by an operating stress level and time (the SN curve), a conclusion can be made that the overall mission critical failure rate of the driveline components will be lessened by the presence of a parallel hybrid. The same can be said for end-of-life failures, where the same driveline components are expected to last longer under a given duty cycle. As an alternative to this benefit, driveline components can be downsized, reducing initial investments and further bringing down the fuel consumed for a given duty cycle. Mission reliability through diagnostics: Parallel hybrid architecture relies on a traditional engine and transmission driveline arrangement to transmit power to the drive axle. The hybrid function couples to this driveline by transfer case and clutching arrangement, allowing the majority of hybrid components to decouple. Decoupling the hybrid from the driveline then becomes the key function in minimising hybrid impact on mission reliability. The remaining hybrid component is the transfer case through-shaft. In many applications, the transfer case through-shaft is replacing a carrier b e a r i n g a r r a n g e m e n t resulting in few, if any, additional mission critical

failure modes of the truck when the hybrid is decoupled.

Control diagnostics enables the parallel benefits of the system to be realised seamlessly with a vehicle’s operation. Embedded control logic reacts to given conditions to not only maintain a truck’s mission reliability, but also determine and

preserve the health of the hybrid system in order to maximise performance and service life. The electronic control unit (ECU) of a parallel hybrid does not treat all fault conditions equally, but rather is programmed to respond based on the suspected cause, behaviour, and resultant effect of the fault condition. For a brake regeneration hybrid system, the main breakdown of responses for the ECU is to shut down the system

until the condition no longer exists, the vehicle is turned off, or till the next vehicle service. Using this management scheme, hybrid uptime can be maximised while protecting the system.

THE GREEN TECHNOLOGY BENEFITParallel hydraulic hybrids are a valuable green technology with an attractive risk/reward ratio

extending into severe duty applications. The power density advantage of hydraulics enables a more effective brake energy recovery over competing electric hybrids. Hydraulic hybrids can return up to 70 per cent of energy normally lost in braking in the form of heat. Parallel hydraulic hybrids can improve fuel economy of refuse trucks

by up to 30 per cent and reduce emissions by 20 per cent based on duty cycle. This improvement offers a significant amount of fuel savings across the active global refuse fleet, especially in the US, where gross vehicle weights can exceed 27 tonne.

Parallel hydraulic hybrid systems supplement a vehicle’s

drive train while a series system replaces it. Although a series hybrid has the potential for additional fuel savings through engine management, a parallel hybrid can improve vehicle acceleration, retrofit to existing trucks, and reduce end-user risks of vehicle downtime. Severe duty applications, such as refuse trucks, will experience benefits in fuel consumption, emissions reduction, reduced maintenance expenses and improved performance from the commercialisation of parallel hydraulic hybrids.

Vincent Duray, Chris Arneson, Robert Isaacs and Michael Stoner, Eaton Corporation, Eden Prairie, MN, USA

Failu

re R

ate

Early Life

Useful Life

End of Life

Figure 5: A typical Bath-tub Curve Model

70%

60%

50%

40%

30%

20%

10%

0%

ISL330_TC421_A3000

Engine Power Torque Converter Power

Transmission Power

Simulated Percent Mean Power Reduction from Parallel Hydraulic Hybrid (EPA Refuse Duty Cycle)

Brake Power

Figure 6: EPA refuse duty cycle simulated mean power reduction from hybrid.

MANUFACTURING ZONE: National Manufacturing Investment Zones

Propelling Manufacturing Growth

on pg. 106

Although a series hybrid can offer more fuel savings through increased engine management, a parallel hybrid offers several advantages of its own, including options to improve vehicle acceleration, the ability to easily retrofit to existing vehicles, and greater vehicle mission

reliability.

Bos

ch R

exro

th (I

ndia

) Ltd

HYDRAULIC EQUIPMENT: HOSE VS. TUBE

hat do lifting chains, bladder-type accumulators and hydraulic hoses have in common? Well, they typically have only one mode of failure – and that

is catastrophic. One minute they are working as they should, and the next thing one knows, something has gone wrong with them.

Definitely, hoses can leak from around their ferrules and show obvious signs of abrasion, both of which are early warning signs that a change would be prudent. But even under these conditions, estimating their remaining service life is virtually impossible.

THE HOSE TROUBLE Beyond the fact that their service life is finite and difficult to estimate, other disadvantages of hydraulic hoses when compared to tubes include: They expand and stretch under

pressure. This flexing requires extra volume and adds to machine cycle time.

They are expensive and typically have a limited operating temperature range.

Their requirement for regular replacement makes them a source of contaminant ingression.

W

TAKINGTAKING THETHERIGHT CALLRIGHT CALLThere has been a constant debate over the use of hydraulic hoses and hydraulic tubes in hydraulic equipments. However, what many fail to understand is that both are different tools meant for different functions. The key lies in critically examining the functionality required and take an informed decision by weighing the merits and demerits.




There is limited space (particularly in mobile hydraulics), and relative movement between machine components and superstructure.

Noise and vibration need to be suppressed. Despite the above disadvantages, hoses

are a necessary feature of most hydraulic systems. This is because the alternative conductor – tubes – cannot be used where: There is limited space (particularly in

mobile hydraulics) and relative movement between machine components and superstructure.

Noise and vibration need to be suppressed. However, hose is often substituted for

tube when it is not necessary. This is because a hose assembly can usually be fabricated much faster than a tube assembly. And, the additional labour cost required to fabricate and install a tube can make hose appear to be a cost-effective solution. But this belies the fact that the same hose may need to be replaced many times over the life of the machine. This false economy is similar to buying the machine itself on initial capital outlay alone without considering its total life-of-ownership cost.

HYDRAULIC TUBING Hydraulic tubing has some compelling advantages of its own. One of these is its superior heat transfer, especially if it is painted. One aspect of heat transfer is thermal radiation. The total radiation from an object is the sum of its reflection, emissivity and transmission of heat through the object.

When hydraulic tubing is painted, it reduces its reflectance and increases its emissivity, enabling better heat rejection, as illustrated by the following case study:

An industrial hydraulic installation was originally designed to operate at 1200 psi and at a maximum operating temperature of 1200F (490C). Zinc dichromate-coated steel tube distributes fluid from the 600-litre reservoir to the various stations around the plant. Over the years, the system had been added to (without any increase in installed cooling capacity) – the point where it was now overheating in the summer months.

Because the system operated satisfactorily for 10 months in a row, the management did not want to spend the money necessary to upgrade the cooling

system. So, one of the maintenance personnel who was familiar with the thermal radiation theory suggested painting the hydraulic system’s tubing.

Before proceeding, the maintenance team conducted a test. Team members applied electrical tape to two of the hydraulic tubes, and using an infrared camera, they measured the difference in temperature between the taped and untaped areas. They found that the taped areas on the tubes were 70F (40C) cooler than the untaped areas.

This gave the maintenance team the confidence to proceed with the idea. Because the rest of the hydraulic system

was painted flat white, the tubing was painted the same colour. A week and 12 cans of spray paint later, the system was running 100F (5.50C) cooler. This might not sound much, but the end result meant that the hydraulic system could now operate through the two hottest months of the year without overheating. It also meant that the need to increase installed cooling capacity was at least deferred, if not eliminated.

MANAGING HOSE REPLACEMENTDespite the superior reliability of tubing, hoses are a necessary feature of most

Instructions to select the appropriate hydraulic pump Assess the budget before beginning to shop for the hydraulic pump.

Remember that these pumps will also continue to accrue certain maintenance costs, even after their initial purchase, so making sure they fit well within the budget is important.

Determine precisely which jobs will be assigned to the new hydraulic pump. With pumps ranging from 100 psi to 75000 psi and the ability to boost the pressure with certain gases, there are literally millions of uses for these versatile machines.

Choose between the various kinds of hydraulic pumps available for both industrial and home use. External gear pumps are most often used in machine tooling while internal gear pumps are better able to handle heavier, more viscous liquids. Lobe pumps are great for use in food-handling machinery, as they are able to process near-solid or solid materials.

Select vane pumps for use with a liquid having low viscosity and non-lubricating properties, such as gasoline.

Decide how much pressure output is needed from the pump. Overpowering of the pump can cause harm to the equipment.

Inspect all the equipment that will be used along with the hydraulic pump to make sure all are compatible.

Decide whether there is a need for continuous or periodic power. Some pumps are designed to give constant pressure while others are designed for intermittent use.

Select a pump with the appropriate pressure rating, volumetric-flow output, speed, efficiency and fluid compatibility for the job.

Review which components need to be purchased separately in order to use the hydraulic pump. Hoses, filters, air regulators and exhaust mufflers will be needed to make the hydraulic pump set-up complete.

Check to see whether the chosen pump includes a power source. Most pumps are purchased separately, with no power source included. If this is the case with the pump, the user will need to find out what kind of source it needs and purchase it as well.



hydraulic machines. And unlike tubing, hoses come under maintenance item, one which usually gives no warning of impending failure. So in a condition-based maintenance environment, it becomes essential to proactively manage the replacement of hydraulic hoses. Well, there are two considerations, which should be the foremost in one’s mind: the downtime cost of in-service hose failures, and not treating all hoses equally. For example:

Two years ago, a mining client faced problems on account of ad-hoc replacement of hoses that failed in service on hydraulic shovels, resulting in machine availability falling to as low as 65 per cent.

In this company’s case, when a multi-million dollar shovel stops, so does a multi-

million dollar fleet of haul trucks. Downtime is a major cost. So, it implemented a hydraulic hose replacement programme. This involved changing every hose on the machine every 18 months.

Whenever a shovel was down for planned maintenance, a portion of the hoses was changed, beginning with the oldest first. The plan worked appropriately and machine availability was soon back above 90 per cent. Of course, large-diameter, multi-spiral hydraulic hoses are not cheap. However, hose expense paled to insignificance when compared to the cost of the downtime it prevented. By any economic measure, the hose replacement programme was a great success. But, it did have a fundamental flaw. It was treating all

hoses the same. And, it was highly unlikely that each hose on the machine was equally responsible for an equal proportion of the in-service failures and downtime. A relatively small percentage of hoses were responsible for the majority of the in-service failures and downtime. In fact, the available data revealed that less than 20 per cent of the hoses on the machine were responsible for nearly 90 per cent of the failures. Armed with this information, the hose replacement programme was optimised to reduce unnecessary hose change-outs.

THE FINAL SELECTIONHydraulic hoses and tubes are not interchangeable and are used for different jobs. The benefits of hose – which make it a necessary feature of most hydraulic machines – come at a cost. It has a finite service life and usually gives no warning of failure. This makes its maintenance difficult. For these reasons, hose should only be used where tubing cannot work.

Brendan Casey, Industrial Hydraulics Equipment Expert, has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulics equipment.

Hydraulic tubing has some compelling advantages of its own. One of these is its superior heat transfer, especially if it is painted.

When hydraulic tubing is painted, it reduces its reflectance and increases its emissivity, enabling better heat rejection

Despite the superior reliability of tubing, hoses are a necessary feature of most hydraulic machines.

QUICK TAKE


HYDRAULIC REBUILDS

Rebuilding of hydraulics equipment involves replacing the necessary parts that would enable it to last long and function like a new one. Therefore, it is important for a user to decipher whether to spend money on rebuilding an

equipment or rather purchase a new one. The key to cost savings lies in making the right choice.

HAULINGHAULINGMONETARY GAINSMONETARY GAINS


HYDRAULIC REBUILDS

ebuilding of a hydraulic component calls for reworking on or replacing all parts necessary to return the component to ‘as new’ condition in terms

of performance and expected service life. Simply put, a rebuilt component should perform as well and last as long as a new one.

The economics of proceeding with rebuilding ultimately depend on the cost of the repair relative to the cost of a new component. In many cases, rebuilding or repairing a component can result in significant savings when compared to the cost of purchasing a new one. As a rule, the more expensive a new component is, the more likely that a repair will be cost-effective.

A component’s rebuild cost is determined by many factors including: Extent of wear or damage to the

component Facilities and expertise of the repairer Repair techniques employed.

If one is responsible for keeping one or more hydraulic machines running and is serious about minimising operating costs, then at some point, a hydraulic component will need to be rebuilt by a specialist. There

are generally three options for rebuilding: the machine dealer, the component manufacturer, or an independently-owned hydraulic shop.

MACHINE DEALERSWith hydraulic component repairs, the capabilities of machine dealers vary. Some have the necessary expertise and equipment to perform most hydraulic rebuilds in-house, while others are completely reliant on outside suppliers to provide this service. If a dealer relies on a third party for repairing hydraulic components, it could end up costing more.

If machine downtime is an issue and the dealer offers an exchange or ‘remanufacturing’ programme, this can be an attractive option.Exchange Programmes: The benefit of an exchange programme is that the dealer carries inventory of rebuilt components. Therefore, instead of waiting for a

component to be repaired, it can be exchanged with a remanufacturing unit from the dealer’s stock.

It is important to understand that the exchange price is not necessarily based on the cost of repairing a particular component. It is usually based on the average rebuild cost for that component plus an inventory charge, and may be conditional on certain parts of the component being reusable.

Because the dealer’s exchange price is based on an average rebuild price, if a component was to be repaired, it could cost more than the exchange price, or it may cost less. Of course, machine downtime costs money and the main advantage of an exchange programme is that downtime is minimised.

If downtime is not a concern, then it is wise to obtain a repair quote for the component before opting for an exchange

unit. This is one reason for scheduling component change-outs upon completion of their expected service life. If component rebuilds can be scheduled when machine downtime is not an issue, it will not be necessary to pay a premium for an exchange unit.

HYDRAULIC COMPONENT MANUFACTURERSWhen a hydraulic component needs to be repaired, a logical option is to send it to the company that manufactured it. It should be noted here that the shop being referred to is a repair shop owned and operated by the hydraulic component manufacturer, rather than an independent hydraulic shop that is an authorised repairer or distributor of the manufacturer’s products. By using the services of a component manufacturer, a repair in accordance with OEM standards can be achieved, but in some cases, this can mean foregoing the opportunity to save money. Here is a case-in-point.

R

Best practices Most automotive-lift needs can be satisfied with a pump from about

1300 to 2000 psi, while pumps designed to operate tools that need to generate lots of torque may need more than 10,000 psi. Smaller jobs like HVAC pumps, may only require around 600 psi.

Always maintain the hydraulic pump properly. These pumps can become blocked or clogged, causing serious damage to equipment and users if not checked regularly.


HYDRAULIC REBUILDS

CASE-IN-POINTSuppose a radial piston motor has been removed from a hydraulic machine and shipped to the motor manufacturer for repair. Upon dismantling the motor, it is discovered that several of the pistons and bores are badly scored as a result of contamination. The manufacturer suggests that because of this damage, the motor housing and all of its pistons need to be

replaced. As a result, the manufacturer’s price to repair the motor is almost as much as a new one.

The client may not want to buy a new motor, if he can avoid it, so he decides to get a second repair quote. This time he takes the unit to an independent hydraulic shop. After inspecting the motor, the repair shop suggests that the motor can be rebuilt for around 60 per cent of the cost of a new

one – a significant saving on a $10,000 motor.

The low cost is possible by employing a money-saving repair technique that involves machining the piston bores to remove scoring, and fitting a set of oversize pistons, thereby salvaging the housing. The oversize pistons are non-genuine or aftermarket parts; however their quality has been proven in a large number of rebuilt units. The repair shop’s confidence in this method of repair is supported by a 12-month warranty.

INDEPENDENT HYDRAULIC SHOPSThe aforementioned example highlights the type of savings possible by using a reputable, independently-owned hydraulic shop to carry out the component rebuilds. The motor manufacturer did not offer this low-cost solution because the oversize pistons are non-genuine parts, therefore the repair is not as per OEM standards. However, just because a repair is not carried out according to OEM standards does not mean the rebuilt component would not perform and last like a new one.

It is important to distinguish between a properly engineered and proven repair technique that will save money and a dubious repair that is likely to cost twice as much in the long-run. It is important to ask two questions before opting for rebuilding equipment at a repair shop: Has the repair technique been proven

successful in terms of performance and achieved service life?

Is the repair covered by warranty?If the repair technique is unproven, or

the shop offering the repair is not willing to back it up with a warranty, think twice before proceeding. There is a need to make an informed decision based on the amount of money the repair technique will save if it works, versus the cost if it does not. The repair shop may be willing to share some of the risk involved in finding out, given that if the technique proves to be successful, it can offer the same solution to other customers. These issues should be discussed with the repair shop before making a decision.

Brendan Casey, Industrial Hydraulics Equipment Expert, has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulics equipment.

Six Easy Steps to Maintain Hydraulic Equipment It is important to first get familiarised with how to use an infrared

thermometer, which is also called a heat gun. If not available, one can purchase it for a modest price.

Next, with a permanent marker or paint stick, draw a small target on the hydraulic tank below minimum oil level and away from the cooler return. Label it 1. This marks the spot to take the tank oil temperature readings. The purpose of these targets is that regardless of who takes the temperature readings, they will be taken from the same place each time.

If the system is a closed-circuit hydrostatic transmission, mark a convenient location on each leg of the transmission loop and number those locations as 2 and 3. Skip this step for open-circuit hydraulic systems.

Next, mark a target on the heat exchanger inlet and outlet and number these 4 and 5, respectively. This records the temperature drop across the cooler. The benefit of this step is that if the oil flow rate through the exchanger and the temperature drop across it are known, the actual heat rejection of the exchanger can be calculated. And if the system is overheating, knowing the actual heat rejection of the exchanger can help determine whether the problem is the result of an increase in heat load (due to an increase in internal leakage, for example) or whether the problem lies in the cooling circuit itself. For example, if a hydraulic system with an input power of 100 kilowatts is overheating, and the actual heat rejection of the exchanger is 30 kilowatts, then the efficiency of the system has fallen below 70 per cent. Therefore, an increase in heat load is the likely cause. On the other hand, if the exchanger is rejecting only 10 kilowatts of heat (which in this example equates to 10 per cent of input power), then it is likely that there is a problem in the cooling circuit or there is insufficient installed cooling capacity.

Install a pressure gauge or transducer to record operating pressure, if one is not already available. If the system is a closed-circuit hydrostatic transmission, install a similar device to record charge pressure.

With that accomplished, now draw up a table to record the date, time, ambient temperature, operating temperatures and operating pressure(s). It needs to be noted that there is little point in recording the temperature across the heat exchanger, if the fan or water pump is not running. And, charge pressure is relevant only to closed-circuit hydrostatic transmissions.


PNEUMATIC SYSTEMS

When it comes to conserving energy by improving the efficiency of pneumatic systems, there are numerous opportunities for savings as a result of a high leak load, intermittent demand, and tubing size reduction among other issues. A few best practices in these areas can

ensure huge returns from pneumatic equipment, be it money or energy.

nergy consumption is one of the key factors that determine the efficiency of a machine or system these days. However, the energy costs generally differ as per

regional variations and over a period of time. But today, users in every region want to extract maximum gains from pneumatic equipment deployed by them in a cost-effective manner. Here are four ways to boost pneumatic efficiency to get the most

out of one’s pneumatic systems:

1BEWARE OF OVER-SIZED COMPONENTSFor decades, managers followed an

interesting practice to always specify over-E

COMPRESSINGENERGY CONSUMPTION


PNEUMATIC SYSTEMS

sized dimension of actuators. If the need were for only 2-inch cylinder, then the specification would be the next larger size. Probably, at the same pressure, the larger actuator would bring more force to the task, and could better cope with heavier or misaligned loads. But, oversizing is equivalent to waste.

The first way to increase energy-efficiency is optimal dimensioning of the components used, thereby avoiding unnecessary air consumption due to oversizing. During the lifecycle of a machine, this adds up to a significant amount of money. Pneumatic components are available in a wide array of sizes, which provide optimal conditions for precise application dimensioning. A cylinder with an application-optimised diameter can reduce air consumption by at least 15 per cent, when compared to one with a commonly oversized diameter.

Many vendors simplify the dimensioning with online calculation and optimisation programmes. Through some basic inputs, the practical result is clearly presented including technical data and recommended components.

In typical installations, by using compact and economical designs with correctly sized cylinders & valves and optimised nominal flows, at least 15 per cent of the air volume can be saved. This equates to energy-related cost-savings of 15 per cent.

2 REDUCE VOLUME BY CUTTING DISTANCE BETWEEN

VALVES AND ACTUATORSMachine efficiency can be substantially increased by reducing lengths of tubing runs between components. Thus, dead volumes would be reduced and pressure losses could be avoided through shorter tube lengths.

In addition, valve/actuator units can reduce tubing connections by 50 per cent and cut energy consumption by 35 per cent. Besides, decentralised systems can also yield faster response times and higher cycle frequencies. This is because, centralised valve manifolds are typically cumbersome, require long air lines, and consume considerable amount of energy. Vendors now offer small, decentralised valves and manifolds that concentrate

pneumatic functions at the point of use. Valves can mount directly to cylinders without hose connections. This direct connection eliminates pressure losses through long lines from the control cabinet to the pneumatic drive.

In order to tackle problem areas in the harsh operating conditions, one needs to consider the decentralised valve units made of engineered polymers that are small, light, chemically resistant and able to withstand the harsh operating environment. Some valves and manifolds have sanitary designs and materials suitable for food processing, eliminating the requirement to house pneumatic valves in remote stainless-steel enclosures with long tubes running to the actuators.

Innovative pneumatics modules with high energy density offer the cycle time advantages of decentralised automation structures and also lower air consumption up to 35 per cent. These compact components are so small and lightweight that they can be integrated directly on the actuators.

3 AVOID USING EXCESS PRESSUREPneumatic systems frequently lead

to energy wastage by supplying higher pressure than what an actuator needs. For instance, in many applications, cylinders either push or pull a load, but not both. Yet most often, machines use the same pressure for both extend and retract strokes, which is extremely inefficient.

Using pressure regulators to supply the

right pressure for each task can lower energy consumption by more than 25 per cent. For instance, ‘smart’ regulators combine digital control electronics with proportional valves. They constantly compare preset pressure limits with actual values to ensure exact metering.

Moreover, there is one concern to guard against – operators generally increase supply pressure on regulators in the hope of improving performance, but this amounts to significant wastage of money in air and operating costs for no actual benefit

– if components are sized correctly. It is important to monitor and ensure that machine pressure remains within designated limits to avoid wastage of energy.

4 MINIMISE LEAKAGEEvery pneumatic system can save energy by avoiding leaks. Statistics

suggest that the problem is widespread: an average facility has to manage 30-35 per cent leakage-related issues, if it has not taken recent action.

Small leakages in compressed air systems can add up to significant costs. Valves and deteriorated seals are two common sources.

Some valve designs, such as lapped-spool valves with metal seals, have inherent internal leakage that is constant as long as air is supplied to the valve. Switching to comparable valves with soft seals can significantly reduce leakage. Another source of leaks is deterioration of seals. If standard seals are observed to degrade, consider using extreme-service seals like viton, teflon or polyurethane.

Modern air-preparation units are available with an integrated air-volume sensor. The sensor emits an electrical pulse each time a specific volume of compressed air has passed through the air-preparation package.

The electrical pulse signals can be totalled by the controller, and therefore, actual air consumption (and energy costs) can be calculated for the machine over a period. This also enables users to detect

increases in machine air consumption that indicate developing leaks or non-scheduled changes to the operating pressures for the motions of the machine. The real-time cost of leakage and over-pressurisation can be

counted, as can be the cost-savings from correcting these problems.

Compiled by Sandeep Pai

Every pneumatic system can save energy by avoiding leaks. Statistics suggest that the problem is widespread: an average facility has to manage 30-35 per cent leakage-related issues, if it has not taken recent action.

VIEW FROM THE TOP: Shyam Kambeyanda, President – APAC, Hydraulics Group, Eaton Corporation

on pg. 54


The hydraulics industry has been at the threshold of progress over the years and most of the developments in this area are offering immense benefits to hydraulic equipment owners. But, it has come at a cost. Higher operating pressures and closer tolerances make the

hydraulic machine more susceptible to wear and damage resulting from oil contamination and inadequate lubrication. This means proactive maintenance is essential for optimum reliability and performance of today’s hydraulic equipment. Here are some do’s and don’ts…

onstant progress is part of life and it manifests itself in different ways. In engineering, it is in the form of technological advancements, with

machines and their component parts becoming stronger, lighter, cheaper, smaller, more powerful and efficient. Nowhere is this more evident than in the field of information technology (IT). In fact, according to Moore’s Law, the power of

computer chips doubles every 18 months. At the same time, the cost of this extra computing power decreases exponentially for the consumer.

But as the cost of computing power to the consumer goes down, when it comes C

GAUGING WHAT’S NEXTGAUGING WHAT’S NEXTININ HYDRAULICS HYDRAULICS

TRENDS & TOOLKIT


TRENDS & TOOLKIT

to fulfilling the Moore’s Law, the cost for manufacturers heads in the opposite direction. This is because R&D, manufacturing and testing costs have steadily increased with each new generation of chips.

This has led to the definition of Moore’s Second Law, which states that the capital cost of semiconductor fabrication increases exponentially over time. This means progress comes at a cost – somewhere along the supply chain, at least.

The rapid and constant development that has been witnessed in the IT sector is hard to match. But like most other areas of mechanical engineering, the hydraulics industry has not been resting on its laurels, either. Component operating pressures have increased steadily over the past 30 years, and this trend is expected to continue. Seal and hose design has improved accordingly, as has oil additive and filtration technology.

Advances in materials and manufacturing techniques mean that more efficient hydraulic components with higher power densities are available at lower cost. And just as Moore’s Law is expected to hold true for another generation, so will the pursuit of performance gains by hydraulic equipment manufacturers. The question that now arises is what will be next in this domain.

It is seen that most of the original equipment manufacturers (OEM) demand components that can handle hydraulic system operating temperatures in excess of 110° C. This number is not for margin of safety, but for continuous operation. But heat is the biggest enemy of a hydraulic system. It is bigger than particle and water contamination these days due to the widespread understanding and adoption of modern filtration technologies. And so, a hydraulic system running at 110° C is not an ideal one. Given below are some of the reasons as to why this is so.

OIL LIFEAccording to Arrhenius’ Law, for every 10°C increase in temperature, the rate of reaction doubles. The chemical reactions – in so far as hydraulic oil life is concerned – are oxidation (due to the presence of air) and hydrolysis (due to the presence of water). This means that hotter the oil, the faster the rate of these reactions.

By way of illustration, if some cooking oil is poured into a glass, it will take days, even

weeks, before it darkens in colour – a sign of oxidation. But pour the same amount of cooking oil into a frying pan – which gives the oil a large contact area with air – and then heat it, the oil will go black in a short time.

Shop floor workers have revealed that when lab-testing hydraulic components at temperatures of 110°C and above for extended periods, the oil had ’turned black as ink and smelt unmentionable’.

OIL VISCOSITYThe operating viscosity of hydraulic oil is crucial for both adequate lubrication and efficient power transmission. The higher the maximum expected operating temperature, the wider the temperature operating window becomes. And the wider the temperature operating window, the more difficult it is to maintain oil viscosity within both allowable and optimum limits.

For example, consider a system with a cold-start temperature of 5°C and a maximum operating temperature of 110°C. To maintain viscosity between 800 centistokes at cold start and 25 centistokes at maximum operating temperature, it would require ISO VG150 oil with a viscosity index of 2291.

SEAL AND HOSE LIFELike everything else, the elastomers used to make hydraulic seals and hoses are improving all the time. But oil temperatures above 82°C accelerate the degradation of most of these polymers. In fact, according to one seal manufacturer, operating temperatures recommended above 10°C limits can reduce seal life by 80 per cent or more.

The constant cycle of heating and cooling – a process known as aging – is

more severe when temperature extremes are greater. Aging causes these polymers to lose their elastic properties. This results in leaking seals and hoses.

FALSE PROGRESSIncreasing the temperature at which a hydraulic system is expected to operate does nothing to enhance machine performance. It only compounds a host of reliability issues, which cannot be solved with current technologies. So, it is not progress, but regress. This false progress will certainly come at a cost – to the hydraulic equipment owners who operate them.

Knowing these criticalities, here are the most common hydraulic equipment mistakes made by the shop floor personnel.

MOST COMMON HYDRAULIC EQUIPMENT MISTAKES

1 1 Changing the oilThere are only two conditions that mandate a hydraulic oil change:

degradation of the base oil or depletion of the additive package. Because there are so many variables that determine the rate at which oil degrades and additives get used up, changing hydraulic oil based on hours in service, without any reference to the actual condition of the oil, is like shooting in the dark. Given the current high price of oil, dumping oil which does not need to be changed is the last thing one would want to do. On the other hand, if one continues to operate with the base oil degraded or additives depleted, it would compromise on the service life of every other component in the hydraulic system. The only way to know when the oil needs to be changed is through oil analysis.

Increasing the temperature at which a hydraulic system is expected to operate does nothing to enhance machine performance. It only compounds a host of reliability issues, which cannot be solved with current technologies.

Using the wrong viscosity oil not only results in lubrication damage and premature failure of major components, it also increases power consumption (diesel or electricity)

The only way to know when the oil needs to be changed is through oil analysis A different set of problems arises from filters installed on the drain lines of piston pumps

and motors, but the result is the same as suction strainers. They can reduce service life and cause catastrophic failures in these high-priced components.

QUICK TAKE


TRENDS & TOOLKIT

2 2 Changing the filtersA similar situation applies to hydraulic filters. If these are changed based on

schedule, it would be like changing them either too early or too late. If it is early, before all their dirt-holding capacity is used up, it results in wastage of money on unnecessary filter changes. If it is late, after the filter has gone on bypass, the increase in particles in the oil quietly reduces the service life of every component in the hydraulic system – costing a lot more in the long run.

The solution is to change filters when all their dirt-holding capacity is used up, but before the bypass valve opens. This requires a mechanism to monitor the restriction to flow (pressure drop) across the filter element and provide an alert when this point is reached. A clogging indicator is the crudest form of this device. A better solution is continuous monitoring of pressure drop across the filter.

3 3 Running too hotFew equipment owners or operators continue to operate an engine that is

overheating. Unfortunately, the same cannot be said when the hydraulic system gets too hot. But like an engine, the fastest way to destroy hydraulic components, seals, hoses and the oil itself is high-temperature operation.

How hot is too hot for a hydraulic system depends mainly on the viscosity and viscosity index (rate of change in viscosity with temperature) of the oil, and the type of hydraulic components in the system. As the oil’s temperature increases, its viscosity decreases. Therefore, a hydraulic system is operating too hot when it reaches the temperature at which oil viscosity falls below that required for adequate lubrication.

A vane pump requires a higher minimum viscosity than a piston pump, for example. This is why the type of components used in the system also influences its safe maximum operating temperature.

Apart from the issue of adequate lubrication, the importance of which cannot be overstated, operating temperatures above 82°C damage most seal and hose compounds and accelerate degradation of the oil. But for the reasons already explained, a hydraulic system can be running too hot well below this temperature.

4 4 Using the wrong oilThe oil is the most important component of any hydraulic system.

Not only is hydraulic oil a lubricant, it is also the means by which power is transferred throughout the hydraulic system. It is this dual role which makes viscosity the most important property of the oil, because it affects both machine performance and service life.

Oil viscosity largely determines the maximum and minimum oil temperatures within which the hydraulic system can safely operate. If the oil used has a viscosity that is too high for the climate in which the machine must operate, oil would not flow properly or lubricate adequately during cold start. If oil with a viscosity too low for the prevailing climate is used, it would not maintain the required minimum viscosity, and therefore, adequate lubrication would be called for, on the hottest days of the year.

But that is not the end of it. Within the allowable extremes of viscosity required for adequate lubrication, there is a narrower viscosity band where power losses are minimised. If operating oil viscosity is higher than ideal, more power is lost to fluid friction. If operating viscosity is lower than ideal, more power is lost to friction and internal leakage.

Using the wrong viscosity oil not only results in lubrication damage and premature failure of major components, it also increases power consumption (diesel or electricity) – two things that are not desired.

5 5 Wrong filter locationsIt is a general misconception that any filter is a good filter. There are two

hydraulic filter locations that do more harm

than good and can rapidly destroy the very components they were installed to protect. The filter locations that should be avoided are the pump inlet and drain lines from the housings of piston pumps and motors.

This contradicts conventional wisdom: it is necessary to have a strainer on the pump inlet to protect it from ‘trash’. The pump draws its oil from a dedicated reservoir, not a garbage can.

If getting maximum pump life is the primary concern (and it should be), then it is far more important for the oil to freely and completely fill the pumping chambers during every intake than it is to protect the pump from nuts, bolts and 9/16-inch combination spanners. These pose no danger in a properly designed reservoir, where the pump inlet penetration is atleast two inches off the bottom.

Research has shown that a restricted intake can reduce the service life of a gear pump by 56 per cent. And, it is worse for vane and piston pumps because these designs are less able to withstand the vacuum-induced forces caused by a restricted intake.

A different set of problems arises from filters installed on the drain lines of piston pumps and motors, but the result is the same as suction strainers. They can reduce service life and cause catastrophic failures in these high-priced components.

6 6 Believing hydraulic components are self-priming and self-lubricatingOne would not start an engine

without oil in the crankcase – not knowingly, anyway. And yet, the same thing happens in case of several high-priced hydraulic components.

The fact is, if the right steps are not followed during the initial start-up, hydraulic components can be seriously damaged. In some cases, they may work adequately for a while, but the harm incurred at start-up then dooms them to premature failure.

There are two parts to getting this dilemma right: knowing what to do and remembering to do it. Not knowing what to do is one thing. However, if one knows the right option, but forgets to do it, that is destructive. It would not be wise to fill the pump housing with clean oil when one does not remember to open the intake isolation valve before starting the engine.

Compiled by Sudhir Muddana

The operating viscosity of hydraulic oil is crucial for both adequate lubrication and efficient power transmission. The higher the maximum expected operating temperature, the wider the temperature operating window becomes. And the wider the temperature operating window, the more difficult it is to maintain oil viscosity within both allowable and optimum limits.


ork output in a potash mine is dependent on machines with high mobility and production efficiency. As global demand for potash increases, Canada’s PotashCorp of Saskatchewan (PCS) has stepped up production at its Rocanville, Saskatchewan

mining facility with a continuous bore mining machine that extracts around 1,200 tonne of potash ore per hour. Propelling the massive four-rotor mining machine are two Eaton Hydrokraft 250-cc motors that constitute the heart of the hydraulic system on the X CEL 44 Series miner built by Prairie Machine & Parts Manufacturing of Saskatoon.

THE NEEDPCS has relied on HyPOWER Systems of Regina, Saskatchewan, an Eaton distributor, to provide hydraulics muscle and hydraulics commonality for its mining machinery. When the need for an additional miner became evident, PCS asked HyPOWER to redesign hydraulic circuitry for the machine and to work with Prairie Machine on fit, functionality and integration requirements. Delving into the project, HyPOWER’s Ken Pagan, technical sales representative, and Cal Ganshorn, mechanical engineering technologist, called on Eaton’s Lyle Meyer, Hydrokraft product manager, for a two-speed hydraulic motor recommendation. “We explained Lyle that the motors would need to increase tram speed over PCS’ current miners that move at a snail’s pace. Besides, it should fit into a tight envelope on the miner. In addition, motors would need default to maximum displacement, if hydraulic system pilot pressure was lost,” Ganshorn explained.

HYDROKRAFT TWO-SPEED MOTORMeyer proposed Eaton’s compact Hydrokraft two-speed motor for the application, after confirming with Eaton’s Wehrheim, Germany, manufacturing facility that a customised version would default to maximum displacement, not minimum displacement as does the standard version, when pilot pressure is lost. Ganshorn specified the

custom Hydrokraft motors into the hydraulic system design proposal that also included Eaton DG4S4 valves, V Series vane pumps, and a Series 2 piston pump that would operate auxiliary functions. PCS liked the proposal and gave HyPOWER its endorsement to design the miner’s hydraulic system around Eaton Hydrokraft motor.

RESULTSFollowing assembly and testing, the miner was completely disassembled in order to be transported down the mineshaft. Along with these projects, the task of carving out rock 3,200 feet below the Saskatchewan prairie was performed in order to build a shop to reassemble the 38-foo0t-long by 22-footwide miner piece by piece.

Overall, the multi-million dollar investment is already paying off for PCS. The machine has been up and running since November 2009 and is significantly faster than the other PCS miners. “Our hydraulic system design with the Eaton Hydrokraft motors has enabled the new X CEL miner to increase tram speed by 40 per cent,” Ganshorn notes. “The time savings enable the operator to help with set-up sooner and allows to move the electrical set much sooner as well,” Huber says.

“Eaton’s Hydrokraft motors offer twice the drive torque to the tracks, which results in better control. Tram pressures are lower, resulting in lower operating temperatures in the hydraulic system.”

Courtesy: Eaton Corporation

W

A potash mine in Canada had been exploring ways to resolve problems pertaining to hydraulic operations, while at the same time increasing productivity and work speed. Eaton’s compact Hydrokraft two-speed

motor accelerated non-productive operations, such as relocating the miner and increasing cutting operation efficiency, through precise delivery of torque to the tracks during mining operations.

PROBLEMNeed for a compact, two-speed hydraulic motor that would increase tram speed of a miner and default to maximum displacement in the event of pilot pressure loss

SOLUTIONEaton’s customised Hydrokraft motor not only augmented the tram speed but also ensured operational efficiency.

SPEEDING OPERATIONS,SPEEDING OPERATIONS,MAXIMISING OUTPUTMAXIMISING OUTPUT

EATON HYDRAULIC MOTOR


HYDRAULICS EQUIPMENT

11UALTERNATIVE PARTS IN OLD EQUIPMENTIn India, most industries use old,

worn-out equipment. These equipment are strong, but unfortunately, easy availability of equipment parts is a major issue. Under the circumstances, companies choose substitutes, make alterations in components or use similar components from other manufacturers to repair non-functioning equipment components. This is not wrong but risky, as often the repair team is not well-equipped to check the direction of rotation of pumps and their capacity. This creates further complexities, as each hydraulic system is designed for certain capacity and all factors of heat, speed, torque are calculated closely. Skipping even a single step, can damage the equipment.

22BENEFITS OF REACHING OPERATING TEMPERATURE

Hydraulic systems are designed to work at maximum efficiency after it reaches the operating temperature. Thus, it is recommended to start the engine or the electric motor and let it run at idle speed for 5-10 minutes. This helps in case of pumps and motors, as they reach their respective operating temperatures to do the assigned work.

33PREVENTIVE MAINTENANCEMost new equipment ranges are

computer controlled with PLC programmed to stop a system, if oil level goes down or if operating temperature rises above normal. No matter how foolproof these machines are made, human errors cannot be ruled out. Proper maintenance of all hydraulic systems can enhance its life for at least five to seven

years. Implementing simple maintenance principles like replacing filters on time to keep the oil clean, replacing hydraulic oil, etc, will keep the system running efficiently.

44REPLACEMENT ISSUESAnother simple cause of damage of a hydraulic system is replacement of

hydraulic hoses. Most technicians are ignorant of what is inside the new hose. These may contain rubber particles of the same hose or iron filings from the wire that is cut when building a hose to the correct length. These filings can damage the pump/motor or even cause malfunction to control valves. In order to prevent damage, all new hoses must be thoroughly flushed from the inside and blown by air at relevant pressure to make it absolutely clean before installation.

55SYSTEM CONTAMINATIONA major fault noticed frequently on

job sites is when an equipment like pump/motor or any hydraulic component is opened, the parts are left open/loose until another alternative or part is replaced. This results in system contamination due to entry of dust from passing vehicles, rainwater, etc causing more damage to the system. In order to avoid this contamination, one must clean the component thoroughly from the outside before opening the machine.

66FAULT-FINDING When executing fault-finding, it is necessary to analyse the problem

before opening any component. A mender should first ascertain whether it is a mechanical, electrical or a hydraulic problem. In all new machines with automated systems, there is override for

every control; one can operate it manually to determine the fault. Like solenoid can be operated manually by pushing pins at ends, overheating of defective solenoid coils also cause problems. Often, hydraulic gauges also signal towards malfunctioning processes.

While troubleshooting, it is also noticed that people keep replacing components until they hit the right spot. A sequence should be followed during fault-finding. The more the number of components opened in hydraulic system, more dirt enters the system.

77HANDY TIPSIf one replaces a piston pump, it is mandatory to observe the charge

pressure as soon as the driving unit is started. If the pressure is not seen (normally 150-300 psi), the unit must be immediately shut down to check fault. Also, whenever a piston pump is replaced, it is important to fill the pump with hydraulic oil to ensure a fulltime lubrication inside the housing. The drive unit RPM should not increase to the maximum, as procedures need to be followed before putting machine under full load after pump replacement.

88FINDING THE RIGHT EXPERTISEOnly skilled workers should

undertake repair of hydraulic components. It may be difficult to get hydraulic technicians on the job site. In order to solve this issue, end-user/equipment owner can hire a skilled consultant to train their technical crew, which will not only cut the downtime cost but also drastically increase the machine’s performance.

Kersi M Pooniwala, Hydraulics Mechanical Consultant

Proper and regular maintenance of hydraulic equipment is a prime concern for industries to ensure longer service life and also prevent damages. Here are 8 handy tips to consider while repairing a hydraulic equipment to increase productivity and achieve cost efficiencies.

&


PAINTS & POLISHES

PAINTS AND POLISHES: ‘Coated’ with Vibrant Opportunities ......................................................90

IR HEATING TECHNOLOGY: Offering Innovative Solutions For Paint Drying & Curing ................96


PAINTS & POLISHES

onsidered merely as aesthetic elements, industrial paints and polishes, to a great extent, had failed to get their due importance in the entire

manufacturing cycle. Considering their criticality in providing durability, protection and ease of application, manufacturers could not only have smooth functioning machinery, but also have higher productivity through the selection of right kind of paints and polishes. With the growing awareness about the benefits of paints and polishes, the industrial paint segment has seen a surge in terms of increasing marketshare and applicability to various verticals in the industrial sector.

SUNRISE INDUSTRY Globally, the industrial paints segment accounts for a major share, indicating that this segment offers many opportunities for paint manufacturers. Since June 2009, production volumes in the sector have substantially recovered due to the recovery in realty. Production of paints grew by a robust 25.2 per cent during April-February 2009-10 compared to a 40 basis points drop in production in the corresponding year-ago period.

The Indian paint industry consisting of decorative paints and its less glamorous counterpart, industrial paints, is coming out of the economic trough and is expected to register over 11 to 14 per cent growth in 2010-11. If that happens, the turnaround, though not staggering would still be quite remarkable, considering that this industry notched up only 10 per cent growth in the first half. The industrial paints segment is further divided into other specific categories, of which protective paints constitute 25 per cent, auto component paints - 25 per cent, OEM paints - 20 per cent, marine paints - 20 per cent and speciality industrial paint another 10 per cent.

Apart from the automotive sector, industrial paints are used in various sectors like power, steel, petrochemicals, oil refineries and gas pipelines, to name a few. The renewed thrust on infrastructure in the budget for 2010-11 will create substantial investment opportunities in the coming months. For instance, the coatings segment can expect a windfall from new projects in the power, road & road marking, port & airport and industrial sectors. Small and medium enterprises constitute 30 per cent of the Rs 15,000-crore Indian paint industry; the rest is dominated by

bigger brands such as Asian Paints, Berger Paints, Kansai Nerolac, ICI and Shalimar Paints.

The paint industry, whose fortunes depend mainly on housing & construction activity

A world without colours is unimaginable. Despite this fact, paints, one of the elements that add colour to life and for that matter responsible in smooth functioning of equipment and machinery, are yet to get their due importance as an essential component of manufacturing. Having said that, things are not lacklustre for the Indian paints industry, which is slowly and steadily gaining pace, thanks to a dramatic surge in the automobile & construction sectors. Time is right for the Indian paints & polishes industry when companies are looking at improving efficiencies and adopting environment-friendly practices.

C PURNA PARMAR & GEETHA JAYRAMAN

‘COATED’ WITH‘COATED’ WITHVIBRANT OPPORTUNITIESVIBRANT OPPORTUNITIES


PAINTS & POLISHES

(decorative), and infrastructure & manufacturing sector, particularly automobile (industrial), had been growing at nearly 15-20 per cent for the past 10 years till recession took its toll in 2008-09. However, now the worst seems to be over, feel those closely associated with the industry. Demand for both decorative and industrial paints has picked up as compared to last year.

“The increasing demand in real estate and automobile sectors, which are key consuming markets for paint companies, has made the paint manufacturers hopeful of witnessing steady business during the current financial year,” says Dr HBS Lamba, President, Indian Paint and Powder Coating Manufacturers Association (IPPMA). The association, which claims to represent the bulk of the paint manufacturers, is confident that the sector will go past the previous year’s growth rate of 9 per cent.

Early signs of economic revival and mounting demand from key user industries have put the scales in favour of the paint industry. Buoyed by these developments, paint companies are charting out expansion plans, albeit cautiously. Strategic tie-ups and alliances are in the offing; and, new and innovative products will soon find their way back into the market.

“There are clear signs of the economy stabilising in India. The third

quarter has shown

satisfactory results. Improved demand from end-use industries and our continuous focus on cost efficiency helped us capture the benefits of this demand,” Prasad Chandran, Chairman & MD, BASF India, noted while announcing his company’s third quarter results.

With the spotlight back on the paint industry, there is, as usual, a keen tussle between decorative and industrial paints. These two segments account for 70 per cent and 30 per cent of the paint market, respectively. Many paint companies manufacture both, though. Experts say that in a few years, the ratio will narrow down considerably and reflect broad global trends. Decorative paints may account for the bulk of the market, but it is far more unorganised than industrial paints. The latter is more profitable and technology-driven.

TECHNOLOGY ADVANCEMENTS The paint industry is not just growing in volume, but is also scaling up the technology ladder. There have been many technological advancements in both decorative as well as industrial paints categories. Umesh Tawde, CEO, Harlequin Chemicals, manufacturer and applicator of speciality coatings and paints, said, “There are many technological advances observed in the paint industry. Often, a new technology is introduced in the market – application techniques as well as chemicals and solvents. The latest technology that is widely used is the nanotechnology, which helps in enhancing the properties of paint and helps in

achieving superior quality paints. Attributes like scratch resistant, stainlessness, gross retention, exposure can be obtained through nanotechnology. In the area of wood coating, the latest technology introduced is Polyurethane (PU) Wood Coating. Inorganic zinc coating, polyester coating, nanocrystaline zinc coating, fluro ply bond, to name a few, are also getting popular.”

Meanwhile, Indian climatic conditions are not conducive for

foreign formulations; and modification cost in product formulation is high. As a result, imports are not much of a threat to Indian players. In the case of industrial paints, major players already have a tie-up with global players for the latest technologies and markets accessible to them. It negates the further supply from the international markets even after reduction of import duty from 40 per cent to 15.3 per cent in the last eight years.

PRODUCT CULTUREMost companies have an identical range of products for the decorative paint market. In the industrial segment, the range is more customised and guided by the technology support provided by the collaborators. In the case of decorative category, the technology has been mostly indigenously perfected over the years and the products can be divided on the basis of interior and exterior applications or in sections such as water-based and solvent-based.

Moreover, most companies have been advertising their products in the interior/exterior emulsions category, which has expanded the market and triggered a shift from distempers and cement paint. While solvent-based enamels are still popular in India, there is a clear shift from solvent to water-based glossy enamels in overseas markets; India will take some time to switch over to water-based coatings.

For the decorative range, it is difficult for international companies to set up shop on a standalone basis because of existing barriers such as the strong network of established players, brand image, range of products (Indian context) and required distribution logistics. Therefore, the safer

The per capita consumption of paint in India is low, even in countries like Nepal, the per capita consumption of paint is much higher than that of India. This is mainly due to the tax imposed by the government. Currently, paints as a product category comes under the luxury segment and the tax imposed by the government is around 13 per cent, making the

product expensive.

RANJIT SINGH,Managing Partner, Balsons Paint Industries


PAINTS & POLISHES

route has been and will be to tag along with existing companies.

For industrial products, however, this may not apply and based on their tie-ups in home countries and their OEM customers, the required range can be produced and sold. There is, however, room for niche players, with radical and unique ranges of products properly conceived and marketed in the Indian context and supported with machines. There is a huge variety of industrial paints available in the market; following are a few examples of industrial paints.

AUTOMOTIVE PAINTS There are various kinds of automotive paints used in the manufacturing industry. Some of them are listed below: Protective Coatings or Industrial

Coatings are used to decorate, protect the substrate. They provide resistance to corrosion, abrasion, alkalis & acids salt, water, etc.

N C Lacquer is a nitro cellulose lacquer, fast drying, single component eco-friendly paint which is used on cars, motorcycles, scooters, truck bodies, etc.

Polyurethane is more durable, attractive and requires no rubbing.

Auto Refinishing is similar to enamel paints and takes almost 12-16 hours for hard drying. It is mainly used on commercial vehicles like auto rickshaws, tempos, and bus bodies where refinishing is required.

PROTECTIVE COATING Protecting industrial asset is increasingly becoming critical owing to rising asset costs, harsh weather conditions and mounting chemical pollution. Therefore, asset owners are looking at specialised protective coatings specific to their requirements. Protective coatings offer a choice of high-performance, heavy-duty coatings, and are designed to protect assets against the specific corrosive environment they are exposed to. These coatings are tested under extreme conditions to ensure that they are durable and can withstand the vagaries of the different climatic conditions. Today, coatings find use across diverse industries such as nuclear, thermal or hydro power plants, chemical, petrochemical or fertiliser plants, refineries, sugar, pulp and

paper industry, offshore structures, pharmaceuticals etc.

TINTING SYSTEMMetal polyurethanes give an unrivalled finish to metals and prepare it to take on the elements of nature. These coatings can take on salty wind, pouring rain or the rising pollution levels all with equal flair.

POWDER COATINGSCustomers today demand higher quality and durability from the products they buy. Not only do they expect these products to perform well but also they want the finish to resist corrosion for a much longer period of time.The finishing processes for powder coatings are thus designed to do just that.

These are blends of resins, curing agent and pigments, which are melt-mixed and pulverised into finely, divided particles. There are no liquids or solvents. Therefore, it is the ultimate coating for environmental friendliness. It is applied to metal products by electrostatic spray, the coated item is then heated and the powder melts into smooth, continuous film. Powder coatings are gaining popularity because of their high

quality, the apparent ease of application and the environmental friendliness of the technology. It has been a commercial reality now for close to thirty years.

GOING GREEN The paints industry is always stereotyped as one of the most polluting industries. However, this scenario has changed and manufacturers have realised the importance

of green globe and started using more eco-friendly measures to produce both industrial as well as decorative paints.

Conventional paints have more than 1,000 chemicals and substances such as formaldehyde and benzene. These chemicals may lead to health problems.

Low-level exposure to paint based on lead-based pigments may irritate or burn the eyes, nose, throat and skin and cause reactions such as headaches, dizziness or nausea, while high levels of exposure to some of the elements in paint, even for a short period, can cause severe and lasting impact such as kidney or liver damage or respiratory problems. Some of the paint companies have proactively worked towards the elimination of lead-based pigments and have substituted non-toxic raw materials.

Thus, eco-paints are non-toxic with low volatile organic compound (VOCs). These paints have no odour and can be converted to any colour with non-toxic tints. They are produced from fewer than 250 chemical components and more than 98 per cent of these chemicals are derived from plant sources and minerals. The raw materials are also low in toxic substances, renewable and feature a low environmental footprint.

Dr Lamba elaborates, “There is a new trend observed in the market; more consumers stress on being environment-friendly, right from their lifestyles to the products that they use are preferred to be eco-friendly. Hence, keeping in mind the growing trend, paint manufacturers have also started manufacturing eco-friendly paints for both industrial and well as decorative segments.”

While decorative paints have found their place in the market and are well-established, eco-friendly industrial paints are still at a nascent stage. Tawde further explains, “While most manufacturers are now producing water-based paints, industrial paints like automotive paints, and

Paints are considered as beautifying agents. However, while paints do add to the aesthetic value of a building or a manufacturing equipment, it also protects it from corrosion. It helps in extending the life span of a machine and also helps in its smooth functioning. We as manufacturers need to highlight these aspects of paints and explore

new areas of application.

DR HSB LAMBA,President, Indian Paint and Powder Coating

Manufacturers Association (IPPMA)

Paint is a raw material-intensive industry. It takes over 300 different raw materials to produce paints, most of which are petroleum-based. Titanium dioxide is the largest consumed raw material. It constitutes approximately 30

per cent of the total manufacturing cost.


PAINTS & POLISHES

coating still remain solvent-based. One of the major reasons for this is lack of finance and infrastructure to test chemicals. Most manufacturers in the SME segment prefer to stick to the traditional solvent-based paints, as they do not have enough finance to test and experiment with chemicals and solvents. To help facilitate this, IPPMA has planned to set up community laboratories for the SMEs in various zones.”

ROADBLOCKS Although the industrial paints segment has witnessed an upward curve, there are still many bottlenecks to be resolved. One of the biggest challenges faced by the industry is the lack of awareness. Although paints and polishes play a vital role in smoothening the manufacturing process, very few consider it as a necessity. Paints are functional and are largely considered as beautifying agents than protective agents. Dr Lamba elaborates, “Paints are considered as beautifying agents. However, while paints do add to the aesthetic value of a building or a manufacturing equipment, it also protects it from corrosion. It helps in extending the life span of a machine and also helps in its smooth functioning. We as manufacturers need to highlight these aspects of paints and explore new areas of application.”

Another challenge faced by the industry is tax and duties imposed by government. Currently, the per capita consumption of paints is only 1.7 litre, which is low as compared to global standards. Even in economies like China and other developing countries like Nepal, the per capita consumption of paints is 16-14 litre respectively. Ranjit Singh, Managing Partner, Balsons Paint Industries, explains, “The per capita consumption of paint in India is low, even in countries like Nepal, the per capita consumption of paint is much higher than that of India. This is mainly due to the tax imposed by the government. Currently, paints as a product category comes under the luxury segment and the tax imposed by the government is around 13 per cent, making the product expensive. But, if the government reduces this tax imposed on the product by removing it from the luxury segment, it would be beneficial for both manufacturers as well as consumers. Often paints are seen as cost, but with less tax

imposed by the government, the consumption of paints would also increase.”

Paint is a raw material-intensive industry. It takes over 300 different raw materials to produce paints, most of which are petroleum-based. Titanium dioxide is the largest consumed raw material. It constitutes

approximately 30 per cent of the total manufacturing cost. Besides this, there are petroleum-based raw materials, which constitute 40-50 per cent of the total raw material consumed. Hence, any fluctuation in crude oil prices has an impact on the prices and profitability in the paint industry.

SELECTING THE RIGHT PAINT While eco-friendly paints are the need of the hour, selecting the right paints for the manufacturing equipment is also equally important. Singh points out, “Selection of paints depends on various factors like atmospheric conditions, chemical exposure of the area of application, acid – alkaline compound of the area of application and the surface to be painted. Moreover, the area of application has also increased in sectors like construction, machines, automotives and accessories application area has increased by 20 per cent.”

FUTURE TRENDS The Indian paints and coatings industry was riding high on the growth in the Indian automobile industry, new construction in

the housing segment and improving infrastructure throughout the country. But the global financial crisis of the recent past had impacted the paint industry to some extent as a result of slowdown in real estate and auto industry. Top-line growth was affected to some extent while the bottom-line was certainly under pressure.

According to Dr Lamba, consumers are looking forward to new product launches

for application in special areas. Companies are increasing the value-added services available to customers by offering a variety of finishes through specialised and trained

applicators, well supported by back-end support of specialised service.

There has been a higher growth of emulsion paints for interiors vis-à-vis

distempers. There is an increasing use of economy emulsion in place of lower-priced distempers. Similar is the trend for exteriors where emulsion-based coatings are now preferred against conventional cement-based coatings.

Continuously looking for better products, more consumers are

switching to marginally higher-priced emulsions where they get more durable and better-looking finishes in a wider range of colours.

According to Dr Lamba, the players with aggressive marketing strategies and comprehensive product portfolios will grow at a faster rate. The emerging trends in technology and marketing indicate that the industry is likely to consolidate in the coming years with industry leaders improving their marketshare.

In spite of economic slowdown, the Indian paint industry is growing upwards. It has tremendous potential for growth in the coming years. The decorative segment has outpaced the industrial segment in growth rate but the industrial segment has the greater potential for growth, as and when the automobile industry business improves.

EQUIPMENT BUYING GUIDE: Energy-efficient Motors

Embracing The Green Solution

on pg. 130


magine if one could reduce the energy bills of paint shop operations by 15-20 per cent, or consider doubling the productivity of painted components

while saving approximately 60 kW of energy per hour. Yes, it is possible to achieve enhanced quality, increased productivity, and yet save substantial energy in the process.

In other words, it is possible for a company to beat its competitors and gain market leadership by producing higher quality products for a lower unit cost. This is now achievable through path-breaking innovation in infrared (IR) heating technology encapsulated in the design of cutting-edge IR emitters, new IR reflecting materials and

the architecture of the heating system and its electronic controls.

THE PAINTING PROCESSIt is a known fact that the painting process

serves the dual purpose of protecting any type of surface as well as enhancing its aesthetic value, thereby giving any product a higher market appeal. Recent trends and awareness in the direction of environment

Considered as the most efficient form of radiation in the electromagnetic spectrum with regards to transfer of heat, infrared (IR) heating technology is being touted as the next generation practice for drying and curing paints. The biggest benefit is that IR emitters can deliver

heat in exact amounts directly to a specific point, thereby saving a significant amount of energy. A quantum leap is possible in paint drying and curing efficiency, provided a radical, out-of-the-box approach is taken when planning new paint curing operations or upgrading

existing facilities.

I

OFFERING INNOVATIVE SOLUTIONS FOR PAINT DRYING & CURING

Convection heating Infrared heating

*First the air is heated. *Then the paint film is heated from outside

by convection which is a slow process. *Heat transfer is through the paint film by

conduction ( paint is a bad conductor of heat)

*IR does not need a medium to heat *IR rays penetrate the paint film, are partly

absorbed in paint film, partly at surface and partly reflected. During reflection they reheat the film. As a result, the film is heated uniformly throughout its thickness.

Note the temp profile:*High at paint surface, low at bottom*Entire mass gets heated*Slow process

Note the temp profile: IR rays penetrate the film.*Hence heating throughout the film is uniform.*Entire mass need not get heated – an especially useful property when heavy castings etc are to be heated.*Fast process- Typically infrared heating takes only one-third the time of convection heating.

A brief comparison of convection heating (hot air), which is a common method of heating in the industry versus IR

INFRARED HEATING TECHNOLOGY



protection has led to worldwide legislation forces wanting to limit the emission of volatile organic compounds (VOC). This has encouraged many companies to become more responsible and adopt water-based paints and coatings (eco-friendly materials) as a replacement to

solvent-based coatings. However, water-based paints are known to require longer drying times, which results in extended process times and reduced throughput, thereby affecting manufacturing operations. By using IR heating, water-based paints are effectively force dried and cured within a few minutes.

HOW IR WORKS FOR PAINT FILMSIR is the most efficient form of radiation in the electromagnetic spectrum with regard to transfer of heat. In other words, the IR emitters heat the object without heating the air in between. It has virtually similar properties as light. It travels in straight lines from its source and can be focussed into specific zones by special reflectors. IR is categorised into short wave, medium wave and long wave. Popular emitters of IR (made in quartz) have low thermal inertia; hence, they are instant on/off type (i.e. heat-up/cool down times of about 1 second).

A few advantages of radiant (IR) heat for surface painting applications are as follows:Non-Contact Heating: As there is no physical contact of the air, there is no contamination due to airborne dust particles. This in important in cases where such contamination can mar the quality of

the surface of any product.Fast Response: Low thermal inertia of an IR heating system eliminates the need for long pre-heat cycles. As IR emitters require only a few seconds to reach operating temperatures, they can be switched off even during small breaks in production, thus saving energy. Shorter Time Cycles: Due to one-stage heat transfer, IR heating times are typically one-third of convection ovens. High Efficiency: IR is energy in the form of electromagnetic waves. Since IR does not impact the air or surroundings, the energy radiated may also be concentrated, focussed, directed and reflected in the same

manner as light. This greatly increases its flexibility and adaptability and reduces energy losses.Control Accuracy: Electric IR emitters can be easily and precisely controlled. They can be zoned wherever required. IR sensors can sense the actual product temperature and be used to control the heater temperature or line speed.Clean heat: Unlike gas-fired ovens, electric radiant heaters do not produce combustion by-products, so the product is not contaminated. Low air velocities reduce the possibility of surface contamination by airborne dirt.

IR can enable breakthrough innovations in the whole of painting process including drying and curing. This is possible by way of using IR boosters, compact IR ovens, infrared heating systems, to name a few.

IR BOOSTERS INTEGRATED WITH EXISTING CONVECTION OVENSMost existing paint curing processes involve a ‘heat-up’ stage followed by a ‘holding’ stage. The heat-up stage often occupies up to 50 per cent oven length in conveyorised operations. In the case of convection heating systems, oven lengths are long. A successful innovation in such a case is to install an IR booster ahead of the convection oven. Here an initial quick boosting of temperature by IR reduces heat-up time, leaving more space for the holding. In practical terms, this can mean 50-100 per

Electric infrared technology provides a paintshop with significant versatility in finishes. Switching from one paint formula or method of application to another is also much simpler with the new drying system. The infrared heaters can be easily adjusted for waterborne painting one day and for a powder-coated finish on the next.

FACT

FACT

Wide spectrum of infrared (IR) for diverse applications

Short Wave (2200oC) (SW)

Fast Medium Wave (1650oC) (FMW)

Medium Wave (900oC) (MW)

Long Wave (650oC) (LW)

30

25

20

15

10

5

Per

cent

Of T

otal

Ene

rgy

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0Wavelength in Microns

Hold time without IR

Hold time with IR

Time

Tempe

ratu

re

A typical graph after the installation of IR booster



cent increase in line speed with 10-20 per cent increase in length.

IR boosters have been an immense success in industry, and they have been used in various ways. Popular applications include curing of paint on automobile bodies, consumer goods, industrial components, etc.

COMPACT IR OVENS FOR CURING PAINT ON LARGE COMPONENTSThe practice of high temperature drying is most commonly accepted for all industrial products. However, for heavy components

like valves, pumps, actuators, etc, the weight and size of component pose problems in designing a conventional hot air oven. Such an oven would be large in size, requiring considerable energy and time to generate hot air to encompass the oven. Sudden shut-downs or start-ups in such systems would be both impossible and impractical. This challenge can be overcome by using IR ovens, which are modular, compact and can be designed optimally in terms of materials.

Such applications also have paints that are cured at elevated temperatures only. However, forced drying of air drying paints gives many benefits such as time span between each coat gets reduced from one shift to one hour or less. In practical terms, it means that the second coat can be completed on the same day and the product or material can be packed and shipped out the very same day. This can also helps in reducing work-in-process inventory drastically.

IR HEATING SYSTEMS DESIGNED FOR ‘JUST-IN-TIME’ OPERATIONSHeating equipment in most operations work on the age-old concept of ‘heat-up time’, i.e. the ovens have to be started much in advance before the production starts and even when the components are

not processed, the oven has to be kept ‘on’.

Short duration, instant switch on/switch off IR ovens are an effective solution in many such situations. With the advent of PLCs, machines are automated and ovens switch on automatically upon sensing the components and switch off automatically when there are no components.

Coupled with short-duration time cycles, this leads to efficient just-in-time operations. In fact in many cases, IR ovens can be switched on/off even for every single component.

USING IR EFFECTIVELY For drying and curing operations, one can consider alternative technologies such as IR heating, which provides several opportunities for improving the efficiency of existing paintshop operations. IR technologies work well for drying inks, coatings, finishes or adhesives applied to materials, especially the sensitive ones such as film, release paper or some types of fabric where the more controlled IR drying helps to avoid damage to the material from excessive heat.

As illustrated above, a quantum leap is possible in paint drying and curing efficiency provided a radical, out-of-the-box approach is taken when planning new paint curing operations or upgrading existing facilities. Established market players who can offer the right combination of IR sources, equipment design and process controls can elevate your operations to world-class and environment-friendly levels.

The sun’s rays are considered the purest Infrared (IR) energy, but remember, the sky is the limit when it comes to innovative and energy efficient IR solutions!

Nilay M Shah, Director, Litel Infrared SystemsE-mail: [email protected]

A few path-breaking IR heating solutions achieved in India: Curing of water-based paint on metal strips by raising the temperature

to 1500C in 3 seconds Water based paint cured on filters in 8 minutes @ 6 m/min. Conveyor

length inside IR oven - 48 m instead of 180 m required for a typical convection oven

Paint drying achieved on heavy valve / actuator / engine components in 15-30 minutes. Turnaround time after primer coat reduced from one day to one hour

PU Paint drying achieved in IR – Convection hybrid oven on plastic components in 4 minutes

Drying of pre-treatment chemicals (PVA) on plastics done in 1 minute Drying of anti-corrosive coating done on MS plates, 3.2m wide, 10m

long and 50mm thick , travelling on a conveyor at 2m/min.

0 1 2 3 4

Time Cycle

Time

Meth

od of

curin

g

Connvection

Infrared

Automated Touch-up IR curing of water-based paints on automobile bodies


SMART MANUFACTURING

ost liberalisation, the Indian manufacturing industry witnessed a wave of improving quality in the manufacturing process, in contrast to countries like

Japan, where the manufacturing sector focussed on ‘just-in-time’ right at the start.

In India, the manufacturing process evolved through ISO, total quality management (TQM), TPM, six sigma and then lean processes. But over the last few years, volatility in oil prices, fast changing customer preferences, need for just-in-time, etc have triggered another wave in manufacturing, which is ‘smart’ and at the same time futuristic.

Today, companies have started looking

at the manufacturing process as an enhancing and enabling point that can make them competitive, cost efficient and quality manufacturers in the future.

The ability to flex as per the demand, as per quality requirements and as per the time limits has come with the adoption of smart manufacturing practices in the global manufacturing landscape. Suneel Aiyar, Associate Director – Consulting PWC avers, “Today, companies have started process improvement by using various value stream mapping tools which measures what a customer values and what he is ready to take and then look into the processes which are non-value adding from the customer’s point of view.”

INSIGHTS INTO SMART MANUFACTURING Looking at the fast pace at which changes are shaping up the future, companies are increasingly adopting tools & technologies that add to their productivity and enhance efficiency. Though these companies have taken one step towards attaining operational efficiency, the question that arises is that are we really being futurist in our approach or are we just taking short-term measures to grow?

For any company that dreams to be sustainable and lead the future growth trajectory, there is an urgent need to imbibe smart manufacturing practices. In a true sense, smart manufacturing is an integrated, knowledge-enabled, model-rich enterprise

A BLUEPRINT TO

P SUMEDHA MAHOREY

Aptly responding to fast changing global consumers’ demands with the right set of variety and quality is any manufacturers dream in this cut-throat competitive era. The use of smart manufacturing practices enables a manufacturer to plan and prepare beforehand with the use of the right set of technology, planning and design tools making him flexible to cater to the ever-evolving volatile markets.

GenX MANUFACTURING


SMART MANUFACTURING

in which all operating actions are determined and executed proactively applying the best possible information and a wide range of performance metrics. Smart manufacturing extends from requirements, product and process design to execution, delivery and life-cycle support. To accomplish this, smart manufacturing encompasses a suite of products, tools and applications, which are Information Technology (IT) enabled and can be used as a strategic tool to enhance manufacturing competitiveness.

The smartness can be visualised in two layers: first, by the inherent smartness introduced into the equipments & processes and, second, by capturing real-time data and enhancing the smartness of business decisions through the integration of enterprise applications, creating in an efficient, safe, flexible and an environment-friendly manufacturing facility.

Andy Kalambi, President Dassault Systemes, South Asia explains, “Smart manufacturing ensures adoption of technologies that use premium manufacturing intelligence in terms of predictive analytics that enable better visibility and visualisation across the entire manufacturing enterprise. The ability to plan ahead of time the manufacturing process virtually, in a simulated environment helps in reducing the cost and wastes that are generated in the manufacturing process.”

THE TRANSFORMATION BEGINS… With the advent of smart manufacturing solutions, profound transformations are coming within this decade in the way goods are manufactured – changes that will fundamentally alter the worldwide competitive marketplace. These changes are happening in three phases:Phase 1: The integration of all manufacturing data throughout individual plants and across enterprises will facilitate significant, immediate improvements in costs, safety and environmental impacts.Phase 2: This data, paired with advanced computer simulation and modelling, will create robust ‘manufacturing intelligence’ that will enable variable-speed, flexible manufacturing, optimal production rates and faster product customisation.Phase 3: As that manufacturing intelligence grows, it will inspire innovations in processes & products that comprise smart manufacturing’s promise.

PLANT- AND ENTERPRISE-WIDE INTEGRATIONIn its first phase, smart manufacturing will interconnect and better harmonise individual stages of manufacturing production to advance plant-wide efficiency. A typical manufacturing plant uses information technology, sensors, intelligent motors, computerised controls, production management software and the likes to manage each specific stage or operation of a manufacturing process. However, each is an island of efficiency. Smart manufacturing will integrate these islands, enabling data sharing throughout the plant. The convergence between machine-gathered data and human intelligence will advance plant-wide optimisation and enterprise-wide management objectives, including substantial increases in economic performance, worker safety and environmental sustainability. The emergence of this ‘manufacturing intelligence’ will usher in the second phase of smart manufacturing.

FROM PLANT-WIDE OPTIMISATION TO MANUFACTURING INTELLIGENCEConnecting in-plant modelling and data technologies with high performance computing platforms (cloud computing) will make it possible to build significantly higher levels of manufacturing intelligence and connect it throughout the factory. Complete production lines and entire plants will run at variable speeds with real-time flexibility – which is not feasible now – in order to conserve energy and optimise outputs. Businesses will be able to develop advanced models and simulations of manufacturing processes to improve current and future operations. For instance, manufacturers will be able to develop models for the mass-manufacture of products & devices that use nanotechnology. It is widely expected to revolutionise technology and industry with smaller, stronger, lighter weight materials and powerful precision devices for nearly every industry.

MANUFACTURING KNOWLEDGE WILL INEVITABLY DISRUPT MARKETSSmart manufacturing’s third phase will transform industry in a similar way... as to how the strategic use of information

technology transformed the business model and consumer shopping behaviour. For example, by capturing extensive data about consumers’ book-buying habits, Amazon developed extensive knowledge about its customers’ lifestyles that enabled a ‘disruptive’ shift in its business model. Within a decade, Amazon expanded its product offerings to span many new categories. It is now the largest US-based online retailer. Smart manufacturing will deliver a similar, extraordinary shift in the competitive landscape of the Indian industry. Flexible factories and IT-optimised supply chains will change manufacturing processes to allow manufacturers to customise products to individual needs, such as medications with specific dosages and formulations. Customers will ‘tell’ a factory what car to manufacture, what features to build into a personal computer or how to tailor a pair of jeans for a perfect fit.

This most dramatic and competitively vital – the third phase of implementing smart manufacturing will come from innovation spurred by a growing body of manufacturing knowledge. These will not be incremental or gradual changes – they will be game-changing, market-disruptive innovations in products & processes. Changes at this phase will push down prices, open new markets and offer a broader array of choices to a wider range of people.

IN VOGUE TECHNOLOGIES To start with, smart manufacturing can be achieved through various communication technologies that include machine to machine communication, field buses, ethernet networks, bluetooth enabled devices and wireless networks. Apart from these, some sensor technologies like wireless sensors, MEMS sensors, virtual instrumentation and smart field devices help in curbing the waste rate in the manufacturing process.

Other IT platforms used in manufacturing such as product lifecycle management with digital manufacturing capabilities for product and process simulation, manufacturing execution systems, enterprise manufacturing intelligence, plant asset management, advanced control and optimisation, quality management systems, non-destructive testing and emissions monitoring and measurement of carbon credit footprint are shaping for GenX manufacturing. Elaborating on the technologies that are in vogue in the


SMART MANUFACTURING

industry currently, Aiyar says, “Waste reduction can be achieved with the help of the right kind of technology. One such technology is the value stream mapping tool that identifies different types of wastes that are created due to use of excessive resources, high idle time, excessive hand-offs, poor quality, etc. Once the wastes are identified, measure can be taken to eliminate the waste.”

Adding further he says, “Earlier companies used to focus on finding out where the wastes are happening in the

company itself but now they are also looking at their partners, suppliers to find out where the wastes are and how they can be eliminated. The mindset has changed towards the adoption of technology and increased the scope of its application in the manufacturing process.”

Manufacturing technologies are demand driven and depend on the how these technologies are being adopted. Technology adoption is a continuous process. Over the past five years there are many technologies that have influenced the way in which manufacturing is done today. As per Kalambi, technologies that have changed the landscape of the manufacturing world are: 1. Digital planning & digital simulation of the factory: Every stage of the manufacturing process is digitally simulated and IT tools are used to find out the most optimal way to manufacture the product. This also helps in reducing error rates and wastages out of it. 2. Move from rapid prototyping to zero prototyping: Earlier, companies used to create one model after the other with the smallest possible change leading to high tooling costs and wastage of man hours. Today, the manufacturing process is

simulated virtually, leading to zero prototyping. 3. Digital continuity: Linking up the manufacturing environment with the digital manufacturing or the virtual manufacturing environment and designing the front end process as per the back end plan is another big thing that has changed the landscape of the manufacturing sector.

Adding to these, Aiyar avers, “Automation is going to be one of the key enablers for companies to gain an edge over others. In factories, robotics is slowly taking place of

manual work, thereby improving efficiency manifolds. The reason for its widespread adoption is the shortage of skilled labour and labour costs that have increased by over 20 per cent as compared to other developed countries where the increase is only 3-5 per cent in the last 5 years.” Elaborating further, he explains, “The basic level of automation is mechanisation which allows the manufacturer

to produce a product continuously with greater flexibility.”

TRIGGER POINTS: THE FUNDAMENTAL DISCONNECT Many issues like high rate of waste generation, high idling time, need for efficient product designs are being witnessed in the current manufacturing process. In Japanese term, it is called ‘Muda’. Elaborating on these wastes, Kalambi avers, “Waste is generated due to defects that arise in the product because of the fundamental disconnect between design and the manufacturing environment. This is popularly known as the inventory bomb mismatch. This also results in building up of inventories.”

Apart from this, sometimes manufacturers don’t have an optimal layout for managing the material flow in the organisation. This increases waiting time, generates the need for extra transport, the material comes in and is held up at the workstation. This is because the process is not synchronised. There are also cases where manufacturers end up having extra capacity. Other issues include improper

layout planning and inappropriate manufacturing materials that create a situation where manufacturing becomes sup-optimum.

Another issue is that not many companies have implemented a digital factory where digital continuity is required. In many companies, the design process is digitised, the execution process is digitised but the whole planning process is not digitised. That is where smart manufacturing comes into picture. It helps in digitising the factory and ensuring that manufacturers get the desired production right the first time. This saves the costs involved in tooling for a product design, which was earlier prototyped. Today, every product can be digitally simulated and manufactured virtually so as to reduce costs involved in creating a manufacturing design.

There are other tools also which help in clearly simulating the whole manufacturing process in a virtual environment. Which means manufacturers can actually define the whole production of the factory virtually along with resource planning.

Additionally, as per Aiyar, manufacturers need to be agile, adaptable and have an alignment towards customers’ wants and needs. Agile manufacturing means manufacturing that can respond to fast changing requirements in the shortest possible time. It also includes catering to demands in small lots with multiple varieties. Adaptability of the manufacturing process can be gauged from the flexibility the manufacturer shows towards currency rate fluctuations and trade slowdowns. The decision to reach the market with macroeconomic, geopolitical variables by sourcing from different locations and factories can be enabled through implementation of smart manufacturing practices. Manufacturers, today, need to align their manufacturing process with that of customer expectations as this would enable them to take the right decisions amid changing market and customer preferences.

BARRIERS TO IMPLEMENTATION Factors that act as the barriers towards the implementation of smart manufacturing practices include the high cost of adoption and integration of manufacturing-IT related solutions, and the costs involved in the installation of energy-efficient equipment, wireless networks and sensors. According

10 Attributes of Smart Process Manufacturing: Intelligent actions and responses Operating assets are integrated and self-aware Adapts to abnormal situations Data when, where, and in the form needed Proactive failure prevention Rapid response for proactive control Environmentally sustainable People: knowledgeable, empowered and trained Recognise the limits of automation Drive strategic enterprise performance

Search November 2010 Ad Name: Sandvik Pg. 103

Search November 2010 Ad Name: Atlas Pg. 104


SMART MANUFACTURING

to Kalpesh Padhye, Senior Research Analyst – South Asia and Middle East, Automation & Electronics, Frost & Sullivan, a major barrier for implementation if smart manufacturing practices is the lack of awareness among Indian manufacturing companies about the technologies and benefits of smart manufacturing.

Apart from this, a lot of businesses in India don’t have the scale of production, Pointing this out, Aiyar elaborates, “Today, most small scale businesses focus primarily on labour cost competitiveness but here, the advantage is short-time term in nature. In order to reach that scale significant investments in training people, building infrastructure, manufacturing systems, etc are required.”

On the other hand, there are another set of companies that are large, and are doing really well. They don’t find investing in manufacturing systems as the need of the hour. Commenting on adoption of technologies in these companies, Aiyar says, “Over the last 2-3 years, these companies have identified that they would be at risk if they don’t change. But, internally, within the organisation there are many cultural barriers which are resistant to change. Factories are insulated from customers, so when put forth a concept of customer to TQM manufacturing a lot of them don’t appreciate.”

SMART ADOPTION: A KEY TO REMAIN COMPETITIVEWith growing manufacturing emphasis on India, smart manufacturing opportunities are abundant and necessary to remain competitive globally. Adoption of smart manufacturing concepts has been relatively slow when compared to other industrial nations. The Indian oil & gas and automotive sectors are usually the earliest adopters of new manufacturing technologies in the Indian industry. However, with increasing number of Indian companies competing globally and setting up manufacturing facilities outside India, the need to integrate and efficiently operate their plants will necessitate faster adoption of smart manufacturing. Also, the need to comply with drug and food safety regulations will promote the adoption in the Indian pharmaceutical and food & beverage industries. Introduction of the perform achieve trade (PAT) scheme by the Ministry of Power enabling power trading will also drive the Indian industrial

sector towards energy management initiatives.

BENEFITS OF BEING SMART Some of the benefits of implementation of smart manufacturing have been discussed below.Absorbing shift in volume According to Aiyar, today’s manufacturing industries look into its process as an enabling point to create a great deal of variety for its customers. For example, if we assume a consumer durable like motorcycle, as a manufacturer, we need to cater to the changing market demands as within six months of the launch of the motorcycle, it may land in the economy segment from the premium segment. Smart manufacturing tools help manufacturers tackle such situations by enabling them with tools that can absorb this significant shift in volume. With the implementation of smart practices, the mix of products has grown up in the last 4 years and given the manufacturers the capability to provide variety of products in small lots to the market. Capital productivityImplementation of smart manufacturing has over the years resulted in very high rate of return and higher shareholders value due to high confidence amongst the investors regarding the quality of the product and reliable manufacturing processes. Manufacturing competitivenessSmart manufacturing technologies help manufacturers achieve customer expectations through their ability to make the product at the most competitive cost at the time they need.

VANTAGE POINTS: ATTAINING SUSTAINABILITY & ENERGY EFFICIENCYThe other major advantages of implementing smart manufacturing practices are: Integrating equipments in the plant will

enable better control of plant processes and lead to improvement of plant efficiency and reduction of costs

Reduced plant cycle time and plant downtime

Efficient production scheduling and tracking key performance indicators

Measures overall equipment effectiveness

Data between plants can be compared and benchmarked for better management visibility

Enables faster innovations in product

and processes by streamlining design and testing

Enables real-time data acquisition and communication between equipments

Reduces energy consumption and emissions, thereby reducing the carbon foot print of the manufacturing facility

Continuous plant monitoring also improves plant safety

ROLE IN ENERGY MANAGEMENTSmart manufacturing technologies help in monitoring energy consumption across the plant in real time by means of energy dashboards and set energy saving targets. Tools like remote plant management enables remote switch on/off of the plant equipments and identifies unnecessary equipments utilisation. This removes redundancy in plant operation and brings in better cost efficiencies. Another advantage of using smart practices is proper load management by assessing load patterns on motors, generators and critical plant equipments which provides for setting optimal operational parameters for plant efficiency.

INDIA: GETTING SMARTER BY THE DAYImplementation and adoption of smart manufacturing is an ongoing process. Delving in-depth on India’s position in the adoption of smart manufacturing practices, Kalambi avers, “India is good at frugal engineering. We have been able to create products which are very different and unheard of. Companies have been able to successfully deliver these products as well. An example of this is Nano. The challenge is now to ensure that our manufacturing practices are also at the same level. To achieve this balance, we need to exploit use of digital tools to the fullest.”

With the manufacturing industry taking bigger strides with every passing day, adoption of smart manufacturing practices is the only solution for companies to achieve cost & energy efficiency, reliability and flexibility in the manufacturing process and gain a strategic upper hand that enables them to remain globally competitive.

Inputs from Kalpesh Padhye, Senior Research Analyst & Ashwin Haleyur, Research Analyst – South Asia and Middle East, Automation & Electronics, Frost & Sullivan; and Sujeet Chand, Chief Technology Officer, Rockwell Automation


NATIONAL MANUFACTURING INVESTMENT ZONES

PROPELLING MANUFACTURING GROWTH

Y SANDEEP PAI

With India positioning itself to become a world leader in manufacturing, the proposal to set up national manufacturing and investment zones (NMIZs) is an excellent step in this direction. These zones will provide the required impetus to the manufacturing units by way of providing the much-needed infrastructural support, a progressive exit policy, structures to support clean and green technologies, appropriate investment incentives, and business-friendly approval mechanisms.

ears ago, well-known economists Colin Clark and Jean Fourastié formulated a fascinating three-sector hypothesis. The hypothesis divides any

country’s economy into three sectors of activity: extraction of raw materials (primary), manufacturing (secondary), and services (tertiary). It points out that countries with a low per capita income are in an early state of development; the main part of their national income is achieved through

production in the primary sector. Countries in a more advanced state of development, with a medium national income, generate their income mostly in the secondary sector. Moreover, in highly developed countries with a high income, the tertiary sector dominates the total output of the economy.

This hypothesis stands true in the modern day world. While advanced economies of the West are driven by the services sector, developing nations such as India have extended their focus on the

manufacturing sector. Such a focus is reflected from the fact that manufacturing has grown by 7.6 per cent (on an average) between 1994 and 2010. In fact, the Indian manufacturing sector has undergone a revolutionary change since 1991, leading to opening up of the manufacturing sector to foreign players who were absent prior to liberalisation and globalisation of the economy.

Though manufacturing sector has high growth potential, contribution of manufacturing to GDP has nearly stagnated

Illus

tratio

n B

y: S

anja

y D

alvi



and has fluctuated at around 15 per cent between 2000 and 2010. Explaining the reasons, Nalinee Giri, Research Associate, Economic Research & Analytics-Global, Frost & Sullivan, says, “Complex administrative procedures involved in starting a business and poor infrastructure have been identified as the main factors affecting the business climate and has offset the advantages of labour cost and growing internal demand.”

NATIONAL MANUFACTURING ZONES: A BEGINNINGTo overcome these challenges and increase the share of the manufacturing sector in GDP to 25 per cent by 2022, the government has proposed to set up the NMIZs. Giri points out, “A series of policy initiatives are under proposal stage to increase the competitiveness of manufacturing sector and promote growth through increased investment. In order to achieve full potential of the manufacturing sector, the government has taken the initiative to create NMIZ.”

According to the discussion paper on NMIZ, an area would be specifically delineated for the establishment of manufacturing units for domestic and export-led production, along with associated services and infrastructure. The area would have a high-class infrastructure and reap benefits of co-sitting, networking and

greater efficiency through the use of common infrastructure and support services. Also, non-processing area would include residential, commercial and other social & institutional infrastructure. Throwing light on the same, Revati Kasture, GM & Head – CARE Research, reflects that the setting up of such dedicated zones would provide a conducive environment for manufacturing sector to flourish in India.

Furthermore, these zones would be run by a special purpose vehicle (SPV) that would be responsible for their development and management. The SPV would, after notification of an NMIZ, prepare a detailed master plan consisting of a regional development plan specifying land use and zoning for processing and non-processing areas. Anand Sharma, Union Minister for Commerce & Industry, confirmed this recently at a forum and declared, “NMIZ would have a governing body, which would be in the form of a SPV formed with the constituents of that specific NMIZ. The SPV would have the delegated authority from the State Governments, Ministries in the Central Government and other government

agencies for issuing necessary clearances for the inception and continuation of business ventures inside the NMIZ. Thus, the concept of NMIZ combines the framework for more business-friendly policies, procedures and approval ecosystem, combined with superior physical infrastructure.”

BOON TO MANUFACTURERSNonetheless, if everything works according to the plan, NMIZs will be a definite boon for the manufacturing sector. Giri says, “The advantages to the manufacturing units can be classified in the form of providing suitable institutional framework leading to paradigm shift in the overall manufacturing trend, liberalised legal framework, appropriate fiscal incentives and accomplishment of green initiatives in support of sustainable development.”

Under the institutional framework, the suitable benefits to the manufacturers are advocated in terms of provision of external physical infrastructure facilities including rail, road (national highways), ports, airports and telecom through government’s funding and public-private partnership. The co-ordination between Central Government and state governments in terms of advocated SPV, which will involve specific member from NMIZ, delegates from respective state government as well as Central Government authority, will lead to the creation of firm institutional framework governing the manufacturing units.

In terms of institutional accomplishments, the advantages to manufacturers are further reflected in the form of provision of common infrastructure facilities, support services, economies of scale and scope observed from combination of production units, public utilities, logistics and environmental protection mechanism.

The proposal has also been made to advance the labour laws in terms of providing women employee with three flexible shifts, flexibility to downsize, non-applicability of Contract Labour Abolition Act and provision of security benefits to the workers. This will provide significant advantages to the manufacturers leading to more liberalised legal framework.

Furthermore, the national manufacturing and investment policy proposal provides opportunities to go green to the manufactures. The policy document

General incentives for units in the NMIZs In order to encourage industrial units in taking on training/retraining of

the workers, such expenditure be treated at par with R&D expenditure. Tax exemption on expenditure incurred in taking national/international

process/product certification/approvals like ISO 9000, BIS 14000, BEE, IS, CSA, UL, VDE, etc.

50 per cent of the expenditure incurred in filing international patents to be shared by the government.

Subvention of interest on working capital by 4 per cent to create parity with international counterparts.

In government purchases, preference should be given to units located in the NMIZs.

In order to encourage supply chain development, Income Tax exemption to suppliers in proportion to the supplies made within the NMIZ.

Special incentives for certain crucial industries where import dependence is high.

Courtesy: CARE Research

National manufacturing and investment zones would be run by a special purpose vehicle (SPV) that would be responsible for their development and management. The SPV would, after notification of an NMIZ, prepare a detailed master plan consisting of a regional development plan specifying land use and zoning for processing and

non-processing areas.



focusses on opportunities to rapidly growing carbon trading market, greening of operations to reduce carbon footprints, greening of manufacturing products, and developing local green technologies in order to create local and global leadership in the form of comparative advantage. The shift in manufacturing mix of the products will help India achieve the path of low carbon and high growth of the manufacturing sector leading to sustainable development.

Apart from these incentives by the Central Government, the state governments may also notify a package of incentives for the development of the NMIZ. Kasture says, “This may include moratorium on all municipal and other local taxes for 10 years, for the NMIZ developers as well as the units that are located in the zone.”

THORNS IN THE WAYWhile the industry at large is satisfied with the initiative, some reservations do exist among the experts. Highlighting this, Kasture observes, “There will be few challenges during the initial stages of setting up of NMIZs. Firstly, poor infrastructural facilities at ports, roads will be a huge bottleneck to promote manufacturing, and secondly, easy

availability of land will be another major hindrance as the same is being observed for special economic zones and power projects.” These aspects are to be looked at during the planning stages, starting from the first proposed zone.

Currently, the government has decided to set up the first integrated manufacturing zone in Neemrana, Jaipur–Rajasthan along

the Delhi–Mumbai Industrial Corridor Project. If this gets implemented properly, then there will be a domino effect across the country.

CROSSING OVERWith the initiative of the Jaipur Zone project, the start has been made. Now what remains is the implementation of the policy to create a suitable institutional framework and bring about a paradigm shift in the overall manufacturing process, which accomplishes green initiatives and supports sustainable development.

A few hurdles are bound to emerge, but they should be dealt tactically. If that is done then India would be all set to become a manufacturing bliss.

With inputs from Frost & Sullivan

DESIGN INNOVATION: Global Design And Manufacturing Partnerships

Collaborating For Success

on pg. 136

The advantages to the manufacturing units can be classified in the form of providing suitable institutional framework leading to paradigm shift in the overall manufacturing trend, liberalised legal framework, appropriate fiscal incentives and accomplishment of green initiatives in support of sustainable development.

NALINEE GIRI,Research Associate, Economic Research &

Analytics-Global, Frost & Sullivan


ENERGY SECURITY

hile the world is full of opportunities, it is fraught with many challenges as well. Globally, we face three critical shortages: food, water and energy.

Given that the world’s population is forecast to increase from six billion currently to over eight billion by 2030, these issues need to be resolved urgently.

RESOLVING ENERGY CRISISI believe that energy is the fundamental

issue. If we fix the problem of energy shortage, it will go a long way in combatting water and food shortages. While climate change is widely recognised, its impact is not well understood. The most severe impact of climate change will be on basic life systems – food and water. Drastic climate

change will only make food and water shortages worse. What we need is sustainable economic and ecological development. And I feel there are three important parts in achieving this. First is attaining energy security. This calls for affordable energy that can be accessed by all to power a low-carbon economy. It needs to be noted here that there are over 1.4 billion people in the world who have no access to electricity – ‘The People Who Live in the Dark’.

Second, we need to embrace new technologies available to deliver energy-efficiency. With many developments happening, from LED lighting systems to low-energy appliances, energy-efficient

buildings and building methods, fuel-efficient transport – the

possibilities are endless.There is a myth that energy-efficiency is

expensive. Our experience has been the opposite. Our global headquarters – Suzlon One Earth – is among the greenest headquarters in the world. Meeting LEED Platinum standards and running wholly on green power, the construction of the facility cost 10 per cent less than a conventional building. Proof that efficiency works is all around us and so is the need to embrace this. This brings me to my third point, energy responsibility. In India, the average

per capita annual energy consumption is just over 500 kg-of-oil-equivalent, whereas it is 7,500 units in the US, and even higher in many parts of the world.

MAKING A DIFFERENCEIt is the way we think about energy. We need to see energy as what it is – a precious and scarce resource – something to be used carefully and responsibly. The government, business leaders, and every one of us have a clear role here. All of us, as individuals, have to accept a new way of using energy, as well as play a meaningful role in educating others.

As an entrepreneur, I am an optimist. So although the shortages of energy, food and water are critical, I see opportunities in those challenges. The renewable sector has already created thousands of ‘green jobs’, but if we really exploit some of our natural resources – wind and solar, for instance, which are available in abundance – then we will be able to create hundreds of thousands of secure jobs. I am here referring to manufacturing, engineering, research and development and much more.

Talking about economic development,

here is an example from India. The major cities in the country are crowded and the infrastructure is pushed to the limit. But thousands flock to the cities everyday in search of work. This, in turn, increases the pressure on the cities, threatens the rural way of life and breaks up family units. But wind farms typically come up in the remotest parts of the country. So, we have started training people in rural communities in wind energy. This means they have secure jobs, and do not add to the migration and our customers get quick and efficient localised

WEnergy concerns are looming large over the world on account of the exploding population and shortage of power to meet the spiralling

demands. To deal with this scenario, renewable majors are exploring ways to ensure energy security. In this backdrop, Tulsi R Tanti, Chairman and MD, Suzlon Energy, reflects on the drivers of investment, the commercial challenges and the future of clean energy in India.

THE FUTURE IS


ENERGY SECURITY

service. I think this small example shows what can be done: inclusivity is responsible business. And we need much more of this at both a micro and macro level.

CONVENTIONAL POWER VS RENEWABLEIndeed, we need to protect this debate from simply becoming nuclear vs coal vs oil vs wind vs solar and all the others. In order to close the gap between energy the world needs and the energy currently generated, we have to maintain a dynamic and mixed energy portfolio. Renewables have an important role to play, but as part of the solution – not the only solution.

As I said earlier, wind has an important contribution to make to a comprehensive energy portfolio. The scope of what could be done is enormous. First, today the world consumes 19,000 TWh of electricity. Second, by 2030 that is forecast to rise to a consumption of nearly 29,000 TWh. Third, there is enough wind potential – in other words, windy places – to deliver about twice what we will need in 2030.

REALISING THE POTENTIAL We need proper and sustained investment in R&D, both for technology solutions and turbine development. At Suzlon, we have set up research, development and innovation centres, which focus on product

development, and also the fundamental, game-changing technologies. We need to look at the bigger picture. A total review of the grid needs to take place: where should we expand? What should we upgrade? How can we be effective across borders? How can our grids be smarter? Where do governments need to invest?

We also need more countries to adopt policy regimes, which encourage and support the renewable sector. India is at the forefront of this, as is Europe – including Portugal – with aggressive targets and strongly supportive policies.

MAKING ENERGY SELF-RELIANCE A REALITYAll countries should set clear CO2 reductions between now and 2050; utilities should target 20 per cent of renewables by 2020; governments should introduce feed-in tariffs

or green certification mechanisms as soon as possible. Additionally, governments need to encourage innovation to deliver the next generation of technological advances. I also believe the governments worldwide should mandate banks to make minimum investments in renewable assets.

I propose this to be 20 per cent.Finally, in terms of policies, dynamic

time-based tariffs are required, with built-in price escalation. In other words, the more energy you use, the more you should pay. With the right mindset, policies and business support, there is no reason why we can not attain energy efficiency in the future. The future can be green. Let’s make it a reality.

This article is an excerpt from the speech given at the Global Clean Energy Forum held in Lisbon, Portugal recently.

What we need is sustainable economic and ecological development. And I feel there are three important parts in achieving this. First is attaining energy security. Second, we need to embrace new technologies available to deliver energy-efficiency. Third important factor is

energy responsibility.


CUTTING EDGE SOLUTIONS

olarpark Rodenäs GmbH has recently developed an intelligent tracking technology that increases the efficiency of

photovoltaic plants by enabling it to track the sun’s position through the use of powerful geared motors from NORD Drivesystems.

Solarpark Rodenäs GmbH specialises in fastening systems for solar panels. As solar cells are most efficient when the sunlight falls onto them vertically, precise tracking of the sun considerably increases their efficiency, at least if the tracking does not consume too much energy. Here, energy efficiency is achieved through NORD motors.

The module, developed by Solarpark Rodenäs GmbH, requires robust geared motors in order to position and securely hold solar modules against strong winds. Commonly available drive units use conventional brakes and require heaters to prevent them from freezing. These are cost and maintenance-intensive components, which also increase the energy consumption of the drive unit. NORD solution fulfills the requirements for weather-resistant, precision, energy-efficient and economic motors.

THE MECHANISM The tracking control is calculated on a daily basis from the data for sunrise and sunset. At sunrise, the solar panels turn to the east in order to track the sun over the course of the day. Every 15 minutes, NORD geared motors are activated by an impulse from the central control unit to track the sun for four degrees and then switch off again. Due to the tracking, the solar collectors achieve a 25-30 per cent greater efficiency in comparison with fixed collectors. With a surface of 16 m² each, the panels offer a large area of resistance to the winds. The gear units from the modular Universal series, which combine two worm gear units, hold the panels in position without additional brakes. They position the panels precisely and firmly against winds, which often exceed force of 10 gales. Over 700 geared motors are doubly protected by corrosion resistant one-piece aluminium housing and a special paint. A high quality synthetic lubricant ensures reliability even at sub-zero temperatures and also minimises

maintenance. Highlighting the role of this technology in enhancing productivity and efficiency, Joerg Niermann, Head – Marketing, NORD Drivesystems, avers, “This technology mainly helps to increase the efficiency of the solar energy production. Firstly, it optimises sun tracking, and secondly, as gears consume low energy, it increases the efficiency of the system. Taking this into consideration, this technology can be implemented in India as well.” With this tracking technology in place, the solar power production is slated to reach major highs in the future with enhanced productivity and the ability to track the sun to the last hour on the horizon.

S

GEARED MOTORS HELP SOLAR PANELS TRACK SUN ALL DAYWith the help of energy efficient geared motors by NORD, Solarpark Rodenäs GmbH has developed solar modules, which can track the

sun’s changing position all day. This enables 25-30 per cent greater efficiency of solar collectors in comparison with fixed collectors.

SUMEDHA MAHOREY

Rodenäs Solar Park, with more than 700 solar modules

mage sensors are used for quality control in production systems and car parking lots. Many times, these sensors have to face very

high and extremely low temperatures that prevail in the environment. In order to maintain their functions in such extreme conditions and to overcome the possibilty of the sensors getting spoilt, the Fraunhofer Institute for Microelectronic Circuits and Systems IMS in Duisburg has developed a complementary metal oxide semiconductor (CMOS) image sensor, which can withstand temperatures ranging from -40 to +115°C. This is a boon for car manufacturers as the charged coupled device (CCD) image

sensors available up to now fail when the temperature goes beyond 60 degrees. “Our chip is not only heat-resistant, it even functions at arctic temperatures,” says Werner Brockherde, head of department, IMS.

A special feature of this sensor is its image size of 2.5 x 2.5 cm, which can be used for special applications with weak illumination or for capturing images in the infrared or UV range. The sensor can be connected directly to an electronic image intensifier. In addition, the sensor has a high resolution of 256x256 pixel. Its high dynamic range of 90 decibels provides increased contrast and optimised detail accuracy both in shadow as well as in

very bright areas. A rolling shutter also permits a higher image frame rate and continuous image recording. This minimises image noise. “We produced the sensor in a standard process using 0.5 micrometre CMOS technology in our own semiconductor factory. We also produce special components here for industrial customers,” states the scientist, reflecting the expertise of the Institute. He further adds, “Our chip is suitable for deployment in chemical and steel production facilities, where it can be used for process and quality control. Very high temperatures prevail, for example, in rolling mills where sheet metal is produced.”

ICMOS IMAGE SENSORS: A BOON TO CAR MANUFACTURERS


CUTTING EDGE SOLUTIONS

hysicists from the University of Arizona have discovered a new way of harvesting waste heat and turning it into electrical

power, using a theoretical model of a molecular thermoelectric device. The technology holds great promise for making cars, power plants, factories and solar panels more efficient.

In addition, more efficient thermoelectric materials would make ozone-depleting chlorofluorocarbons, or CFCs, obsolete. “Thermoelectricity makes it possible to cleanly convert heat directly into electrical energy in a device with no moving parts,” says Justin Bergfield, a doctoral candidate in the UA College of Optical Sciences. Elaborating on the power generation capacity, Charles Stafford, Associate Professor of Physics, UA College of Optical Sciences, says, “We anticipate the

thermoelectric voltage using our design to be about 100 times larger than what others have achieved in the lab.”

A LOOK AT THE BASICS Unlike existing heat-conversion devices such as refrigerators and steam turbines, the devices require no mechanics and no ozone-depleting chemicals. Instead, a rubber-like polymer sandwiched between two metals acting as electrodes can do the trick. Car or factory exhaust pipes can be coated with the material, less than 1 millionth of an inch thick, to harvest energy otherwise lost as heat and

generate electricity. The physicists take advantage of the laws of quantum physics, a realm not typically tapped into when engineering power-generating technology. The key to the technology lies in a quantum law physicists call wave-particle duality: Tiny objects such as electrons can behave either as a wave or as a particle.

“In a sense, an electron is like a red sports car,” Bergfield says. “The sports car is both a car and is red, just as the electron is both a particle and a wave. The two are properties of the same thing. Electrons are just less obvious to us than sports cars.”

BACKGROUNDERBergfield and Stafford discovered the potential for converting heat into electricity when they studied polyphenyl ethers, molecules that spontaneously aggregate into polymers – long chains of repeating units.

The backbone of each polyphenyl ether molecule consists of a chain of benzene rings, which in turn are built from carbon atoms. The chain link structure of each molecule acts as a molecular wire through which electrons can travel.

Bergfield designed the benzene ring circuit in such a way that in one path the electron is forced to travel a longer distance around the ring than the other. This causes the two electron waves to be out of phase once they reunite upon reaching the far side of the benzene ring. When the waves meet, they cancel each other out in a process known as quantum interference. When a temperature difference is placed across the circuit, this interruption in the flow of electric charge leads to the build-up of an electric potential - voltage - between the two electrodes.

Using computer simulations, Bergfield grew a forest of molecules sandwiched between two electrodes and exposed the array to a simulated heat source. “As you increase the number of benzene rings in each molecule, you increase the power generated,” Bergfield adds. Analogous to solid state versus spinning hard drive type computer memory, the UA-designed thermoelectric devices require no moving parts. By design, they are self-contained, easier to manufacture and easier to maintain compared to currently available technology. “You could just take a pair of metal electrodes and paint them with a single layer of these molecules,” Bergfield says. “With a solid-state device, you don’t need cooling agents, you don’t need liquid nitrogen shipments, and you don’t need to do a lot of maintenance,” he adds.

The effects of this experiment were not unique to the molecules used in the simulation process. Explaining further, Bergfield says, “Any quantum-scale device where you have a cancellation of electric charge will do the trick, as long as there is a temperature difference. The greater the temperature difference, the more power you can generate.”

USE FOR THE FUTUREMolecular thermoelectric devices could help solve an issue currently plaguing photovoltaic cells harvesting energy from sunlight. “Solar panels get very hot and their efficiency goes down,” Stafford says. “You could harvest some of that heat and use it to generate additional electricity while simultaneously cooling the panel and making its own photovoltaic process more efficient.”

According to Bergfield, “With a very efficient thermoelectric device based on our design, we could power about 200 100-Watt light bulbs using the waste heat of an automobile. Put another way, one could increase the car’s efficiency by well over 25 per cent, which would be ideal for a hybrid since it already uses an electrical motor.”

With the world facing severe energy crisis, the new experiment has paved the way for generating electrical power from non-conventional sources.

Courtesy: University of Arizona

With a very efficient thermoelectric device based on our design, we could power about 200 100-Watt light bulbs using the waste heat of an automobile. Put another way, one could increase the car’s efficiency by well over 25 per cent, which would be ideal for a hybrid since

it already uses an electrical motor.

JUSTIN BERGFIELD,Doctoral Candidate, UA College Of

Optical Sciences

P

TURNING WASTE HEAT INTO POWERBy analysing the quantum effects of molecules, physicists from the University of Arizona have discovered a new way of converting waste

heat into electrical power. The development of this technology paves way for more efficient power plants, factories and solar panels.

A “forest” of molecules holds the promise of turning waste heat into electricity.


OFFSHORE WIND FARM

enewable energy has reached a clear tipping point in the global energy supply, with supporting investment in new renewable power capacity

installed over the last two years accounting for more than 50 per cent of the total capacity added in power generation. A milestone in this rapidly evolving renewable era is the recent development of the world’s largest offshore wind farm at Thanet, off England’s south east coast, by Vattenfall, one of the biggest wind power operators in Britain and the fifth-largest energy producer in Europe.

FARM SPECIFICITIES The Thanet Offshore Wind Farm has 100

turbines and is expected to generate electricity equivalent to the annual consumption of over 2,00,000 British households. Between 2009 and 2011, Vattenfall plans to double its wind power electricity generation by constructing nine wind farms in six countries to supply electricity equivalent to the demand of

8,00,000 households annually. The electricity generated from the English Channel winds will constitute a significant increase of green energy in the UK and is slated to add substantially to Vattenfall’s efforts in decreasing the amount of carbon dioxide emissions from its electricity generation.

R

With rapid capacity addition in renewable energy production, many companies are looking out for opportunities offshore. Attaining remarkable feat in power generation, Vattenfall’s offshore wind farm launched recently at Thanet, England, has set a record for itself by being the world’s largest offshore wind farm producing 300 MW electricity, which can suffice the energy needs of over 2,00,000

households. The success of this project has set inspirational benchmarks for others to follow...

ATTAINING REMARKABLE FEAT IN OFFSHORE POWER GENERATION

Energy Generation & Potential The Thanet Offshore Wind Farm will generate a total of 300 MW of

renewable electricity, enough to power 2,00,000 homes. The connection of Thanet’s 300 MW of capacity in 2010 will boost UK’s

offshore wind capacity by more than 30 per cent. The Thanet Wind Farm is only one of the five potential offshore wind

farms in the Thames Estuary Strategic Environmental Area.

SUMEDHA MAHOREY

123

OFFSHORE WIND FARM

THE LAUNCH The opening of the wind farm took place at sea in the auspicious presence of Øystein Løseth, CEO & President, Vattenfall, and Chris Huhne, British Secretary of State for Energy and Climate Change, among other participants.

“With Thanet Offshore Wind Farm, Vattenfall has taken a major step towards doubling its power generation from wind until 2011 and we continue to lead the way in offshore wind development. Wind power will be a cornerstone of delivering both profitability and sustainability for Vattenfall in the years to come,” says Øystein Løseth. Pointing out that Thanet Offshore Wind Farm’s 300 megawatt (MW) will take UK’s installed wind power capacity across the 5,000 MW line, Chris Huhne hailed Vattenfall’s impressive engineering achievement and praised the energy company’s commitment towards wind power generation in the UK. He said, “I am pleased that we have reached the point where 5 GW of our energy comes from onshore and offshore wind – that is enough electricity to power all the homes in Scotland. Getting these massive structures here into the sea is a tremendous feat of engineering and I applaud all involved with this awesome achievement.”

He adds, “We are in a unique position to become a world leader in this industry. We firmly believe that we should harness wind, wave and tidal resources to the maximum. I know that there is still more to be done to bring forward the large sums of investment we want to see in low-carbon energy in the UK, and the government is committed to playing its part.”

The construction of the 300 MW Thanet Offshore Wind Farm has taken just over two years and the wind farm is expected to operate for at least 25 years. At 300 MW, it is the largest offshore wind farm in the world. Each turbine is up to 115 metre tall at its highest point. The wind farm covers an area of 35 square kilometre, which is enough to cover 4,000 football pitches.

BREAKING INTO THE MAINSTREAMVattenfall is slated to double its wind power production to 4 TWh by 2011 and provide a total of 8,00,000 homes with electricity

from wind power alone. With this rapid addition to the global offshore wind power generation, renewable energy is slated to break into the mainstream of energy markets sooner than later, and witness accelerating private & public investment along with numerous technology advances in the future.

Image courtesy: Vattenfall

Technical Specifications The Thanet Wind Farm is the largest operational wind farm in the

world. The Thanet Wind Farm is located in water depths of 20-25 metre and

covers an area of 35 km, which is equal to 4,000 football fields. Each turbine is up to 115 metre tall at its highest point, with a minimum

clearance above sea level of 22 metre. The nearest turbine is located approximately 12 km northeast of

Foreness Point. Thanet Wind Farm consists of 100 Vestas V90 wind turbines. The distance between the turbines is approximately 500 metre along

rows and 800 metre between rows. The total investment for the Thanet Wind Farm is around £880 million.

Getting these massive structures here into the sea is a tremendous feat of engineering and I applaud all involved

with this awesome achievement.

CHRIS HUHNE,British Secretary of State for Energy and

Climate Change

N O V E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK


MECHATRONIC SYSTEMS

SMART SOLUTIONS TO

COMPLEX PROBLEMS

echatronic systems constitute the state-of-the-art technologies in automation systems, intelligently integrating

mechanical and electrical elements to perform increasingly complex and demanding functions. When designing electromechanical systems, mechanical and electrical engineers may tend to emphasise on the technologies, components and design principles from their single area of expertise, which can result in systems with higher operating costs, increased maintenance demands and less than optimal performance. However, in the process, often inefficiencies and unnecessary complexities can be unintentionally designed into machines. In order to resolve these problem areas, the following measures can be considered.

11CREATE A CLEAN DESIGNGood mechatronic design starts with good mechanical design – the best

electronics and electrical systems cannot compensate for poor mechanical design. The most successful designs are ‘clean’ – they feature a strong & rigid frame, and utilise materials and structural principles to ensure that whatever motion the machine undergoes, its long-term stability is engineered-in.

It is important to make sure that rigid bearings and support are utilised where motors are mounted on machines. This helps to prevent shafts from getting sheared off due to microfractures that occur if the

motor shaft is mounted out of alignment with a pillow block

bearing or gearbox input planetary gear. Moreover, motors should be placed

on the machine in the best location, so that

operators do not accidentally step on cables and connectors causing damage. It is also essential to design machine guarding with easy access points to get to motors mounted under the wing base of the machine while still protecting them against harsh environments.

Most importantly, a clean design balances mass and motion: sturdy, durable framing that withstands years of vibration and shock, combined with light-weight components for the moving parts of the machine. This helps reduce mass, provides more energy-efficient motion, and makes it easier to size-up smaller motor/drive components for the machine.

MMechanical and electrical engineers often overlook important issues when specifying different parts for an electromechanical system. This tends to create complexities and affects smooth functioning of a machine. Mechatronic systems, with their sheer capability of intelligently

integrating mechanical and electrical elements to perform increasingly complex and demanding functions, prove to be a boon for engineers. By taking into consideration five elementary factors, engineers can resort to smart solutions to drive productivity.


MECHATRONIC SYSTEMS

22DIRECTLY COUPLE THE MOTOR TO THE LOADEffective mechatronics starts with a

clean slate design. In the past, machines were often built around a single AC motor powering a machine line shaft, to which gearboxes, pulleys, sprockets, chain drives and other mechanical devices were attached for moving individual areas of the machine in synchronisation. This powering approach can be traced back to the dawn of the Industrial Revolution.

Now let us consider replacing this architecture with individual servomotors coupled directly to the load that is being moved. There are multiple design, machine cost and operational advantages to this solution. First comes cost: every time a gearbox is added, it results in multiple costs – it is an additional point of failure, which has to be lubricated and needs spare parts. Plus, there is a need to add mechanical backlash that has to be compensated for during machine commissioning. But now, thanks to technological developments, every time there is a product changeover, the motion and axes synchronisation complexity is eliminated by today’s intelligent drives and servomotors.

When servomotors are strategically located as close as possible to the area of motion they are serving, the incremental cost of electric drive components is almost completely offset by eliminating the cost of labour and mechanical components that must be purchased, machined, assembled and configured. In particular, not having to stock multiple sets of sprockets, gears and cams, as well as saving the time involved in changeovers with mechanical drives, can really drive down the total cost of ownership for the machine.

33UTILISE ELECTRONIC GEARING AND

CAMMINGThe electronic drives and motion control platforms available today give the mechanical engineer a powerful, flexible tool to improve the accuracy and performance of the machines. This technology enables to create an ‘electronic line shaft’ that can electronically synchronise all the drives and motors on the machine, eliminating the mechanical line shaft. In the process, one can dramatically improve axes synchronisation

and accuracy – from 1/16th or 1/32nd of an inch typical with mechanical line shafts, down to motion precision closer to hundredths or even thousandths of an inch with electronic line shafting. And this synchronisation can be accomplished with zero mechanical backlash and fewer product jams. It also eliminates a host of mechanical adjustments to bring the machine online, as well as the operator adjustments each time the machine is stopped and restarted.

Electronic gearing and camming makes machine changeover completely programmable. The camming technology makes it possible to build multi-segmented cam profiles based on position, velocity or time-based motion profiles. When a section of the electronic cam is altered through a recipe change with the help of HMI, the control platform will automatically optimise

the rest of the cam profile across all the machine’s motion elements. This enables the machine to run a shorter cycle time, or provide smoother dynamics for the machine, even though a change has occurred – a different bag seal-time or flap tucking cam position – on a cartoning machine.

44INCORPORATE ENERGY-EFFICIENT TECHNOLOGYOne of the fastest growing costs for

any manufacturing operation is energy. A good mechatronic design can help control these costs through the application of electric drive and motor systems designed to save energy. In machines that utilise servomotors directly coupled to critical axes of motion on the machine, and also employ electronic synchronisation and camming, the proper sizing of the servo system can create a highly energy-efficient machine. Proper sizing requires an accurate assessment of several motion factors (motor by motor) such as how fast the axis needs to accelerate, the size of the mass that needs to be moved, and how precise the acceleration and deceleration needs to be.

Undersizing will lead to strains on the drives and motors; oversizing will draw too much power to do too little work. Some of the most cutting-edge systems available now include a highly energy-efficient feature: bus sharing. Multiple drives are daisy-chained together and share power from the same bus; in many multi-axis machines, some motors are

accelerating (drawing power), others are decelerating (regenerating power). With bus sharing, rather than having to deliver maximum power to the accelerating motors and bleed off the decelerating motors into heat across a bleeder resister, power is shared, so the machine’s energy consumption is significantly reduced. A

Important Electrical Considerations for Mechanical Engineers The five considerations mentioned here simplify mechanical design challenges and provide resources for driving innovation and creativity in machine design. Create a clean mechanical design to ensure that whatever motions the

machine undergoes, its long-term stability is engineered-in Couple the motor directly to the load to greatly reduce wind-up and

backlash, improving machine commissioning time Utilise electronic gearing and camming to dramatically improve axes

synchronisation and accuracy Incorporate energy-efficient technology to cut down on operation costs

and reduce wasted energy Use HMIs for troubleshooting to show where a problem is and

measures to put the machine in a safe mode for maintenance.

A clean design balances mass and motion: sturdy, durable framing that withstands years of vibration and shock, combined with light-weight components for the moving parts of the machine. This helps reduce mass, provides more energy-efficient motion, and makes it easier to size-up smaller motor/drive components for

the machine.


MECHATRONIC SYSTEMS

further energy-efficient technology is called regenerative power supplies. In many machines, multiple servomotors will decelerate at the same time, boosting the voltage to excess levels on the power bus. Older generation electrical drives would bleed that excess electrical energy as heat – wasting the power and adding to the factory floor’s heat production, requiring additional cabinet cooling. With regenerative power supplies coupled to a shared bus system, what was once wasted power can now be fed back through the shared bus and sold back to electric companies.

55USE HMIs FOR BETTER TROUBLESHOOTINGThe computer revolution has spread to today’s machine control panel, replacing knobs and pushbuttons with sophisticated PC-

based and embedded HMIs with advanced programming and Windows-based operating systems. For instance, when there is a paper jam in a typical office copier, a touchscreen control indicates where the jam is, which door to open, how to correct the problem, and prompts what needs to be done next, once the jam is cleared. The same user-friendly intelligence is now available to machine designers through the latest touchscreen HMIs featuring the latest graphical user interfaces. Machine layout drawings and schematics can be incorporated into control menus and diagnostic tools to better manage the machine’s day-to-day operation and troubleshooting ease.

Drawings and interactive instructional tools can not only show the precise point where a problem is, but also show how to open enclosures and what steps an operator can take to put the machine in safe mode for initial maintenance. Besides, these also give indication on other support resources to resolve a problem and step back through the tasks to restart production.

Advanced graphics can be combined with the distributed intelligence inherent in servomotor-driven machines to prevent machine failures or faults before they happen. Called predictive maintenance, this capability lets machine designers set fault tolerance bands in drives and then monitor drive performance. Electric drives and motors allow a broad range of conditions directly associated with mechanical performance to be monitored. Variations in load, temperature, vibration, torque, belt tightness, gear meshing are all mechanical events that generate changes in the torque profile of an electric drive and motor moving those machine elements. Mechanical engineers can set tolerance bands for these components, and if they exceed them, then predictive maintenance alerts can be clearly and intelligently displayed via the HMI to operators, along with specific advice about next corrective measures to tackle the issue before it becomes a serious production problem that can damage the machine.

BLENDING TECHNOLOGIES FOR OPTIMAL VALUEEvery electromechanical system should perform its designed function through minimal use of energy, motion and components required to get the job done – that is the fundamental goal of any engineer.

Electrical drive and servomotor systems now offer a wealth of reliable, energy-efficient, digitally intelligent platforms to power the integrated vision of mechatronics to greater value an more innovative manufacturing and automation solutions.

Courtesy: Bosch Rexroth Group

VIEWPOINT: Energy Security

The Future Is Green

on pg. 112

ENERGY-EFFICIENT MOTORS


he growing emphasis on technological efficiency is just one of the several forces behind the pressure on companies to ‘go green’ despite a trying economy.

Yet green investments, particularly those related to motors in plants, are likely to lead to conflict between two forces. One is plant management, which is convinced that the best path to a green operation is to operate motors at the highest efficiency; and the other is accounting department that always questions whether expenditures lead to an acceptable return on investment (ROI) in the shortest possible time.

Some will argue that investment in a large motor with a higher efficiency rating than equipment currently in use may be more expensive. But it will pay off in the long run because of enhanced productivity, output and lower long-range costs – a point inevitably debated by accountants who may not be so enthusiastic about long-range ROI and may consider a green initiative as cost-prohibitive.

It is a classic battle fought in corporations large and small, but it does not have to be zero sum – all or nothing. Technology can

help resolve this issue through detailed computerised analysis of the motor, the power environment in which it operates, and even its reliability. All of these relate to cost savings as much as they do with the growing green movement in industry.

APPLYING GREEN TECHNOLOGY TO MOTORS The ultimate criterion that determines whether a motor is truly green is energy-efficiency. In this case, it is all about less use of electricity or other resources, such as water. Clearly, any motor that offers optimum levels of production and energy conservation qualifies for a green or environment-friendly design. Considering that electric motors at most facilities are the largest sources of energy consumption and costs, efficient, outlay-reducing green machinery should be in demand.

Companies leery of additional capital expenditures, particularly during a difficult business climate, are content with the status quo under the mistaken assumption that the motors producing at optimum levels are as efficient as can be reasonably expected. However, there is another parameter of measuring a motor’s

efficiency, and it is one that is usually overlooked when discussing motor technology. That standard is reliability, and it deserves to be included as part of any efficiency evaluation. It needs to be kept in mind that if an old motor requires maintenance well above routine scheduled work, the end result is most likely higher costs due to maintenance, parts, labour, and the additional electricity required to keep it operational. Elevated costs and power usage due to unreliability fall far short of green standards.

Another impact on a motor’s efficiency is the process in which it operates. When a motor functions at well below its rated horsepower, the motor’s environment is considered ‘unloaded’ and its troubles are attributable to an inefficient power system. It is a process failure that is more accurately described as waste rather than unused capacity. The energy required by every piece of rotating machinery can vary, particularly in the method of delivery. A brand new high efficiency motor will be flawed, if it is operated in an unreliable application. One example is a voltage imbalance from the transformer to electric lines to the motor – a classic case of a high-

TThe goal of any green technology is to eliminate waste. In many facilities, old motors are the primary culprits and the biggest energy

‘offenders,’ making them costly in the long run on account of additional expenses necessary to keep them functioning. This calls for green solutions such as energy-efficient motors and other green technologies for doubling the gains, both profit and environment-wise.

greenS LUTION

Embracing The



performance asset in a low-performance environment. Imbalance always has a negative impact on efficiency and performance, regardless of the motor’s efficiency rating.

The green movement as it relates to motors is the result of industry becoming environmentally conscious and more aware of reducing its carbon footprint. Today, the term which was originally applied to the release of greenhouse gases has been broadened to include waste and inefficiency associated with factory operations in general and motors in particular. Still, a company regardless of its green intentions has to factor in the costs of reducing carbon emissions when making the important decision to repair or replace. New green technology provides some tools that can help companies make the right choice.

EFFICIENCY AND FAULT ZONE ANALYSIS One such tool is the technology used to conduct a real-time analysis of six crucial areas of motor function. These areas are referred to as fault zones, and all require independent testing because problems in any one of the six is likely to impair efficiency and output. An effective analysis of each fault zone will play a major role in determining whether replacement or repair will achieve maximum efficiency and a green production environment. The fault zones include: Power Quality: The focus on this fault zone follows the increasing use and reliance on AC and DC drives. An ongoing concern about power quality is the possibility of distortion of voltage and current levels from variable frequency drives. Other sources of trouble with power quality include harmonic distortion, voltage spikes (sometimes resulting from excessive cable length between the drive and motor), and unbalanced voltage. Another factor that wreaks havoc with power quality, in particular, and efficiency, in general, is heat. Harmonics in a distribution system produce excessive heat because of the increasing current demands. Left undetected, heat above acceptable levels can either lead to malfunctions or shorten the motor’s lifespan. Power Circuit: This fault zone is defined as the system of conductors and connections running from the point of origin of testing to connections at the motor. The circuit can include breakers, fuses, contactors and lug

connections. There should be no doubt that a problem in the power circuit impairs efficiency. A study conducted in the mid-1990s determined that more than 46 per cent of the faults found in industrial power distribution systems stemmed from difficulties within either the connectors or conductors. Faulty power circuit conditions place the most efficient and well-maintained motor at risk for reduced horsepower that can lead to excessive heat and insulation damage. Insulation: There is potential damage to insulation between the windings and the ground, which is generally caused by dirt contamination, high temperatures, moisture and age. A faulty power circuit is a culprit in insulation damage, but advanced testing is required to ascertain if the damage was the cause of a motor disruption or something else – a symptom of another problem yet to be analysed. It should also be noted that a system that ensures the dryness of insulation could as much as double the life of the motor as can testing and maintaining the ground insulation. Stator: This fault zone is sometimes misunderstood. A stator consists of copper windings connected with solder joints between the coils. Electrical engineers sometimes differ on the role of the stator as the root cause or symptom. Apart from design or manufacturing defects, the stator is often the symptom of another fault mechanism. The real goal for stator-related incidents is to identify conditions conducive to stator faults and correct them before they result in a stator failure. Stator failures can often be catastrophic, resulting in unplanned outages and defective products, which increase the use of energy and create waste. Rotor: In more specific terms, the rotor fault zone refers to the rotor bars, laminations and end rings. The percentage of motor failures attributed to rotor problems is low, but its trouble spots can cause extensive damage to the motor if left unchecked. The stator is also at risk because of its close proximity to the rotor. For example, a cracked rotor bar will lead to a heat build-up, intense enough to melt insulation on its laminations as well as on the nearby stator. Again motor efficiency will be compromised without the advanced technology necessary to detect a crack or break in the bars. Air Gap: The gap between the rotor and stator assures efficiency when it is evenly

distributed around 3600 of the motor. When distribution is uneven or non-symmetric, the usual result is an unbalanced magnetic field that can lead to failure of the stator windings and stress on bearings that are also likely to fail.

All six fault zones have one requirement in common: ongoing testing of the highest standards and tolerances that will help ensure efficiency. Chances of achieving green-oriented goals are unlikely with anything less.

GREENWASHED VS GREENWISE Going green can be compared to a pressure point applied to companies seeking to reduce waste in their usage of electricity and water while maximising efficiency. Constant pressure to be environmentally responsible is bound to take its toll on firms trying to balance out green-related efficiencies with cost. Sometimes, the balance tilts unfavourably. That, in essence, is what happens when a company is ‘greenwashed’. It decides to invest in new motors based solely on high-efficiency ratings. Certainly, no company is going to make such a decision without a serious cost/ROI analysis. In a bid to achieve two outcomes (green energy and increased profits), a company may find itself yielding to its laudable desire to show its green colours. It is not that the firm has placed its ROI on the backburner; it is more likely that the company has not adequately considered the possibility of attaining its green goals without a massive investment in new motors.

Any assumption that purchase of a higher-efficiency motor is an automatic step into green nirvana may well be viewed as a greenwashed-based decision. This is because the decision was reached through a simple math process based on motor design information (usually referred to as the nameplate) instead of evaluating a number of critical variables. Simple math is limited to rated horsepower and production output, use of energy to achieve that output, savings due to less energy requirements and the time it takes to achieve ROI. At first glance, the savings from the massive investment may be viewed as astronomical and a ‘no-brainer’, but there is a caveat: these calculations should be recognised as limited and the savings that they project may not be close to accurate. Variables such as distribution system, load history and accurate efficiency calculations are left out of the equation.



The technology is available to measure the data of these variables, which may determine whether being green means a full-scale motor replacement or a less costly repair. A ‘greenwise’ decision examines all the variables and projects’ actual savings. True, manufacturers are providing the highest-efficiency motors available in the market, but their value and performance have to be predicated on the plant environment where they will operate. Greenwise testing and computations take into account the actual running conditions of the motor in addition to the motor’s nameplate rating. The company may conclude that the payback for the purchase of a new motor may be less than preliminary calculations indicated because of information revealed through fault zone testing.

That is especially true when utility costs, the largest expenditure in a motor’s lifecycle, are factored in along with wasted capacity – the result of a power condition that forces the motor to work at less than its rated horsepower.

GREEN TECHNOLOGY FOR MOTOR MAINTENANCE AND MANAGEMENT Software for motor maintenance has evolved to the point that its use can be considered a valuable step towards going green. The introduction of reliability-centered maintenance (RCM), which

created a centralised base to co-ordinate motor asset management, is one of the recent advancements. RCM became the first step in the evolution to predictive maintenance software that represents a ‘cradle to grave’ diagnosis of a motor and its fault zones – a co-ordinated package that communicates between separate software analysis systems. The lesson these advanced systems provide is that motor maintenance and management must be co-ordinated throughout the entire lifecycle. Without it, a company could waste money, energy, labour and utilities trying to repair a recurring problem without recognising the actual cause of the breakdown.

Some businesses have responded with the creation of the machinery information management open system alliance (MIMOSA) – a consortium that promotes a standard protocol to reduce difficulties in data conversion from disparate software applications. This too should be considered a step in the green direction since it aids enterprise resource planning while providing useful data to determine ROI for either motor replacement or repair. Its goal is maximum efficiency, which is rapidly becoming a synonym for green industrial operations.

One of the newest types of software, the energy cost analysis module, produces real data for any existing motor application. The actual running condition is analysed

prior to any consideration of replacement. Additionally, the nameplate data is considered along with the variables that impact operations. Following information input, the software produces data on actual efficiency, repair based on fault analysis, or necessity of replacement.

Equally important, one must not forget reliability. High-efficiency ratings mean little if the motor is unreliable, especially after its warranty has expired. The new technology can accurately assess the motor’s reliability while projecting its years of useful life.

ROI DECISIONS FROM A GREEN PERSPECTIVE By now, it would be clear that going green requires a significant reduction of energy consumption, which is what the newest maintenance software is designed to determine. Motor circuit evaluation has unified everything from fault zones inside the motor to the exterior environment and all of those variables associated with it including a realistic assessment of the motor’s lifespan – all necessary for the projection of ROI.

It is the software revolution that may turn the tide to green’s favour and bring an end to those ‘greenwashed’ decisions based solely on motor efficiency ratings. Accountants who tend to equate conversion to green technology with questionable ROI may be swayed by the bigger picture that the new software information can provide.

It is not a stretch to consider upgrades in energy-efficiency among the most important steps a company can take with its green conversion. One may not immediately connect the operation of a 1000 hp motor with environmental improvement, but consider that the more efficient the operation of the motor and its environment, the less the requirement for electricity and power, which means lower operating costs. That merits the green label by any contemporary standard. Motor reliability should be considered the same way.

Analysis technology can improve motor efficiency and reliability, and its sophisticated evaluation software may well be one of the best opportunities to maximise a motor’s lifespan while limiting its carbon footprint. One does not have to be an ardent environmentalist to appreciate the value of this green strategy.

Noah Bethel, CMRP, VP – Product Development, PdMA Corporation

Things you must know about energy-efficient motors Energy efficient motors are much better off than standard-efficiency

motors under full, partial, and unloaded conditions. The efficiency of any motor varies with factors as size, speed, and loading.

Most manufacturers are designing their energy efficient motors to provide peak efficiency at 75 to 100 per cent load. Typically efficiency stays fairly constant from full down to 50 per cent load.

Generally, the initial cost is about 15 to 30 per cent more than standard motors, but depending on the specific motor manufacturer and market competition, they can be even less expensive.

The price premium per horsepower is lower for the larger motor ratings. As the population of energy efficient motors increases, the initial cost will come down and may be available at the same cost as a standard motor in the near future.

For new purchase decisions, the simple payback on the incremental cost of a continuously operated energy efficient motor can be recovered through energy savings from few months to 2 years depending on the hours of use and efficiency of replaced motors and tariff.

Source: International Copper Promotion Council India


GLOBAL DESIGN AND MANUFACTURING PARTNERSHIPS

oday, the design element is essential to business success. Yet it seems like only yesterday, although it has been decades, since designers simply handed

off their work to be executed by engineering and manufacturing departments, later only to be surprised that the product has greatly deviated from the original vision or intent. However, things are changing now, and currently, the industrial design, engineering and manufacturing functions truly constitute a team effort. This is especially valuable, given that companies now source from a global supply chain, and both manufacturers and designers offer value-added services to their clients and partners. But, the issues of distance, time, speed and culture act as frequent impediments to successful collaboration.

AIMING AT SUCCESSFUL COLLABORATIONThe definition of successful execution of a design has shifted within various professions, and the stakes for declaring a design successful have also been elevated considerably. Hence, it has become pivotal to build effective partnerships among design, engineering and manufacturing departments. If this strategy is pursued successfully, the

result is breakthrough design, and if such partnerships fail, the end result is unhappy customers.

There was a time when handing over a promising rendering was the end-goal for designers. Then mock-ups and models were needed to help teams visualise, and more recently, fully functional prototypes with engineering detail to provide alignment became the need of the hour. Designers soon became involved with the details of

production. Today, design strategy illuminates a clear path

from sketches to empowered consumers. For this to happen, the realities of implementation – business models, distribution methods, and budgets – have to be integrated into the strategy and design process and collaboration between the innovation and production teams must be ensured.

As the design process has evolved in complexity, so too has the world of

T

COLLABORATING FORSUCCESSAchieving effective global design, engineering and manufacturing partnerships have become imperative for every company to make a mark in the market. But often organisations struggle to reap success from collaboration. When these relationships are strong, one gets designs that delight consumers and produce bottom line results. When they go awry, even the best brands find themselves struggling to answer uncomfortable questions about design flaws and conditions in the factories they partner with.

Just as the worlds of design, strategy and brand are converging within executive circles, so too are the fields of design engineering and manufacturing amid an increasingly truncated production process, often spread across the globe. Each profession must make the mental leap from designing objects to designing experiences – and work collaboratively in order to do so.


GLOBAL DESIGN AND MANUFACTURING PARTNERSHIPS

manufacturing and distribution. The most profound change has been the decoupling of the location where designs are created, where they were made vs. where they are sold. Many companies, especially those in North America, send their designers over to the manufacturing floor to understand how things work. However, maintaining the constant connection between the functional teams is often extremely difficult, and the focus on consumer priorities can get relegated to the back burner.

Yet, manufacturers play a vital role in delivering a consistent and meaningful user experience – a key ingredient in creating and maintaining brand trust. Products often form an impression of the brand and the country in the minds of the consumer. In 2009, the US imported an estimated $296 billion worth of manufactured goods from China, and $21.9 billion from India.

So, the need for collaboration across the globe is now clear, but the tools to create an effective collaboration are not well-known. Here are some tips that would make the process smoother and lead to better results:

CONSIDER USING VISUAL TOOLS Designers and engineers are no strangers to sketches, renderings and CAD drawings. But the visual understanding needed should go beyond the bill of materials and assembly. Sharing the usage scenarios that have been developed during the design process, the vision of the consumer experience that is sought, and the retail setting that the product will live in are all equally important.

This is the type of understanding that can lead to breakthroughs or the meaningful tweaks that can transform a good design into a great one. Being visual helps align stakeholders and can also catch potentially costly mistakes or oversights early in the process.

A leading company has achieved huge success by utilising a highly visual process called ‘Psycho-Aesthetics’, which incorporates basic psychological teachings and product interaction understanding to help guide its strategy process and lead to compelling design solutions for consumers with better regularity.

HAVE A CONVERSATION ABOUT VALUES, NOT JUST PROCESSESCompanies and consumers know that the choice of a manufacturing partner is one that can communicate the values of the company to the general public. It is up to both parties to ensure that they share knowledge about

the guiding principles of each organisation. The sharing of values shifts the focus from legal compliance to one where people are connected and concerned with one another’s welfare. Data from across industries supports the fact that satisfied employees create more innovative products and pave the path for high-performance companies. This understanding should extend to partners as well. The outsourcing of services has shown that this broadening of values buy-in is possible in a timely and cost-effective manner.

EXPLAIN THE ‘WHYs’This point may seem obvious, but under deadlines, it is often missed. Both designers and manufacturers tend to focus on ‘what’ needs to be accomplished, and ‘when’. However, explaining ‘why’ certain design decisions have been made and ‘what’ they are intended to accomplish can lead to creative solutions. It is essential to understand what can be streamlined, alternative ways to deliver solutions and have a meaningful dialogue about how to customise for different markets. Going forward, this level of dialogue will be critical in the era of cradle-to-cradle design, with increasing demands for sustainability.

Companies are gradually bringing the design function into higher levels of their corporate culture, and consulting designers earlier in the process. The same needs to be done with manufacturing. There is nothing more disheartening than a great concept being shelved in which everyone has invested emotionally because it cannot be manufactured as desired. However, when the ‘whys’ are clear, and there is a

shared ownership of the idea, true innovation can happen.

BE REALISTIC ABOUT COSTSIt is a competitive world and the pressures on both designers and manufacturers to reduce costs can be enormous. However, it is in the interest of all parties to be as

forthright as possible about the true costs of various design solutions and manufacturing processes. Consumers generally pay for value when they see it, even in tough times. They are unlikely to embrace products that are cheaper, but provide an inferior experience and deplete brand trust over time.

USE IT TO OPTIMISE COMMUNICATION The benefit of IT to enable 24/7 real-time communication does not need to be emphasised. When selecting IT solutions, simplicity should be paramount. Relying heavily on IT for all communication purposes can actually hamper outcomes, especially in the final stages of a project. Picking up the phone can be more effective in achieving alignment while saving time.

SHARE TECHNOLOGICAL DEVELOPMENTSJonathan Ive’s intense dedication to keeping Apple at the forefront of what modern manufacturing can accomplish is a major aspect of the company’s product and commercial success. For example, Apple is reportedly experimenting with liquid metal manufacturing, which combines the conveniences of precision injection-moulding of plastics with new metalic materials. Their actions should be noticed and their lead should be followed. With design processes and manufacturing techniques being improved and streamlined constantly, collaboration between designers and manufacturers around new capabilities can be valuable in terms of design enhancement, cost reduction and the corresponding impact on profitability.

DESIGNING EXPERIENCESThe challenges of working with global teams are daunting at times – but the reward is winning in global markets.

Ravi Sawhney, Founder & CEO and Deepa Prahalad, Lead – Global Insights, RKS Design

Today, design strategy illuminates a clear path from sketches to empowered consumers. For this to happen, the realities of implementation – business models, distribution methods, and budgets – have to be integrated into the strategy and design process and collaboration between the innovation and production

teams must be ensured.

Search November 2010 Ad Name: GW Pg. 139

Search November 2010 Ad Name: Igus Pg. 140


INDUSTRIAL EQUIPMENT SEGMENT

he industrial equipment segment has attained a significant stature over the years. However, like any other sector, it faces increased competition in domestic and overseas markets, and has to deal with bottlenecks on account of volatile fuel prices and stricter environmental regulations. But certain

challenges are particularly pronounced. Some of these are elaborated below:

BALANCING SUPPLY AND DEMANDIndustrial equipment manufacturers (IEMs) are striving to succeed in highly competitive and slow-growing markets in their home countries. For instance, the demand in

North America and Europe has slowed as customers started reducing or delaying capital spending, thereby leading to a slash in production by manufacturers.Increasing globalisation, growth in emerging marketsRapid globalisation is generating new opportunities and at the same time resulting in rising competition in emerging regions, as some former ‘low-cost’ economies transform into attractive markets for selling goods. This has led to increasingly complex supply chains and growing competition from domestic manufacturers in these markets.

Volatile energy costs & stricter regulationsHighly volatile energy and commodity costs, together with government and public pressure have led IEMs to focus on

TFuelled by rising demand for different categories of equipment for varied applications, the industrial equipment segment is witnessing a growth spurt. While the opportunities are many…unforeseen challenges in its way pose major threat to its growth. Braving all odds, the

segment has been adopting key success levers such as operational excellence to be globally competent and cost-efficient.

CHALLENGED, TRANSFORMED CHALLENGED, TRANSFORMED & POISED FOR GROWTH

To achieve operational excellence, industrial equipment manufacturers must focus on issues such as supply chain visibility & optimisation, demand & inventory planning,

while also rationalising their supplier base.


INDUSTRIAL EQUIPMENT SEGMENT

minimising their impact on the environment and reducing energy bills. In many cases, this has resulted in operational challenges as they look for greener ways to source, manufacture and ship their products. But just as every challenge has some or the other solution, the industrial equipment manufacturers can use the following six key levers to address their problems:

1PRODUCT AND SERVICE INNOVATION

This lever focusses on bundling the product offering with value-added services and leveraging technology partner relationships. Establishing close collaboration with customers and suppliers earlier in the product lifecycle and across the value chain is essential to manage this lever.

2COST REDUCTIONKey elements of this lever include shifting some portion of manufacturing offshore, outsourcing non-core

business processes and restructuring initiatives such as consolidation, standardisation & harmonisation of processes and systems.

3SERVICES FOCUS AND SALES GROWTHWith slow revenue growth and tight margins, some IEMs are beginning to shift their focus towards services,

while at the same time taking advantage of emerging markets and multi-channel sales and distribution strategies. Solutions to help IEMs focus on this lever include service strategy and transformation, multi-channel optimisation, sales/market roadmap development, campaign and loyalty management, sales effectiveness, and price & revenue optimisation.

4OPERATIONAL EXCELLENCETo achieve operational excellence, IEMs must focus on issues such as supply chain visibility and optimisation, and

demand & inventory planning/integrated business planning, while also rationalising their supplier base.

5CUSTOMER CENTRICITYAs the industrial landscape becomes more global, partnerships grow in importance. Critical success factors include an

improved understanding of the customer’s business and closer collaboration.

Long-term customer relationships will be achieved via approaches such as integrated after-sales services. Solutions designed to improve customer centricity include customer relationship management (CRM), call-centre operations, service parts management and repair and business information management (BIM).

6GREEN INITIATIVESTo address environmental, ecological and ethical concerns, IEMs need to focus on designing and developing sustainable

products, as well as implementing a green IT strategy. These solutions not only help IEMs optimise business processes

but also help in creating newer standards in the industrial equipment manufacturing industry.

Courtesy: Capgemini

Key Levers to Manage Industry Challenges

Product & Service Innovation

Cost Reduction

Service Focus & Sales Growth

Operational Excellence

Customer Centricity

Green Initiatives

Key Levers Action Towards Excellence Select Solution Areas

� Collaboration with customers and suppliers earlier in product lifecycle and across the value chain

�and process innovation

�standard, harmonised processes and controls

� Transformation to a service organisation

� Complete functional integration internallyand externally

� Improved value chain performance

� Product offering bundled with value-added aftersales services for better customer service and integration

� Devising and deploying sustainable products

� Implementing green IT strategy

� Innovation & Lifecycle Management

� Enterprise Performance Transformation

� Outsourcing– IT– Procurement– Finance & Accounting– Customer Care & Insight

� Supply Chain

– Sourcing– Supply Chain– Logistics

� Service Transformation

� Green IT

Best-in-Class Networked Value Circle Model for Industrial Equipment

SUPPLY CHAIN PARTNERSAND NETWORKS

INNOVATION PARTNERSAND NETWORKS

MANUFACTURING PARTNERS AND NETWORKS

IT-FACILITATEDCOORDINATION

SUPPORTFUNCTIONS:

From supportinga chain to managing

a value-creatingnetwork

SUPPLYCHA

IN

MANAGEMEN

T

Fromcontracts

topart

nerships

MARKETING, SALES

ANDSERVICE

Fromrelationship

management

tocustom

er partnership

MANUFACTURING

Fromworld-class manufacturing

toworld-class manufacturi ng

management

PRODUCT

DESIGN

AND INNOVA

TION

Fromdoin

g it to

resourc

ing it

This model helps industrial equipment manufacturers focus on three strategic capabilities:identifying global competencies by realising core competencies and connecting to other valuechains; identifying relationships that will be either long-term assets or strategic assets to gaincompetitive advantage in a value chain; and using their management skills and technology toform, manage and exploit relationships whether they are two-company partnerships or wide,open, network relationships.


HITECH MATERIAL HANDLING SHOW

INSPIRINGINSPIRINGINNOVATIONSINNOVATIONS

aterial handling plays a fundamental role in today’s manufacturing setup. Right from raw material handling to the final dispatch of the product to the end-

customers, material handling plays an indispensable role. In a nutshell, an efficient material handling equipment (MHE) increases throughput, controls costs and maximises productivity. While the applications are many, every industry vertical demands a unique set of equipment to store inventories as well as to dispatch the final product. Justifying the same, Tushar Mehendale, MD, ElectroMech, avers, “Any manufacturing unit, in any sector, requires equipment to handle materials in the factory. Different verticals require different solutions to cater to their MHE needs. Chemical industry, pharmaceutical, construction, electronics, energy, food & beverage, metalworking, metal casting, plastics, aerospace manufacturing, automotive industries – all are dependent on the MHE industry. This reflects the critical significance of material handling in every industry vertical.”

Elaborating on how efficient material handling brings profits to the industry, Sudhanva Jategaonkar, Associate Vice President - B2B Publishing, Infomedia18 (A Network18 Company), opines, “Efficient material handling and smart storage solutions are the means for enhancing profitability for small and medium enterprises (SMEs).” In order to cater to the growing needs of the customers and to create an awareness about the GenX material

handling solutions for the industry, Network18 Group is organising a mega industry event in February 2011. The event is aimed at providing a conducive platform for showcasing best in class solutions that aid in attaining manufacturing efficiency.

HiTech Material Handling is a first-of-its-kind event showcasing latest material handling innovations under one roof. From MHEs like forklift trucks and automated logistics systems to innovative and cost-effective ideas in racking, shelving, storage solutions, transport and distribution, packaging; handling system design & warehousing, the event will display the best of new-age material handling solutions.

HiTech Material Handling Show will be concurrent with HiTech Automation, under the umbrella show HiTech Manufacturing.

AN ERA OF EVOLUTIONIn the past few years, material handling has become a new, complex and rapidly evolving science. For moving material in & out of warehouse, a variety of equipment and system are in use, depending on the type of products and volume to be handled. According to Vijay Devta, Senior Sales Executive, Safex ElectroMech, some of the new-edge technologies in India for MHE are hydraulic conveyors, hydraulic working platforms and material lift, passenger cum material lift in construction industries and in-process industries roller conveyor. Manufacturers have a wide variety of choice in the types of MHE available in the market.

To add to this, globalisation and international trade & commerce are propelling competitiveness and driving the

development of novel and efficient material handling technologies in the market. According to Mehendale, the size of the Indian MHE industry is estimated at approximately `5,000 crore and is likely to grow at 20 per cent year-on-year over the next five years, in terms of the overall economic growth. Domestic production and foreign trade are the two growth drivers for this segment.

ONE-STOP SHOP FOR MATERIAL HANDLINGHiTech Material Handing will help the entire material handling industry converge into a single lucrative platform that will serve as a foundation for the future growth of this industry. The event will display cutting-edge technology, breakthrough innovations and interactive demonstrations from the leaders in the material handling industry.

“HiTech Material Handling showcases the best and the latest in the industry. This show is a must attend for all SMEs. For those who will be a part of this extravaganza, the exhibit will provide tremendous networking opportunities and scope for business generation,” avers Jategaonkar.

With this show, the material handling industry will be witnessing a slew of exciting new developments, which, in turn, will help the businesses maximise their return on investment (ROI).

HiTech Material Handling show is poised to equip India to shape its futuristic aspirations of building a robust innovative material handling equipment industry, with an objective of achieving a world-class position.

M

To keep pace with the increasing demands and manufacturing advances, the Indian material handling industry needs to innovate and deliver futuristic solutions. HiTech Material Handling is a first-of-its-kind show exhibiting futuristic products & services across the material handling spectrum. A one-stop shop for GenX material handling solutions, the event is all set to provide a success ladder to one & all...

SHIBANI GHARAT

Mumbai | 17-19 Feb, 2011


DRIVE & CONTROL

INTEGRATING SAFETY INTEGRATING SAFETY intointo WORKPLACE WORKPLACE

ystem integrators with motion expertise are often in demand with regard to retrofitting servo-controlled motion to an existing machine or

process. This is because servo control offers advantages of greater speed to reduce cycle time, increase changeover speeds for different product variants, or provide a motion profile that eliminates existing mechanical problems. However, modification of existing or addition of new motion features should take into account the functional safety aspect of the machine.

FUNCTIONAL SAFETYFunctional safety forms the part of machine or safety equipment and depends on the proper operation in response to its inputs, including safe response to equipment failure

and operator errors. It provides a workplace free of unacceptable damage (direct physical damage to equipment or product in process or indirect damage such as loss of productivity, environmental hazard or financial impact of medical and litigation costs) or risk of injury to personnel. Functional safety is best applied from the base as part of the overall machine design process rather than adding at the end. It must be designed as part of the control system. Earlier, the conventional approach of considering safety as the last step may have worked to an extent when the safety approach comprised hard guarding and fencing.

The electrical, electronic and programmable systems (E/E/PS) of a machine or process carry out system control and monitor operations; however, safety depends on proper functioning of the entire system. The functional safety analysis

should include even non-electric sources of motion, or a potentially hazardous stored energy like hydraulic or pneumatic systems under pressure, or suspended weights that may fall under gravitational effect. Functional safety is an integral part of the system, and not simply a guard to prevent personnel from entering hazardous areas.

RETROFIT CONSIDERATIONSWhile implementing a retrofit, it is often difficult to convince the owner of the equipment about the requirement of safety-rated components and methods. Explaining a situation, Steve Cortese, Controls Integrator, Automation Works, Mount Prospect, IL, says, “When an existing user has not had an accident or a runaway with normal machine controls, he may not see the need for redundant safety-related control architecture. The earlier practice

S

Eliminating potential injuries to personnel and increasing safety aspects of machines in a manufacturing facility have become a priority today. Thus, often, equipment manufacturers need to strengthen functional safety of machines by implementing servo control in existing machines or processes. This will ensure enhanced productivity as well as prevention of new risks,

thereby making the workplace safer.


DRIVE & CONTROL

was to open a guard door and engage a set-up bypass circuit that allows normal jogging. Hence, the user may not see the need for a monitored, safely limited speed to ensure that even a single failure does not result in unexpected or uncontrolled motion. This may put the machine operator in danger.”

Here is another example. A high production automotive airbag assembly manufacturer described the method for improving cycle time followed by the company. The company connected a light curtain at the access to the load-unload station to the forward overtravel limitinput of the servo drive that moves the bag folding arms. If the operator enters while the machine is still moving towards the unload station, the axis would stop.If it were moving away after releasingthe completed airbag, motion would be allowed even though the operator’s hands were through the curtain. With the useof a standard (non-safety) input with no redundancy or diagnostics, it is possiblethat a single failure could cause loss of the stopping function and allow rapidmotion towards the operator’s hands – the hazard they were attempting to avoid. Overtravel input is a circuit in the drive designed with normal good practicethat has not failed in a hazardous situationtill date.

In retrofits, the original system may not be updated on the basic guarding and interlocking systems when using the conventional methods of removing power when doors are open. This would prevent unexpected motion that may present a risk

to personnel involved. Further, in conventional methods, often a simple, single-channel, non-redundant emergency stop to remove power is the maximum facility that was provided. Adding a proper guarding and door interlocking that decreases power to servo drives may result in new errors and sequence restart issues. Decreasing input power contactors also puts stress on servo drives’ bus capacitors, wastes energy from discharging & recharging and takes more time to restart, which could otherwise be used for enhancing the production cycle.

Dave Stuber, Controls Integrator, Custom Controls Solutions, St. Charles, IL, points out, “One should use the Safe Stop 2 functionality, as defined in standard IEC EN 61800-5-2, which allows the drive to

maintain torque and hold position while stopped. All axes in a complicated system can maintain position and synchronisation while doors are opened for set-up adjustments.

The safety function monitors motion and shuts down to no torque, if motion is beyond the determined safety limit. These help avoid power cycling stress, contactor wear, time delay, errors and additional logic for mid-cycle restart. These new techniques are allowed under changes to standards like NFPA 79-2007, permitting a servo drive designed for stopping functions without requiring power disconnect by an electromechanical device.

SAFETY DESIGN PROCEDUREThe overall steps to applying safety are the

Safety steps Determine the limits of the machinery Identify hazards through individual hazard analysis or task-based analysis Evaluate the risk, and determine if it has been adequately reduced After each step in the process, it is also important to evaluate if new

hazards have been created The hazard evaluation process is then successively iterated until all

identified risks have been mitigated Human factors must be considered, especially in retrofits, where the

process executed by an operator is being changed. It is better to design, in advance, the special modes of access and motion required to clear jams, perform cleaning operations, etc, to ensure that added safety features do not complicate the operator’s job.

By using a standard (non-safety) input with no redundancy or diagnostics, it is possible that a single failure could causeloss of the stopping function and allow rapid motion towards the operator’s hands.


DRIVE & CONTROL

basis of most standards today. The first step includes determining the limits of the machinery, and the second is identifying hazards through individual hazard analysis or task-based analysis. Further, it is important to estimate & evaluate the risk, and determine if the risk has been adequately reduced. If the risk is still at unacceptable levels, one should proceed with the risk reduction for that hazard.

The priority for risk reduction is eliminating the risk by inherent design or change in the process (e.g. move the column where an operator might be injured, if struck by a moving machine). If this is not possible, add safeguards (e.g. create a mechanical barrier to keep the operator away from the area and automatically reduce the speed of motion, if he must enter and still move the machine for recovery or jam removal operations). For any residual risks, it is essential to provide information for equipment use so that the operator can avoid the potential hazards. If the protective measure involves safety-related parts of the control system, standards define an iterative process (the ‘V-model’) for specification, design, coding, testing,

integration and validation of the control system.

Also, risk evaluation after each step is important to know whether the changes made have created new hazards. For example, if a mechanical guard that has been added to protect an operator from possible hand injury is positioned such that it can trap the operator between the guard and a wall, it indicates that a new hazard may have been created. The hazard evaluation process then undergoes successive iterations until all identified risks are mitigated.

In particular, in retrofits, where the process that an operator executes is being changed, the human factors must be considered. Incorporating protection that makes it difficult or impossible for the operator to perform the concerned job will most certainly result in finding a way to work around or disable the intended protection. Thus, one should design, in advance, the special modes of access and motion required to clear jams, remove bad product, perform cleaning operations and tasks other than the normal automatic cycle of the equipment. In this way, the accepted solution does not outrun the safety

measures incorporated to prevent injury and damage.

CURRENT TECHNOLOGY IN SERVO DRIVESThe safety motion functions defined in IEC EN 61800-5-2 Adjustable Speed Electrical Power Drive Systems, Safety Requirements – Functional come into play in special modes. Servo drive safety functions defined in IEC EN 61800 are now offered insafety-certified servo drive equipment that allow continuous application of power to enable motion in special modes. These features include safe operating stop, maximum speed, limited speed, direction and limited increment. It also includessafe homing, braking & holding system, as well as safely monitored position, deceleration & stopping processes. These drive safety solutions can easily be integrated into existing & new machines, and reduce risks to acceptable levels, while enhancing machine productivity and making machine safety functions transparent to themachine operator.

Gary Thrall, Senior Product Support Engineer, Bosch Rexroth Corp.

Belonging to the ‘state of businessmen’ that is Gujarat, Ahmedabad is never out of business and investments. Supported by excellent road network, railway connectivity and port proximity, and ofcourse, the most pro-active government, the opportunities that Ahmedabad provides for companies to set up their base are aplenty. With increase in the number of investments, companies need to spread awareness about their innovative offerings in the relevant segment. Providing such lucrative opportunities to companies, Engineering Expo Ahmedabad, in its 9th edition is all set to break its own records in generating business, and providing opportunities.

Since the time immemorial, Gujarat has been known for its ‘business-friendly’ attitude. Experts have always attributed the growth of Gujarat to its proactive approach towards entrepreneurship and innovations. Its citizens are known for their leadership and entrepreneurial skills, risk-taking abilities and aspiration to explore new avenues of growth.

Thriving with booming investment prospects, Gujarat is a state that every company would want to associate with. The reasons are many. First and foremost, Gujarat houses a number of multinational corporations, private sector companies, public sector enterprises and medium & small-scale units. This is not all. The business-friendly policies add to the immense opportunities that the state holds.

At the heart of business in Gujarat is the city of Ahmedabad. The city, which pumps

in opportunities and growth prospects in the state, has become a commercial hub of Gujarat. As per September 2009 figures, investment projects worth `1,80,000 crore had already been implemented and projects worth `4,90,000 crore were under various stages of implementation. Investments particularly in power, gas, ports and infrastructure has given a boost to the progress of the state. When it comes to providing a conducive working environment, Ahmedabad was ranked fifth after Ludhiana, Hyderabad, Bhubaneswar and Gurgaon in a citywise analysis by the World Bank reported in ‘Doing Business in India, 2009’.

The presence of several industrial firms like Adani Group, Reliance Industries, Nirma Group of Industries, Arvind Mills, Claris Life Science, Shell, Bosch and many others, justifies the tremendous business potential existing in Ahmedabad. Many

investors prefer this region because of the presence of excellent infrastructure, availability of land, and negligible presence of trade unions. Moreover, the government has made all possible efforts to drive the growth of industries here. The proposed Delhi-Mumbai industrial corridor, Dholera (special investment region) and Gujarat International Financial Tech (GIFT) city are also expected to fuel the industrial growth of Ahmedabad.

AHMEDABAD INDUSTRIAL BASETalking of industrial base, Ahmedabad accounts for 21.5 per cent of factories and employs 18 per cent of workers in the state. Of the total industrial productivity of the state, 60 per cent is contributed by the city alone. Ahmedabad is an industrial base for sectors like chemical, textile, drugs & pharmaceuticals, agro and food processing industries.

FLYING HIGH WITHBRIGHT PROSPECTS

Engineering Expo Ahmedabad 2010-11

SHIBANI GHARAT

Such promising avenues call for the increased awareness about latest product offerings of companies to broader audience. Having been established as an undisputed leader in providing a trade platform to manufacturers and service providers, Engineering Expo Ahmedabad 2010-11 is stepping into its 9th edition from December 10-13, 2010. Abuzz with prospects, the Expo is set to offer a cornerstone for companies that aspire to set up base in and around the city. It would also be an ideal platform for companies willing to strengthen their base in Ahmedabad.

Exhibitors are also upbeat on the possibilities that the Expo presents. Talking about the business benefits, Paresh Talsania, Proprietor, Talsania Engineering

Works, a Vatva-based company, says, “The return on investment in Ahmedabad is very good. Not only are short-term gains possible, but the long-term business growth is also achievable.” Talsania is participating at the Expo for the first time and is optimistic about creating awareness about the company and interacting with various prospective buyers.

Seconding his thoughts, Kailash Katkar, CEO, Quick Heal Technologies, informs, “We expect good number of enquiries from corporates and SMEs, since clients from these segments are expected to visit the show.” In a similar vein, CB Panchal, Director, Modern Power Semiconductor, a five-year-old company based in Vijapur, notes, “Engineering Expo offers us a platform to advertise and promote our products, and hence, generate more awareness about our company and our diverse range of products.”.

RENDERING SUPPORT TO NEIGHBOURING CITIESAhmedabad plays a vital role in rendering commercial resources and market access for the economies of neighbouring cities. The city of Ahmedabad, which in itself is a successful industrial hub, has also helped trade and industry to flourish in neighbouring cities like Gandhinagar, Rajkot, Surat, etc. Engineering Expo is thus, a platform that brings together decision-makers and visitors from leading industrial centres such as Vadodara, Rajkot, Gandhinagar among others, who are in search of latest engineering solutions to improve business prospects.

ENGINEERING EXPO: AN IDEAL BUSINESS DESTINATION Engineering Expo is a perfect manufacturing & engineering trade fair to display latest products & services. As proved by 1,000+ companies that participated

in the previous editions of the Expo, it is one of the most preferred platforms to grow business. Exhibitors like Parag Patel, Proprietor, Samruddhi Industries, who had participated at the event earlier, are reaping huge benefits. “We exhibited precision measuring instruments aimed at mechanical, piping and fabrication industries and pharma sector. In a span of four days, we sold more than 500 units of our products. With the number of inquiries we have received, we are sure to have a 10 per cent rise in our business,” says Patel. Garnering such leads, the company has decided to be a part of this year’s Ahmedabad edition as well. This speaks of the might that Engineering Expo has been able to harness in its eight years of existence. Highlighting on the performance of Engineering Expo in helping the growth of SMEs, Sudhanva Jategaonkar, Associate Vice President - B2B Publishing, Infomedia 18, a Network 18 company that will be organising this mega industry event, says, “The brand Engineering Expo is a brilliant example of starting humbly and achieving an enviable feat over the years. We celebrate the entrepreneurial spirit of Gujarat and are partners in our customers’ progress. With the coming months looking promising for the manufacturing sector, we aim to provide more business development opportunities through our Expo.”

OPPORTUNITIES CALLING… Being an all-inclusive engineering show, Engineering Expo-Ahmedabad will provide an ideal opportunity for the exhibitors from allied sectors in engineering and manufacturing to improve their business prospects. The exhibitors are expected to receive an overwhelming response from the visitors, and hence, generate tremendous business leads and new partnerships in Gujarat.

Engineering Expo, organised by Infomedia 18, is one of the engineering industry’s biggest events in the country. The 2009-10 edition of Engineering Expo saw business transactions worth over `150 crore. Launched in Ahmedabad in the year 2002, the event today boasts of a fabulous visitor turnout. The Expo is a preferred destination for SMEs and manufacturing & engineering companies to transact, network, form tie ups, and exchange ideas. The Engineering Expo 2010-11 is scheduled to take place in four cities, starting off at Pune in November 2010 and proceeding to Ahmedabad, Indore and Chennai in subsequent months.

Ahmedabad | 10-13 Dec, 2010We exhibited precision measuring instruments aimed at mechanical, piping and fabrication industries and pharma

sector during last year’s Ahmedabad Edition. In a span of four days, we sold more than 500 units of our products. With the number of inquiries we have received, we are sure to have a 10 per cent rise in our business.

Parag Patel, Proprietor, Samruddhi Industries


mall and medium enterprises (SMEs) have been considered one of the ‘driving forces’ of modern economies due to their multifaceted

contributions in terms of technological innovations, employment generation, export promotion, etc. Of these, the ability of SMEs to innovate assumes significance because innovation lends a competitive edge to firms, industries, and ultimately, economies. Therefore, technological innovation has the potential to spur growth of individual enterprises at the micro level

and aggregate industries & economies at the macro level.

Given this fact, it is essential to understand issues such as factors driving SMEs to innovate; nature of SME innovations and the resulting achievements and their outcomes. Overall, it needs to be understood whether SME innovation facilitates the growth of firm size, and if so, how can SMEs tap this promising avenue.

THEORETICAL FRAMEWORKTechnological innovation is a key factor in a firm’s competitiveness. It is unavoidable for firms that want to develop and maintain a

competitive advantage and/or gain entry into new markets. Among firms of different sizes, SMEs are generally more flexible, adapt themselves better and are well-placed to develop and implement new ideas. The flexibility of SMEs, their simple organisational structure, low risk and receptivity are the features facilitating them to be innovative. Therefore, SMEs across industries have the unrealised innovation potential.

There is a substantial evidence to show that a number of SMEs in a wide variety of sectors do engage in technological innovations, which play a significant role in their success. However, the innovative

S

SMEs are generally known for information innovations due to the resource constraints they face owing to their small size. It is the combination of internal and external factors, which drive the majority of SMEs to undertake both product and process innovation. A recent

research carried on Bengaluru SMEs provides a classic example of how small incremental innovative approaches drive the growth of the Indian SMEs to be globally competent.

ROAD TOPERPETUAL GROWTH

ROAD TOPERPETUAL GROWTH

TECHNOLOGICAL INNOVATION



capacity of SMEs varies on the basis of sector, size, focus, resources and the business environment in which they operate. Particularly, innovation in the manufacturing sector is a complex process that is propelled by numerous factors.

This leads us to the question as to what drives manufacturing SMEs to technologically innovate. If a firm has to do so, it should have in-house technological competence in the form of technically qualified and motivated entrepreneurs or managers with innovative ideas and skilled employees.

Similarly, there must be a market demand for the innovative products in the form of explicit customer demands or implicit market opportunities. Of course, the relative importance of these internal as well as external factors might vary from firm to firm or from industry to industry or even from economy to economy from time to time.

FACTORS INFLUENCING INNOVATION There are four primary issues concerning innovation and growth of SMEs, which include driving forces, dimensions, achievements and outcomes. Internal factors comprise self-motivation, technical education background, work experience and innovative ideas of entrepreneurs. On the other hand, external factors involve customer requirements, information given by suppliers of equipment/materials, market opportunities, availability and accessibility of institutional support, economic incentives, competition, etc. However, for successful innovation, a combination of both internal and external factors may be required. It is also important to note here as to whether SMEs are exclusively product focussed or process focussed or do they necessarily have to undertake both together.

Firms might focus on the development of new products with either old or new technology, or on the improvement of existing products by changing the shapes/designs or on quality improvement and cost reduction through substitution of raw materials, etc. However, the question that arises is what are the achievements of innovation by SMEs. If innovation is successful, it is important to assess whether new or improved products emerge due to product or process innovations, and whether the share of such innovative products is likely to increase the total sales of the firm. If this happens, such firms would

be able to achieve growth in their sales turnover, investment and employment resulting in the growth of firm size.

In this backdrop, a study was conducted with respect to auto components, electronics and machine tool manufacturing SMEs in both rural and urban districts of Bengaluru. The objectives were: To ascertain the growth rates of sales

turnover, investment and employment rates in innovative SMEs vis-à-vis non-innovative SMEs

To probe the relationship between innovation and growth of sales turnover in SMEs

TECHNOLOGICAL INNOVATIONS BY SMEsA description of general features of SMEs in the three sectors is meant to set the stage for subsequent analysis. Almost 90 per cent of SMEs in these sectors were started as new ventures and the rest were either inherited or acquired.

Technical education background in the form of diploma or degree (BE/ME/PhD) is a significant feature of entrepreneurship of these SMEs: 70 per cent entrepreneurs of auto, 69 per cent of electronics, and 81 per cent of machine tool SMEs were technically qualified. What is more significant is that majority of the entrepreneurs in these sectors had set up their firms to gain self-employment by implementing their innovative ideas and/or to exploit market opportunities. Their size characteristics revealed that structure of the SMEs was more skewed towards micro and small enterprises than towards medium-sized enterprises.

Given this, it would be appropriate to know how many SMEs in the three sectors are innovative and how many are not. A majority of SMEs are innovative in all the three sectors. A greater proportion of SMEs in the auto sector is innovative, relative to electronics and machine tool sectors.

SMEs are generally known for informal innovations – they carry out their innovations along with their day-to-day manufacturing operations within the same premises. The obvious reason is resource constraint. The same holds good for the SMEs surveyed in Bengaluru in all the three sectors. About 95 per cent of the SMEs in auto and machine tool sectors and 77 per cent in the electronics sector carry out innovations informally, without any exclusive innovation department. Given this, it is

important to know the driving forces of innovation. A sizable majority of the SMEs identified both internal and external factors as the driving forces of their innovations.

However, a considerable number of SMEs in the machine tool sector have also identified external factors as the only driving force of their innovations. By and large, it is clear that both internal factors such as self-motivation, technical education background, work experience, and innovative ideas of entrepreneurs on the one hand, and external factors such as customer requirements, information given by suppliers of equipment and materials, competition, etc, are responsible for a majority of SMEs to innovate. This implies that both firm-level technological competence (technology push) and market demand (demand pull) are important, if innovations have to emerge. Given this, it is appropriate to understand the dimensions of SME innovations. In general, SME innovations may be product focussed or process focussed or both.

PRODUCT AND PROCESS-FOCUSSED INNOVATIONA higher proportion of SMEs in auto and electronic sectors have undertaken both product- and process-focussed innovations whereas a majority of machine tool SMEs have undertaken only process-based innovations. Product-focussed innovations comprised the introduction of new products and/or the improvement of existing products through changing product designs and dimensions or quality improvement to suit customer requirements. Process-based innovations involved the introduction of new process technology for existing products, adoption of cost reduction techniques, etc.

What SMEs achieve out of their innovations is an important issue. Only if they are able to convert their product and process innovations into sales, their innovations will be fruitful and not otherwise. Irrespective of whether new or improved products emerged due to improved designs, quality improvement, cost reduction, material substitution, introduction of new or improved processes, innovative firms must be able to sell innovative products in the market as part of their total sales. More successful innovative firms might realise a higher share of innovative products in total sales compared to less successful innovative firms.



A higher percentage of innovative SMEs have succeeded in converting their innovations into sales in the auto component sector relative to electronic and machine tool sectors. Among those SMEs that have succeeded in converting their innovations into sales, the majority accounted for a share of innovative products in total sales in the range of 10-25 per cent in all the three sectors.

A more significant reflection of achievements of SMEs through innovation will be in terms of recognition won by them. The recognitions won in terms of citations, and particularly national awards, are more impressive in all the three sectors. Overall, the ‘patenting culture’ is low among innovative SMEs, as has been observed internationally. The limited resources of SMEs generally constrain them from going for obtaining product and process patents.

Finally, it is interesting to find out the outcomes of achievements of these innovative SMEs. If innovative SMEs are able to convert their innovations into sales,

they might be able to increase their sales turnover and increase capacity utilisation, or energy or manpower utilisation.

Besides, they can also improve inventory management or enter the international market. It is clear that the majority of the SMEs in all the three sectors have identified increase in sales turnover as the most significant outcome of their innovation –achievements indicating that innovation has helped them to achieve growth in sales.

To sum up, it is the combination of internal and external factors, which drive the majority of the SMEs to undertake both product and process innovations. As a result, many of them have been successful in selling innovative products in varying proportions of their total sales. Though the recognitions won, particularly in terms of patents are not noteworthy, a considerable number of them have won national awards. Also, more than half of the innovative SMEs have achieved sales growth due to their innovations. In this context, a comparative growth analysis in terms of sales, investment

and employment for innovative and non-innovative SMEs is appropriate.

INNOVATIVE AND NON-INNOVATIVE SMEs: GROWTH OF SALES, INVESTMENT AND EMPLOYMENTThe growth performance of SMEs has been analysed in terms of sales turnover, investment and employment for all the SMEs of each sector – be it innovative or non-innovative. For measuring growth, all the SMEs are clubbed together in each sector. Further, in terms of innovative and non-innovative SMEs, the growth was measured for the respective group of SMEs together, without segregating growing ones from the rest. The same holds good for further analysis in terms of innovative SMEs, which have claimed to develop new products/processes, and those that have claimed to only improve products/processes.

It is clear that innovative SMEs have registered a higher rate of growth compared to non-innovative SMEs in terms of sales, investments and employment in all the three sectors. However, the growth rates of the three variables differ within as well as between sectors. In the auto component sector, both innovative and non-innovative SMEs registered a higher growth of investment followed by sales and then employment. In fact, employment of non-innovative SMEs declined to a great extent. In the electronics and machine tool sectors, sales growth was higher than that of investment and investment growth was higher than that of employment for both innovative and non-innovative SMEs.

In the electronics sector, non-innovative SMEs registered negative growth in terms of investment and employment. Overall, the growth analyses for the three sectors clearly indicate that innovative SMEs perform better relative to non-innovative SMEs.

In auto and electronic sectors, innovative SMEs engaged in the improvement of existing products/processes registered a higher sales growth than innovative SMEs engaged in the development of new products/processes. However, in the machine tool sector, sales of the latter grew faster than that of the former. How far SMEs have benefited from their innovations to increase their sales and grow in terms of investment and labour would depend more on their ability to satisfy customers’ needs and requirements rather than on the nature

Karnataka has been an industrially progressive state in the country. Bengaluru, the state capital, is one of the 46 ‘global hubs of technological innovation’ and the highest ranked global hub in Asia (UNDP 2001). Among the districts of Karnataka, urban and rural districts in Bengaluru had the highest proportions of small-scale industry (SSI) engaged in R&D and innovation. Similarly, among the two-digit level industries (as per National Industrial Classification 1987), machinery & equipment and transport equipment & parts industries had the highest proportions of small-scale enterprises engaged in R&D and innovation. The former comprises electronics & machine tools industries, and the latter includes auto component industry, among others. Bengaluru being industrially developed with a relatively high concentration of engineering and electronics industries in the country, it was only appropriate to focus on SMEs in this region to find out the technological innovation prospects in small businesses and their benefits, if any.

CASE IN POINT

Most of the innovative SMEs attributed the origin of their innovations to a combination of: Firm level technological capability owing to internal factors such as self-motivation,

technical qualification, knowledge, experience, and innovative ideas of entrepreneurs,

Market pressure due to external factors like customer requirements and demand, information provided by suppliers of equipments and materials, market opportunities, and competition.

QUICK TAKE

Search November 2010 Ad Name: Samson Pg. 157

Search November 2010 Ad Name: Cosmos Pg. 158



of innovations in terms of new products/processes or improved products/processes.If improvement of existing products/processes as required by their customers is appropriately done, it may prove to be more useful to increase sales rather than developing new products/processes. What might be more decisive is customer satisfaction to expand the market base of an enterprise and grow. Given this, it would be difficult to say whether new products/processes or improved products/processes are more helpful to SME growth.

INNOVATION AND GROWTH OF SMEsIf innovation helps a SME to improve sales performance, the following may hold good: There is a positive relationship between

the percentage of innovative products in total sales and rate of growth of sales of innovative SMEs.

Higher growth SMEs will have more share of innovative products in total sales relative to medium growth SMEs, which in turn will have higher share of innovative products in total sales compared to low growth SMEs.

Share of innovative products in total

sales, along with rate of growth of capital as well as that of labour, has a significant influence on the rate of growth of sales turnover of innovative SMEs.

RIDING HIGH ON INNOVATIONMost of the innovative SMEs attributed the origin of their innovations to a combination of firm-level technological capability owing to internal factors; and market pressure due to external factors. Thus, both ‘technology push’ and ‘demand pull’ have contributed to the emergence of innovations.

The major objective of SME innovations was enhancement of competitiveness in the form of quality improvement, cost reduction, extension of product range and replacement of phased-out products, apart from penetrating the international market. Accordingly, they have primarily focussed on both product and process innovations in the auto and electronics sectors and process innovations in the machine tool sector. What is significant is that a substantial majority of the innovative SMEs could convert their innovative efforts into sales, as they realised varying proportions of innovative products in their total sales.

Innovative SMEs registered higher growth relative to non-innovative SMEs not only in terms of sales turnover, but also employment and investment in all the three sectors. There was a statistically significant positive correlation between innovation sales and sales growth. Innovative SMEs, which experienced higher growth, accounted for a higher share of innovative products in their total sales relative to those that experienced lower sales growth. Innovation sales, along with investment growth and employment growth, had a positive influence on gross value added (GVA) growth, in all the three sectors. To conclude, it can be said that innovation contributes immensely to the growth of firms.

This article is an excerpt from the white paper, ‘Importance of Technological Innovation for SME Growth’ by M H Bala Subrahmanya & K N Krishnaswamy, Indian Institute of Science and M Mathirajan, Anna University. E-mail: [email protected]

Hydraulics & Pneumatics

on pg. 61


ENGINEERING EXPO PUNE 2010

iding on the global upswing, the Indian engineering industry is reviving at a fast pace. The growing business prospects that have surfaced as a result of

galloping stock market and huge foreign investment inflow suggest that it is the right time to spread our wings and make the most out of these opportunities.

As the market improves and opens up new avenues to be explored, it has also highlighted new challenges like the changing business dynamics and high customer demands. However, in order to survive the challenges, it is of paramount importance to keep a keen eye on the upcoming trends and have regular interface with customers to understand the market demands.

Here lies the significance of trade fairs where buyers and sellers network and offer real-time innovative solutions to each other. Emphasising on the importance of exhibitions, Anand Rajadhyaksha, Advertising Manager-Nilkamal, says, “An exhibition always helps exhibitors to spread awareness of their products among potential customers. Moreover, for visitors, it increases their options to know about the latest products or technologies available in the market.”

Further talking of trade fairs, Engineering Expo stands tall and has earned a well-deserving position among its counterparts. Having proved its mettle during the last eight years,

the Expo has become a brand to reckon with. Through its vast experience in providing exhibitors and visitors a trade platform to boost their bottom line, the Expo has been setting milestones every year. Critical locations like the four most prominent and emerging industrial hubs in the country namely Pune, Ahmedabad, Indore and Chennai, and relevant themes in niche industrial segments such as machine tools, hydraulics & pneumatics, material handling, automation and various other segments of engineering, make it a unique event that play the role of trade facilitator.

Highlighting the path-breaking performance of Engineering Expo in its earlier editions, Sudhanva Jategaonkar, Associate Vice President - B2B Publishing, Infomedia18, says, “Looking at the current economic boom and the advent of MNCs in the country, it has become important for companies to be proactive in tapping the opportunities that have emerged. The Engineering Expo provides the right environment and enables companies to

capture the emerging business potential. The Expo has managed to generate business worth more than ̀ 155 crore during the last fiscal. It has not just facilitated business, but also promoted new product launches and joint ventures between companies.”

ENGINEERING EXPO-PUNE 2010Taking the legacy forward and being one of the most successful editions of Engineering Expo, the Pune Expo has gained an edge over other trade fairs in the business community. Engineering Expo-Pune is back in its strikingly optimistic fifth edition from November 19-22, 2010, at Auto Cluster Exhibition Centre, Pimpri-Chinchwad, Pune.

With more than 200 exhibitors, 25,000 business visitors, 6,900 business leads and business worth `65 crore last year, it is a much-awaited event for the manufacturing fraternity.

The event has already elicited high expectations from the exhibitors. Upbeat

with booming prospects, exhibitors at the Pune edition are looking forward to be a part of this year’s extravaganza. Reflecting his thoughts on the same, Rajadhyaksha adds, “We are looking forward to promote our enhanced product range to buyers in the automotive and allied ancillary sector, who are expected to visit Engineering Expo-Pune 2010.”

Agrees K Jagannathan, Executive Director – Sales

R

The fast emerging global mega trend of an economic boom is opening up new opportunities for businesses. While entrepreneurs leave no stone unturned to make the most out of these upcoming opportunities, trade fairs have emerged as a catalyst to help businesses flourish. In an endeavour to help engineering and manufacturing industry further leverage these opportunities, Engineering Expo-Pune 2010 is all

set to roll out its fifth edition from November 19-22, 2010, at Auto Cluster Exhibition Centre. A preview…

THE EUPHORIA BEGINS

200+ exhibitors25,000+ business visitors

Business generated worth `65 crore+6900+ business leads generated

92% + exhibitors were highly satisfied with the quality of visitorsProduct launches: Engineering Files by Pilot India,

CNC Lathes & CNC Turning Machines by Electronica HitechAutomation Partner: AVG Electronics

Power Partner: Kirloskar Oil Engines & Goel Power Controls

ENGINEERING EXPO PUNE 2009 STATS

PUNE19-22 Nov ’10Auto Cluster Exhibition Center



& Marketing, Guindy Machine Tools, “Engineering Expo-Pune provides exhibitors with an excellent opportunity to showcase their latest products as well as interact with a wide spectrum of customers. For the visitors, it is not only a purchasing resource, but a source to see the latest technology trends. This is the first time we are participating in Engineering Expo-Pune and we have high expectations both in terms of sales and consolidating our position as India’s premier manufacturer of workholding products and indigenous coordinate measuring machine (CMM).”

CREATING A LEGACY With the advent of major MNCs setting up their base in the city, Pune has become a preferred investment destination in the country. Driven by innovation and design competence, Pune is being recognised as the nerve centre of manufacturing in India. More so, the investment spread in the city

promises to provide a growth trajectory for manufacturers. The testimony to the fact is that in the last one year alone, three massive new plants owned by General Motors, Volkswagen and Mahindra & Mahindra were inaugurated here. Further establishing this fact, Jagannathan opines, “Pune has always been an important region for our products. We are hoping to make inroads in the CMM market as well as find new markets for our workholding, work positioning and machine tool products.”

Another factor that has increased Pune’s manufacturing competitiveness is the proximity it has with the financial capital of India, Mumbai. Jagannathan further adds, “Pune is the leading centre for the automotive sector in India as well as one of the densest automotive clusters in the world. Automotive manufacturers like Tata Motors, Bajaj Auto, Mercedes-Benz and Fiat have their units here. Recently, three massive new plants from General Motors, Volkswagen and Mahindra & Mahindra were inaugurated here. Apart from this, there are other global players too in this region. Thus, Pune combined with good infrastructure and skilled workforce has become an ideal investment destination.”

What adds to the confidence of exhibitors in participating at Pune edition is the presence of leading companies such as Misumi India, Alfa Laval, Praj Industries, Thermax, Bharat Forge, Kirloskar Oil Engines and Atlas Copco, among others.

Engineering Expo 2010-11: Season begins Epitomising on the fast recovering engineering and manufacturing industry, the Engineering Expo 2010-11 is all set to contribute its humble share towards this growing surge of health among the Indian Inc.A complete manufacturing and engineering trade fair to display various products and services, the Expo is one of the most preferred platforms to grow business, as proved by 1,000+ companies, which participated in the previous editions of the Expo. More than 75,500 industrial buyers benefit from the Expo every year. Having generated a business of more than `155 crore and 17,200 business leads in the last fiscal, the Expo is expected to attract 1,00,000 footfalls by way of visitors from domestic and overseas markets in this year’s edition.The Engineering Expo will be held in four cities − Pune, Ahmedabad, Indore and Chennai. It will be held at Pune from November 19-22, 2010; Ahmedabad from December 10-13, 2010; Indore from January 7-10, 2011; and Chennai from March 11-13, 2011. All large, medium and small industries from the manufacturing & services sector will be showcasing their latest products and technology at the event. Leading engineering companies comprise the esteemed exhibitors list at the Expo. Some of these include: Autotech Machine Tools, Gandhi Automation, CTR Manufacturing, Atlas Copco, S&T Engineers, Omron Automation, Tussor Machine Tools, Boge Compressed Air Systems, Elgi Equipments and Igus India, among others. With the dedicated pavilions on machine tools & accessories, process machinery & equipment, electrical & electronics, hydraulics & pneumatics, automation & instrumentation, packaging & auxiliaries, IT products & services, safety & environment, general engineering, material handling equipment, logistics, testing & measuring equipment, banking and finance services, the Engineering Expo 2010-11 edition is all set to surpass its own expectations.

The 4th Edition of Engineering Expo in Pune had an overwhelming response of over 25,000 business visitors.

WIN

NIN

G

START



INNOVATIVE PRODUCTS & COLLABORATIONS Gauging the lucrative prospects of the Indian economy, companies are vying for a major share of the pie. In order to achieve this goal, companies are coming up with a new range of products & services. While the Expo provides a lucrative platform for launching new products & services, it also sets the stage for forging JVs and new partnerships.

The Pune Expo shall witness a gamut of new product launches and technology developments in the market. Vikram Mane, VP- Saatveeka Trading Company, says, “We will be announcing a tie-up with M/S Schmolz + Bickenbach as its Channel Partner. With this tie-up, we will be in a position to service our customers for their total needs.”

While talking about the products planned to be launched by Ferreterro India, Saurabh Khandelwal, Director of the company avers, “We are launching three new products at the Expo for the first time in Asia. These include ‘PEWAG – World’s strongest chain manufacturer’, ‘First Sling – World’s first and most transparent lifting sling’ and ‘Ferreterro Exxtreme – World’s strongest

sling to lift 300 tonne goods.” Talking about the latest technology

products, Milan Supanekar, Director – Welding Technologies India, says, “We have added few latest technology products. So far, we have been mainly focussed on welding products (welding machines and consumables) and all range of products related to welding & cutting. We have recently established new partnerships for environment-friendly products used for welding & cutting as well as in welding consumables. We will use the exhibition as

a platform to showcase them.”Jagannathan adds, “Apart from our top-

of-the-line workholding products like the power operated auto indexing chuck and special workholding tailor-made to meet customers’ requirements, we will be showcasing our newly launched GMT Co-ordinate Measuring Machine– Grano 7-10-6.”

COUNTING BACKWARDS Time and again, Engineering Expo has proved to be a preferred display point of latest innovations in the field of engineering. And this time again, it is expected to surpass all the industry expectations. Gauging from its past experiences, it is believed that the Engineering Expo-Pune is geared up to offer the best platform for the engineering fraternity to explore new product offerings and technology advancements by bringing in tremendous opportunities for them. It is now action time for the manufacturing industry to reap the maximum benefits by taking the lead in encashing on the booming prospects that Engineering Expo – Pune Edition 2010-11 is slated to offer. Curtains open on November 19, 2010…

Engineering Expo-Pune provides exhibitors with an excellent opportunity to showcase their latest products as well as interact with a

wide spectrum of customers.

K JAGANNATHAN,Executive Director – Sales & Marketing,

Guindy Machine Tools


ELECTRONICA + PRODUCTRONICA INDIA 2010

he electronics industry in India is growing rapidly and investments are flowing in to augment the

manufacturing capacity. To provide an effective platform to sustain the growth of the electronics industry, in India and Southeast Asia, electronica India 2010 and productronica India 2010 was organised at the Bangalore International Exhibition Centre (BIEC) from September 7-10, 2010, by Messe München International and its subsidiary MMI India.

EVENT AT A GLANCEThe event encompassed 869 exhibitors and represented companies with 331 direct exhibitors, recording a 21 per cent increase as compared to last year. In two halls, covering an area of 13,000 sqm, exhibitors from over 25 countries including Japan, Switzerland, the US, Italy, Spain, Korea, Malaysia and Hong Kong showcased their products. Countries like Germany, UK, China, Singapore and Taiwan showcased their innovative offerings for Indian customers. The exhibitors witnessed closures of major deals and an increase in the number of quality inquiries. Altogether, the show attracted over 12,245 visitors which is an increase by 18 per cent. Highlighting their experience, Yukihiro Terada, Deputy General Manager, Manufacturing Systems Division, Sony Thai Co, said, “We are highly satisfied by the turnout and have received several new inquiries. We are looking forward to participating in the Delhi exhibition next year too. In addition to meeting prospective

clients, we were surprised to see a huge number of budding engineers at the exhibition.” Meanwhile, a first-time exhibitor, Praveen Madaan, Regional Sales Manager, ASYS Group Asia, said, “This is the first time we are exhibiting here, and MMI has surpassed our expectation with their professional approach. We are aiming to use

this platform on an ongoing basis to showcase our product and service offerings.”

FOCUS ON CONFERENCESThe fair featured LED in the special focus

area. Two high-profile international conferences were also held at electronica India and productronica India. The ‘Conference on Contract Manufacturing: The Indian Perspective’ held on September 7, 2010, highlighted trends, new technologies, opportunities and requirements of the Indian EMS/contract manufacturing industry. The second conference on September 8, 2010, titled the ‘Symposium on the Trends and Future Requirements in Automotive Electronics’ focussed

on various developments in the area of automotive electronics.

Commenting on the success of the event, Norbert H Bargmann, Deputy Chairman & CEO, Messe München International, said, “Having seen the response to this year’s edition of the exhibition, it is evident that India is emerging as an important port of call for companies from around the world. This country has one of the fastest growing economies globally and has made its presence felt in international trade fairs and exhibition industry.” Darryl Dasilva, CEO, MMI India, further added, “With the high growth that the electronics industry has witnessed over the past few years, platforms such as electronica India and productronica India will play a vital role in building the future of this industry.”

ON A PROMISING NOTEThe event ended on a positive note, with over 42 per cent of the exhibitors rebooking themselves for electronica India and productronica India 2011. The next electronica India and productronica India will be held from September 13-16, 2011, at Pragati Maidan, New Delhi.

T

The electronics industry has been a sunrise industry globally. Its rapid growth is evident from the huge success of the recently held trade exhibition, electronica India 2010 and productronica India 2010 at Bengaluru. Organised by Messe München International and its subsidiary MMI India, with SEARCH as media partner, the event had an electrifying impact and proved to be a leading platform for the electronics industry in India and Southeast Asia.

CHARGING UP FOR GROWTH

Esteemed dignitaries lighting the traditional lamp during inauguration ceremony

Having seen the response to this year’s edition of the exhibition, it is evident that India is emerging as an important port of call for companies

from around the world.

NORBERT H BARGMANN,Deputy Chairman & CEO,

Messe München International


NATIONAL SEMINAR ON CHALLENGES IN TRANSMISSION & DISTRIBUTION

utomation has definitely worked wonders in the area of transmission and distribution (T&D), but it needs to be deployed on a wider scale for the benefit

of the power sector and the people at large. This was the general sentiment witnessed at the ‘National Seminar on Challenges in Transmission & Distribution & Role of Automation’ held recently in New Delhi.

While inaugurating the event, Gireesh B Pradhan, Additional Secretary, Ministry of Power, Government of India, said that with ever-increasing demand, and the resources available for power transmission unevenly spread across the country, the guiding objective lies in the optimal utilisation of the national grid through automation. “Keeping in view the critical role of the power sector in promoting the overall development of the country and consequent poverty alleviation, adoption of automation in power T&D is the key to furthering the goal of ‘Electricity For All’ and in providing electricity to the unelectrified villages. Efficient T&D would make a real difference in how we manage the supply and demand situation,” he said.

A smart grid will be essential to the power sector, and keeping this in mind, the Power Ministry has constituted a task force as well as a smart grid forum to address the issues pertaining to this. In building the smart grid, the stakeholders should not lose sight of the entire chain of T&D, Pradhan said.

EVENT FOCUSThe event brought to the fore various challenges faced by the power sector. SK Chaturvedi, Chairman and MD, Power Grid Corporation of India (PGCIL), in his address, said that the focus on sustainable development

would pose challenges as well as create opportunities for the power sector.

The challenge lies in ensuring 24x7 quality power supply with stable voltage to all, he said, while adding that over the next two decades, the Indian power sector will occupy the centre stage of development and attract world’s attention. According to Chaturvedi, the key challenges with respect to T&D include: Non-availability of price preference to

domestic industry in domestically-funded projects having international competitive bidding

Bunching of orders leading to sub-optimal utilisation of manufacturing capacities

Lack of standardisation in technical specifications

Absence of price variation clause Lack of adequate testing facilities and

limited trained manpower base Taxation-related issues Barriers to the use of automation.

Though automation finds various applications in the power T&D segment, more needs to be done. Standardisation of processes and practices is the need of the hour and all states should seek to follow specific industry standards while pursuing power T&D programmes, voiced industry experts present at the seminar. Pradhan pointed out, “The Power Ministry is keenly focussed on enhancing domestic equipment and services employed in the sector. Moreover, as it realises the need for a large pool of trained manpower to complement the modernisation of the sector, the ministry has encouraged the establishment of industrial training institutes (ITIs) for developing a cadre of skilled manpower for the power sector.” Adding further, he said, “Excess reliance on overseas suppliers often

leads to bottlenecks in the after-sales services, availability of spares, etc. The adoption of appropriate technologies and designs will help the sector in overcoming some of these barriers.”

MAKING INDIA THE POWERHOUSEThe growing use of gensets, voltage stabilisers, and other electrical appliances is an endorsement of the vibrancy of the sector. Adding to this, Ramesh Chandak, Chairman, CII Transmission Line Division, & MD, KEC International, said that for India to become a major powerhouse in the global economy, the power generation sector would have to become the backbone of the economy. In terms of transmission, he said that bulk transmission of power has increased from 3,700 ckt km in 1950 to over 1,65,000 ckt km now, indicating a 40-fold growth. Supporting the organisation of such events, Vimal Mahendru, President, Indian Electrical and Electronics Manufacturers Association (IEEMA), & Executive Director, Indo Asia Fusegear, said that major events like ELECRAMA have demonstrated robust character of the power sector.

PROMISING OUTLOOK From 3,000 electrified villages in 1951, there are 4,98,000 electrified villages today. This demonstrates the government’s effort for rural electrification through various schemes including Rajiv Gandhi Grameen Vidyutkaran Yojana. The experts urged the government to address the issues related to payment terms in financing of the projects on priority. The power sector would greatly benefit if bank guarantees were provided against release of funds upon completion of projects, they noted.

A

DRIVING EFFICIENCY DRIVING EFFICIENCY THROUGH AUTOMATIONTHROUGH AUTOMATION

GEETHA JAYARAMAN

Capacity addition has been high on the agenda of the power sector, but efficient transmission and distribution through optimal utilisation of power grid through automation is the need of the hour. Highlighting the significance of automation to ensure effective T&D, the ‘National Seminar on Challenges in Transmission & Distribution & Role of Automation’ was organised by the Confederation of Indian Industry with SEARCH as a media partner on October 1, 2010, in New Delhi. A report...


HYDRAULICS

HYDRAULIC PRESSES

Powercom hydraulic presses (IR P 55) offered by Qureishi Enterprises have been designed to compress joints on

conductors and steel cables during stringing operations. Hydraulic presses of 55-ton compressive capacity are suitable for compression of joints on conductors and steel ropes for electric lines. Excellent weight/power ratio (2.9 ton/kg), easy to operate on suspension working platforms and steel towers, are some of the features of these hydraulic presses, thanks to the specific cover fitted on the press body. Maximum hexagonal key of 44 mm allows pressing of an electric cable of 31.5 mm diameter. Power/weight ratio is good and pressing cycle is very short. All the components are interchangeable and all the presses can be supplied with motorised (petrol or electric engine) or hand pumps. All presses comply with European safety standards (CE). The hydraulic presses come in two types, ie, dual pipe and single pipe.

Qureishi Enterprises, Mumbai 400 050.Tel: 022-6785 9999, Fax: 022-2643 4462Email: [email protected], Website: www.slingset.com

This section gives information about products, equipment and services available in the market. If you know what you want. . .refer to Product Index on Page 248 to find it quickly

HYDRAULIC TANK ACCESSORIES

Fluden hydraulic tank accessories offered by Fluid Power Engineers are designed to suit

all hydraulically operated machines. These tank accessories include strainers, breathers, oil level indicators, check valves, tube clamps and curved tooth gear couplings. The accessories are of small prices but of big value for any hydraulic system (claims the company).

Fluid Power Engineers, Ahmedabad 382 415.Tel: 079-2289 1665, Fax: 079-2289 1666, Mob: 09426068483Email: [email protected], Website: www.fluden.com

HYDRAULIC PRESSES

Panel board operated hydraulic presses manufactured by Dowel Engineering Works range from 15 ton to 300 ton capacity in mild

steel robust construction. The crown, column and bottom are solid without bend and welded. Table is vertically operated by worm winch gearbox and rest on load pins placed in holes in column at desired height. Here is an option to operate bed-by-bed lifting attachment electrically operated. Rollers are provided with the bed for easy handling of heavy jobs. The cylinder is made from honed tube and hardchrome plated ram is made from mild steel, operated by double- acting cylinder. Good quality seals assure long working life. The ram is provided with replaceable socket to facilitate attachment of dies and tools, on customer’s request. These presses are equipped with high-pressure hydraulic pump, DC valve, pressure relief valve, etc.

Dowel Engineering Works, Rajkot 360 002.Tel: 0281-2362465, Fax: 0281-2362465, Mob: 09824231975Email: [email protected], Website: www.thedowel.com

HYDRAULIC CYLINDRICAL GRINDERS

Pitroda Utility Industries offers hydraulic cylindrical grinders (model PUI-300) available in hydraulically and mechanically

operated versions. The base of these cylindrical grinders is made of close-grained and heavily ribbed casting for high rigidity. The hand-scraped V-flat table guideways have continuous lubrication. Longitudinal hand travel of the table is by rack & pinion arrangement

and automatic travel by hydraulic mechanism. The hydraulic system consists of hydraulic pump, valve, lever, piping, etc; conveniently housed in the base as well as separate powerpack. Wheel head spindle is made of case hardened nickel chrome alloy steel ground and micro-finished and runs in adjustable Phosphorous bronze metal bush bearings to achieve high accuracy adjustable

and long life. Drive to the wheel head is transmitted by two V-belts. Workhead spindle is made of special alloy steel and runs in taper roller/angular contact bearings. The hydraulic cylindrical grinders are supplied with all electricals suitable for 400/440 V AC, 50 Hz.

Pitroda Utility Industries, Wadhwancity 363 030.Tel: 02752-243795, Fax: 02752-243167, Mob: 09825416108Email: [email protected]: www.pitrodautilityindia.com

HYDRAULIC PALLET PUMPS

Zenith Hydromatic offers pallet pumps in capacity ranging from 1 ton to 5 tons with 115 mm stroke. The sealing arrangement

imported PU seal/bronze filled for long life and frequent replacement by a new one is not required. Piston rod and plunger is hardened, hard chrome plated and internal bore honing for longer life of the seals. The mounting arrangements can be altered to suit the mounting dimension as specified by customers. Also manufactured are hydraulic cylinders, force feed lubricators, hydraulic power packs, valves, auto bike lifters and double plunger pumps. Special-purpose lubricators, hydraulic cylinders, valves, pumps and lifting jacks are also developed

as per specifications given by customers.

Zenith Hydromatic, Ahmedabad 382 330.Tel: 079-2281 2945, Fax: 079-2281 2945, Mob: 09824167178Email: [email protected]: www.hydraulicsystemsindia.com

HYDRAULIC CYLINDERS

Trident Products manufactures and offers tie rod hydraulic cylinders for machine tools as per ISO 6020 specifications.

These hydraulic cylinders are available in bore sizes ranging from 40 mm to 100 mm and stroke of 100, 150 & 200 mm. They are also be available in 32 mm to 160 mm bore sizes. The hydraulic cylinders are designed and manufactured as per customers’ requirements, these are also available with position feedback systems.

Trident Products Pvt Ltd, Gurgaon 122 016.Tel: 0124-4300626, Fax: 0124-4300627Email: [email protected]


HYDRAULICS

HYDRAULIC POWER PACKS

Ace Automation Engineers offers hydraulic power packs for machine tool industry. For the

machine tool industry a number of applications have been covered. These include standard applications, like auto lathe, surface grinding, milling & also special-purpose machines like gap grinding machines (piston ring plants), button removal (piston plants), caulking machines (automobile plants), drilling & milling (brake shoe plants). Operations performed are job clamping, fast tool approach, slow machining feed, fast retraction & de-clamping. The feed rate is controlled using pressure & temperature compensated valves to ensure constant feed rate irrespective of temperature & pressure variations.

Ace Automation Engineers, New Delhi 110 015.Tel: 011-2511 8561, Fax: 011-2515 3917Email: [email protected], Website: www.acefluidpower.com

HYDRAULIC FLOOR JIB CRANES

Handy hydraulic floor jib cranes manufactured by Technical Enterprises

are available with extendable boom, in 1-, 2- and 3-ton capacities and vertical height reaching up to 4 meters. These cranes are also provided with extended base in the rear for putting counter weight, in case the boom is extended beyond the base


HYDRAULICS

HYDRAULIC FLOOR CRANES

Vikas Hydro Inc offers hydraulic floor cranes that provide an efficient low-cost alternative to other material handling

equipment. These cranes are strong, robust, sturdy and built to very high standards. They are easily maneuverable and have a very small turning radius. The cranes are ideal for loading, unloading and shifting of heavy loads. Structure of the cranes consists of chassis, vertical column, derrick (inner & outer boom) and the hydraulic cylinder assembly. All models above 1-ton capacity have a double column box frame made of steel pipes. The box frame

can take heavy loads, while its wide bearing on the chassis effectively avoids twisting and damage to the crane under rough and unskilled

wheels. They are suitable for loading/unloading heavy materials from trucks in the open yard and carry them inside the shop. The cranes are extensively used in engineering workshops for loading/unloading jobs on the machine tools where there is no provision of an overhead crane or it is busy elsewhere. In repair garages, these are required for handling engines and its parts. They are equipped with high precision hydraulic cylinder and hard chrome plated ram, which provides upward thrust to the boom while lifting. Lowering is hydraulically cushioned to avoid jerks.

Technical Enterprises, Meerut 250 103.Tel: 0121-2440660, Fax: 0121-2440666Email: [email protected], Website: www.handyonnet.com


HYDRAULICS

handling. Advantage of this structure is that it diverts the resultant force to the centre of the chassis thereby greatly reducing the possibility of imbalance about the longitudinal centre of the chassis.

Vikas Hydro Inc, New Delhi 110 044.Tel: 011-3098 9505, Fax: 011-2989 3217, Mob: 09313807583Email: [email protected]

HYDRAULIC CYLINDERS

Vertex Hydraulics manufactures and offers hydraulic cylinders that are suitable for heavy-duty applications up to 160 kg/cm² and

250 kg/cm². These cylinders are available in bore sizes of 40, 50, 63, 80, 90, 100, 125, 140, 160, 180, 200, 220, 240 and 260 mm. Some of the construction features are: welded construction to rigidity; surface finish of micro honed tubes of ones 0.4 Ra; piston rods (ground), hardchrome-plated and reground to finish better than 0.1 Ra for longer seal life; fine adjustable cushioning with locking arrangements; provision of bleed screw at both ends; and option of minimum two rod sizes for each bore. Special purpose adjustable stroke cylinder is provided with 30 to 35 per cent adjustment in stroke. These hydraulic cylinders find application in plastic injection moulding machines, where moulded goods are picked up by robots.

Vertex Hydraulics Pvt Ltd, Ahmedabad 380 009.Tel: 079-6521 4825, Fax: 079-2676 5650, Mob: 09824039374Email: [email protected], Website: www.vertexhydraulics.com


PNEUMATICS

PNEUMATIC NAILERS

Kaymo Fastener Company offers pneumatic nailers (model PNKF-38100) that weigh 5.24 kgs and have coil nail type of

16-degrees. Salient features include: top exhaust deflector to direct air away from the operator; ergonomically designed handle with a soft rubber grip; high nail loading capacity nylon magazine; special screwable handle fitted near the nose for proper maneuverability; side metal guard to prevent tool body getting damaged; reversible bumper for longer durability; operate at air pressure between 75 psi to 120 psi; and air consumption @

5.38 LPM. Technical specifications are: head dia of nails 5.8 mm to 7.2 mm; nail diameter from 2.5 mm to 2.9 mm; shank lengths 60, 65, 70, 75, 80, 90 & 100 mm; and shank type as smooth, ring & screw. Applications are in pallet manufacturing, packaging (wooden crates), furniture, door frames, fencing, wooden decking, etc.

Kaymo Fastener Company, Mumbai 400 011.Tel: 022-2495 2966, Fax: 022-2493 6823Email: [email protected], Website: www.kaymo.com

PNEUMATIC ROTARY ACTUATORS

Aira Euro Automation offers pneumatic rotary actuators as per ISO:5211 International standards for quarter turn ball valves,

butterfly valves, damper controls, etc. Torque values up to 4500 Nm are available in size range suitable for ball valves up to 10” and butterfly valves up to 24”. These provide sliding skates between the piston and inner surface of the actuator. This prevents metal-to-metal friction and enhances the life of the actuator. The actuators


PNEUMATICS

are compact in design and offer high torque value by consuming more air due to the deep hole in the racks. They contain preloaded spring cartridges, which prevent accident risk during disassembling. Accessories include: solenoid valve as per

Namur standard; limit switch box with position indicator as per Namur standard; filter + regulator with gauge; manual override; pneumatic valve positioner; and I/P converter.

Aira Euro Automation Pvt Ltd, Ahmedabad 382 405.Tel: 079-4024 7003, Fax: 079-4024 7012Email: [email protected], Website: www.airaindia.com

PNEUMATIC VALVES

Veljan Hydrair manufactures and offers pneumatic valves that are 2/3/4-way directional control valves with air pilot, hand lever,

roller cam and solenoid operators. The detented three-position mechanism provides stable positioning. Stainless steel spool moves on thin film of air with micronic clearance. There is no wearing contact, no seals to wear and low shifting forces. Other features include: quick response & high cycle rates; extremely long service life;

unique advantages by direct mounting onto the cylinder; and available from 1/8” to 1” with BSP or NPT port threads.

Veljan Hydrair Pvt Ltd, Hyderabad 500 037.Tel: 040-2377 2794, Fax: 040-2377 2794Email: [email protected], Website: www.veljan.com

Search November 2010 Ad Name: Micromatic Pg. 175

Search November 2010 Ad Name: Hindustan Pg. 176


PNEUMATICS

PNEUMATIC PLUG VALVES

Rotex Automation offers pneumatic plug valves with rotary actuators. These

plug valves are ideally suited to aggressive corrosive and potentiality hazardous media. They have absolute tight shut-off in case of sleeved plug valve. Other features include: long life due to taper plug construction, frequency operations possible, suited for slurry application, line plug valve suited for corrosive service on/off or control duty. The design of the plug valves is as per BS:5343 (with sleeved plug valve); and fire safe as per APED, fre tested to AP16FA. Various types are available, such as lubricated, taper plug valves, pressure balance sheet plug valves, and sleeved plug valve. Materials of constructions include: cast iron, double iron, cast steel/cast stainless steel, alloy steel. Special materials are available upon request.

Rotex Automation Ltd, Vadodara 390 010.Tel: 0265-2638136, Fax: 0265-2638130, Mob: 09727766313Email: [email protected], Website: www.rotexindia.com

PNEUMATIC CLUTCHES & BRAKES

Airtorq India offers pneumatic clutches & brakes that consist of an air actuated disc clutch and spring applied disc brake. The

compact design combined with high thermal capacity and low air consumption makes them ideal for high-speed, high cyclic, heavy-duty industrial application. When the cylinder is pressurised, the piston clamps the clutch disc to the hub, which transmits the torque


PNEUMATICS

to the shaft. When the cylinder exhausts, the springs moves the piston in the opposite direction clamping the brake disc and stopping the shaft. Overlap between the clutch and brake is completely eliminated. Some of the advantages are: high thermal capacity, stable coefficient of friction, low air consumption, low operating & maintenance cost, easy removal of worn out linings, etc. Applications are in power presses, press brakes, guillotines, printing machines, woodworking machines, etc.

Airtorq India, Delhi 110 042.Tel: 011-2783 5798, Fax: 011-27834798, Mob: 09810120341Email: [email protected], Website: www.airtorq.com

PNEUMATIC CYLINDERS

ETA Engineers manufactures and offers a wide range of air cylinders, designed for

reliability and trouble-free operations. These cylinders are available up to bore size of 200 mm and stroke length of 500 mm with different rear and front mountings, like clevis, trunion, flange, etc. The cylinders are also offered as per customer’s specific requirements. Pneumatic systems to suit various pneumatic applications are also manufactured.

Eta Engineers, Mumbai 400 003.Tel: 022-2344 9893, Fax: 022-2342 3189Email: [email protected], Website: www.etaengineer.com


PNEUMATICS

PNEUMATIC STIRRERS

Fuji air Tools offers pneumatic stirrers (model APAM-3-4TS) that can be mounted on a flange. These stirrers have free speed of

500 rpm. They have stainless steel rod and a set of four blades. The pneumatic stirrers can be used continuously for stirring of paints, chemicals, fluids, etc. Being pneumatic, they are completely flameproof, shock-free and spark-free. If there is an excess load during stirring, the stirrers will just stall temporarily, and when the excess load is gone, they will start working normally, without any damage. Exhaust air can

be left to the atmosphere through a silencer, or it can be piped away to another location. Applications are in paint industry, pharmaceutical industry, processing and petrochemical industry, etc.

Fuji Air Tools (India) Pvt Ltd, Pune 411 043.Tel: 020-2439 1152, Fax: 020-2439 0955Email: [email protected], Website: www.fujindia.com

PNEUMATIC FEEDERS

SKI Automation fabricates a wide range of vertical pneumatic self-feeders that are manufactured using superior quality steel

and aluminum. These pneumatic feeders are appreciated for their high tensile strength and anti-corrosive properties. The range can also be customised as per the requirements of customers. The pneumatic feeders are both durable and safe to use.

SKI Automation Pvt Ltd, New Delhi 110 027.Tel: 011-6545 2401, Mob: 09312593170Email: [email protected], Website: www.skifeeder.com


PNEUMATICS

PNEUMATIC FASTENING TOOLS

San Air Tools offers pneumatic fastening tools that are used as drilling tools. The range of air drills is made from high-grade

steel, brass and other alloys. These handy air drills are offered with straight and gun handle design. They have a chuck capacity of 6 mm and can operate at a speed of 1600 and 2500 RPM. These cost-effective drills are capable of executing mass drilling of holes that is very much required in aircraft industry, rail coach, bus body assembly and other similar applications. They are operational at working pressures of 6 kg/cm². The pneumatically or air-operated drill machines are available in straight-type or gun-type.

San Air Tools, Thane 400 601.Tel: 022-2534 1981, Fax: 022-2534 2692, Mob: 09819747122Email: [email protected], Website: www.sanairtools.com

PNEUMATIC MACHINE VICES

Orcan Products of India manufactures pneumatic machine vices. Gripping

through manual screw adjustment and rigid clamping is done through these pneumatic machine vises. The machine vices have in-built sophisticated piston mechanism. They have clamping power of 4500 N at 7 bar (100 PSI) air pressure. Ground and hardened tool steel jaws are provided for perfect parallelism.

Orcan Products of India, Faridabad 121 001.Tel: 0129-2230063, Fax: 0129-4033248, Mob: 09811043930Email: [email protected], Website: www.orcan.com


INDUSTRIAL PAINTS & POLISHES

PAINTS & ALLIED PRODUCTS

Balark Chemicals manufactures and offers pigment raw materials like liquid chlorine, caustic soda lye, caustic soda flakes,

aluminum chloride, cotton bales, anti-corrosive paints, etc. A wide range of products starting from anti-corrosive coatings, like polyurethane, epoxy, chlorinated rubber paints, epoxy base floor coatings, special polymer base paints, heat resistance aluminium paints, coatings for rubber, leather, plastic, FRP, for architectural and hygienic wall coating, peelable coatings, glass coatings, matching primers and thinners, etc, are also available. Job work in supply and apply basis, ie, on turnkey basis is also undertaken in case of considerable job value and for corporate clients.

Balark Chemicals, Ahmedabad 380 014.Tel: 079-3008 9006/09, Fax: 079-3008 7007, Mob: 09824001010Email: [email protected], Website: www.balarkchemicals.com

PAINT COAGULATION SYSTEMS

Prism Surface Coatings offers compact online paint coagulation and sludge removal systems manufactured by HydoItalia, Italy.

These systems eliminate all the shortcomings of the conventional sludge pit type paint removal system. In automatic paint sludge removal systems, paint content in the water circulated in the booth is maintained constantly below 0.2 per cent. Hence, there is no sludge clogging the venturi, pipes or eliminating the necessity to clean the scrubber resulting in uniform performance of the booth, less maintenance work and reduction in maintenance work by 90 per cent. Due to this, changing the water needs to be carried out only once in a year as compared to 3 months in the conventional pit type system. The size of the pit required for this system is 1/6th of the conventional systems greatly reducing capital cost and freeing valuable floor space. BBOT model is available for large plants.

Prism Surface Coatings Pvt Ltd, Bengaluru 562 158.Tel: 08810-417999, Fax: 08119-417900, Mob: 09844400285Email: [email protected], Website: www.prismsurface.com

PNEUMATIC PISTON PUMPS

Technochem Service Corporation offers pneumatic piston pumps. These piston pumps supply paint

continuously to the gun. They can be used for transferring of paints and inks. Ratio available is 1:2.5,5. Operating pressure is 7 kgf/cm². Maximum paint output is from 4 to 20 LPM.

Technochem Services Corporation, Pune 411 018.Tel: 020-2766 0862, Fax: 020-2766 0862, Mob: 09922556565Email: [email protected], Website: www.tscspraypaintgun.com

CHEMICAL-RESISTANT PAINTS

Ugam chemical-resistant paint products offered by Leader Paints

Marketing, have excellent chemical resistance and are widely used in chemical industries. Special products are also manufactured as per requirements for special chemical resistance on request. The chemical-resistant paints provide chemical resistance to all mild

acids and mild alkalies.

Leader Paints Marketing, Pune 411 030.Tel: 020-2443 4075, Fax: 020-2443 4075, Mob: 09371012245Email: [email protected], Website: www.leaderpaintmarketing.com

AUTOMOTIVE PAINTS

Emperol Colours manufactures and offers automotive paints. NC automotive finish is a single component, air-drying, and

nitrocellulose based paint. Refinishing coating is ideal for auto car, and other vehicle to get good abrasion resistance, petrol and oil resistance with better polishing property. NC super finish is economical single component, air-drying, nitrocellulose based paint. Refinishing is coating ideal base coat for auto car, and other vehicle to get good abrasion resistance, petrol & oil resistance with better polishing property. These paints are also good for furniture and appliances coating where

fast drying is required.

Emperol Colours Pvt Ltd, Mumbai 400 075.Tel: 022-2506 5576, Fax: 022-2506 5253, Mob: 09869711706Email: [email protected]: www.emperolcolours.tradeindia.com

PAINT REMOVERS

Hero Paints offers paint removers or strippers that are solvent mixtures designed to remove paint and other finishes

and also to clean the underlying surface. The principal active ingredient is usually dichloromethane. Formulations with orange oil (or other terpene solvents), N-methyl pyrolidone, esters (often di-methyl esters of shorter dicarboxylic acids, sometimes aminated, for eg, adipic acid or glutamic acid), aromatic hydrocarbons, dimethylformamide, and other solvents are known as well. The formula differs according to the type of paint and the character of the underlying surface. Paint strippers come in a liquid, or a gel (thixotropic) form that clings even to vertical surfaces. The principle of paint

strippers is penetration of the paint film by the molecules of the active ingredient, causing its swelling; this volume increase causes internal strains, which, together with the weakening of the layer’s adhesion to the underlying surface, leads to separation of the layer of the paint from the substrate.

Hero Paints Pvt Ltd, Delhi 110 035.Tel: 011-2831 3601/3782, Fax: 011-2831 1493Email: [email protected], Website: www.heropaints.com



POLYURETHANE THINNERS

Austin Paints & Chemicals offers a wide range of chemicals and paints in order to ensure

that the demands of different clients are perfectly met. A wider variety helps customers to select the required products as per their needs. An extensive range of top quality polyurethane thinners are offered that has excellent wear or scratch resistance and can be used for durable finish.

Austin Paints & Chemicals, Kolkata 700 056.Tel: 033-2564 7407, Fax: 033-2553 5788, Mob: 09836001985Email: [email protected], Website: www.indiamart.com/austinpaints

TOUCHUP SPRAY PAINTS

Com-Paint touchup spray paints manufactured and offered by Aeroaids Corporation are the first Indian

original touchup spray paints (claims the company). These touchup spray paints are specially formulated to touchup cars, motorcycles, refrigerators, washing machines and other components. Features include unique easy-to-spray paint, dry in minutes; no more trips to the painter, save money and time; available in original shades for cars & motorcycles; and clear lacquer for metallic shades available separately. The Com-Paint touchup spray paints are available in three sizes, ie, 100 gms for motorcycles, 160 gms for cars, and 300 for general use.

Aeroaids Corporation, Delhi 110 033.Tel: 011-2722 0190, Fax: 011-2713 1455Email: [email protected], Website: www.com-paint.com



CORROSION-RESISTANT PAINTS

Star Paint & Oil Industries offers Rubberex acid, alkali, chemical and corrosion-resistant paints that are based on a highly stable rubber

hydrocarbon compound of uniform quality, which gives a highly durable and anti-corrosive protective coating. These are fast air-drying paints with which the coating obtained is of excellent hardness elasticity and free from pores. Due to the chemical inertness, the paints shield the effects of water, moisture, stream, acid fumes, alkalis, salt vapoors and transitory wetting organic solvents on metal surfaces. Applications include: protection from effects of acid fumes, industrial pollution and corrosion on steel structures and pipelines in refineries and petroleum complexes, stresses (Kate) of overhead roofs in sugar and chemical plants, suspension springs of motor vehicles, ship body from salty sea conditions, etc.

Star Paint & Oil Industries, Mumbai 400 023.Tel: 022-2265 2243, Fax: 022-2265 3201Email: [email protected], Website: www.starpaintindia.com

WATERPROOFING & DECORATIVE OUTDOOR PAINTS

Ahura Consultants offers Phencoat (white) a very high quality waterproofing-cum-decorative outdoor paint. It is off-white in

colour and can be stained with standard paint stainers to any required shade. The paint is based on chlorinated rubber, which gives excellent long term waterproofing on concrete or plaster and has outstanding resistance to UV rays in sunlight and all other weathering factors. It has high adhesion to China mosaic and is fungus-resistant.

Ahura Consultants, Mumbai 400 007.Tel: 022-2388 7771Email: [email protected], Website: www.ahuracontractors.com



SYNTHETIC ENAMELS

Aroma Paints offers full gloss hard drying synthetic enamels (Aroma No 1) based on special synthetic resins and selected

light fast and chalk resisting pigments. These synthetic enamels are recommended for all types of exterior and interior surfaces, such as wood, sheet metal, castings, transport and passenger vehicles, sign board painting, agricultural implements, machinery and plasters. They are tough & durable and highly resistant to marine and industrial atmospheres. The synthetic enamels

come in packing of 1, 4, 10 & 20 ltrs; and 50, 100, 200 & 500 ml.

Aroma Paints Ltd , Sonepat 131 001.Tel: 0130-6534070, Fax: 0130-2256558, Mob: 09812043070Email: [email protected], Website: www.aromapaints.com

INDUSTRIAL PAINTS

Bajrang Paints manufactures and offers industrial paints in various thicknesses and colours that perfectly suit the requirements

of clients and are also cost-effective. These paints provide good shine and superior finish to the walls, f loors as well as ceilings. All paints are made after intensive research so that they provide the desired effect in just one coating. The range of paints include polyurethane, acrylic, polyester, epoxy-coating (single pack/two pack), synthetic, stoving, fast drying, metallic shades, hammer-tone, wrinkle finishes,

flooring, heat resisting silicon, aluminum (30°C to 100°C), non-conductive, black Japan and stack black.



PAINTS/THINNERS & ALLIED PRODUCTS

Chemico Paints (India) manufactures and offers paints, industrial paints, domestic paints, and lead-free thinners.

The range of coatings is used in a variety of painting applications, such as automobiles, interiors and exteriors of buildings. The entire range of products is available in various chemical specifications. However, to suit the individual requirements of clients, customised solutions are also offered. The products are manufactured using latest technology that has been appreciated all over the world (claims the company). The product range includes: commercial thinners, industrial & decorate paints, water-resistant & enamel paints, epoxy paints, acrylic paints, natural paints, glass-coat paints, exterior paints, oil paints, interior paints, coating industrial paints, NC paints, lacquer paints, etc.

Chemico Paints (India), Meerut 250 005.Tel: 0121-4024689, Mob: 09837021306Email: [email protected]

Bajrang Paints, Gurgaon 122 001.Tel: 0124-2321491, Fax: 0124-2300183, Mob: 09810119966Email: [email protected]



PAINT SYSTEMS

Kansai Nerolac Paints develops and supplies cost-effective paint systems that are used on finishing lines of major electrical

components, cycle, and material handling equipments, bus bodies, containers and furniture industries. The product spectrum includes a comprehensive coating system starting from PT chemicals, primers, top coats and lacquers, coil coats, heat-resistant paints, metal decoration coating, etc. A diverse range of PT chemical is offered for various substrates and applications ensuring excellent surface prior to painting. Primers are used to cover minor surface defects, protect corrosion, and improve adhesion, finish and durability of subsequent topcoats. Topcoats and lacquers are available in a wide range of customer specific colours offering excellent finish, gloss, gloss retention and durability suiting diverse application conditions. Heat resistant paints are offered in technical collaboration with Oshima Kogyo Co Ltd, for speciality paints possessing varied areas of application and temperature resistance from 200°C to 650°C.

Kansai Nerolac Paints Ltd, Mumbai 400 013.Tel: 022-2499 2825, Fax: 022-2493 5743Email: [email protected], Website: www.nerolac.com


NEW LAUNCHES

EARTH RESISTANCE TESTERS

Kusam-Meco has introduced new clamp-on type earth resistance testers (model KM-1620/KM 1720) that are major

breakthrough in traditional grounding resistance measurement. These earth resistance testers are widely used in grounding resistance measurements of power, telecommunications, meteorology, oil-field construction; as well as in industrial and electrical equipment. They are safe, fast and simple to use. Both models function of easy operation, high accuracy & good adaptation of testing environment and beyond the limitation of traditional methods and can be applied in the situation not in the range of the traditional methods. They can measure the integrated value of the grounding body resistance and the grounding lead resistance. The earth resistance testers are equipped with standard testing coil, which can be used to do the self-testing with accuracy, as well as with a long jaw, particularly suitable at places where the grounding is done using Bus bar.

Kusam Electrical Industries Ltd, Mumbai 400 015.Tel: 022-2412 4540, Fax: 022-2414 9659, Mob: 09867000456Email: [email protected], Website: www.kusamelectrical.com

PERIPHERAL EXPLORER KITS

Giving students and new real-time control developers an easy-to-use, cost-efficient foundation for jumpstarting designs,

Texas Instruments Inc, USA has announced its enhanced floating-point F28335 Delfino microcontroller (MCU) peripheral explorer kit and free C2000 MCU teaching ROM. The new C2000 teaching ROM is a comprehensive guide to C2000 MCUs, also providing an introduction to real-time control design considerations. The teaching ROM includes labs based on TI’s F28335 peripheral explorer kit for superior hands-on learning. This new F28335 peripheral explorer kit brings increased integration over previous explorer kits to reduce development cost and enhance learning exercises. Together, the teaching ROM and peripheral explorer kit will enable more engineers to leverage the performance of C2000 MCUs to develop more energy-efficient real-time control applications, such as motor control, digital power, renewable energy and lighting. All exercises are provided in two versions to run under code composer studio IDE v3.3 and v4.

Texas Instruments India Pvt Ltd, Bengaluru 560 093.Tel: 080-4138 1665, Fax: 080-2504 8308Email: [email protected], Website: www.ti.com

DC POWER SUPPLIES

Tektronix, Inc has announced two additions to its line of bench instruments: the PWS4000 series programmable DC

power supply and the PWS2000 series DC power supply. These power supplies smoothly integrate with other Tektronix bench instruments, such as oscilloscopes & digital multimeters, and deliver wide current & voltage ranges for maximum versatility across a variety of applications. The new power supplies are ideal for design engineers who require high performance, feature-rich power supplies at competitive price points. Series PWS2000 and series PWS4000 offer performance

and ease-of-use advantages compared to similar offerings currently available in the market (claims the company). These new power supplies compliment the FCA3000/3100 and MCA3000 series timers/counters/analysers also introduced by Tektronix separately. With wide current and voltage ranges, plus up to 0.1 mA and 1 mV resolution, engineers using the PWS2000 or PWS4000 series can precisely generate the power needed for a variety of applications.

Tektronix (India) Pvt Ltd, Bengaluru 560 025.Tel: 080-2227 5577, Fax: 080-2227 5588Email: [email protected], Website: www.tektronix.com

DATA ACQUISITION MODULES

National Instruments has announced the NI PXIe-4331, latest in the NI SC Express family of high-performance data

acquisition (DAQ) modules with built-in signal conditioning. These DAQ devices are simultaneous high-speed bridge input modules that provide signal conditioning for dynamic measurements from strain, pressure, torque and load sensors. The NI PXIe-4331 increases the speed of bridge-based measurements and, with PXI Express, provides 250 MB/s of dedicated bandwidth per device to give engineers the freedom to increase channel count without compromising sampling rates or data throughput. It features eight channels with 24-

bit analogue-to-digital converters (ADCs) per channel and 102.4 kS/s per channel sampling rate. To improve accuracy and reject noise, the module offers antialiasing and digital f ilters per channel. Additionally, the module includes an independent programmable 0.625 to 10 V excitation voltage on each channel for flexibility and fault protection. The NI PXIe-4331 also provides remote sensing, internal bridge completion and shunt calibration options per channel.

NI Systems (India) Pvt Ltd, Bengaluru 560 103.Tel: 080-4119 0000, Fax: 080-4119 0010Email: [email protected], Website: www.ti.com

VIBRATING TABLES

Elscint Automation has introduced a new line of vibrating tables. The vibratory motion of these vibrating tables is

particularly suited for settling granular to coarse materials. These are also very effective for handling a wide range of metal parts, such as nuts, bolts and rivets. The vibrating tables are of electromechanical construction and are available in various models. The most popular is the

VT 50 model. It has a capacity of 130 kgs with a VA rating of70 VA. Even with this VA rating, the highly efficient design takes a current of just 1 A, just saving on energy costs. All models ofthe vibrating tables are totally enclosed, dust-tight and splashproof.


NEW LAUNCHES

Elscint Automation, Pune 411 026.Tel: 020-2712 2059, Fax: 020-2712 2994Email: [email protected]: www.elscintautomation.com

FPGA DESIGN FLOW SYSTEMS

Single FPGA design flow support range of embedded processor offerings based on ARM, Intel, MIPS architectures. To

accelerate the integration of programmable logic and processors in embedded systems, Altera Corporation has announced its embedded initiative. With this initiative, Altera provides designers a single FPGA design flow based on its Quartus II development software, including the new Qsys system, level integration tool, a common FPGA intellectual property library, and new ARM Cortex-A9 MPCore and MIPS Technologies MIPS32 embedded processor offerings. The design flow allows embedded designers to quickly and easily target Altera’s Nios II, ARM- and MIPS-based embedded processors and the recently announced configurable Intel Atom-based processor. The Qsys system-level integration tool leverages the industry’s first FPGA-optimised network-on-a-chip technology to support a wide variety of industry-standard IP protocols, improved quality of results and numerous productivity features.


NEW LAUNCHES

LASER DISTANCE METERS

Fluke Corporation has introduced the most advanced and capable distance measurement device, the Fluke 421D

laser distance meter. Their advanced features include: audible feedback for taking room angle and incremental measurements, a ±45-degree tilt sensor for taking indirect measurements in hard-to-reach areas and enhanced pythagoras calculation for indirectly determining distance. These laser distance meters automatically store last 20 measurements for quick recall of previous measurements. They measure distances up to 100 m (330 ft) with one push of a button. Laser distance measurement technology makes them far more accurate and dependable than devices using ultrasonic technology (claims the company). The instruments are IP54 rated for resistance to water spray and dust. Like other

Fluke distance meters, the Fluke 421D helps electricians, facilities managers and HVAC contractors save time and labour. The laser distance meters have a bright laser for easy targeting and large liquid crystal display.

TTL Technologies Pvt Ltd, Bengaluru 560 008.Tel: 080-2525 1859, Fax: 080-2529 1285Email: [email protected]: www.ttlindia.com

Altera Corporation, USATel: +1-408-5446397, Fax: +1-408-5446403Email: [email protected], Website: www.altera.com

Mr Ashish BhattDirectorV.R.VALVES Pvt Ltd

“SEARCH magazine is a delight in every sense, whether it’s response, inquiries or content. We have been associated with SEARCH magazine for the last 9 years. We promote our products through this magazine and receive many genuine inquiries in response. This has played significant role in our growth. We look forward to a long-term value laden relationship with Infomedia 18.

It is undoubtedly the leading industrial magazine & we wish them all the very best in their endeavours for the years to come.”


NEW LAUNCHES

COLOUR PRINTERS

Xerox India, a part of Xerox Corporation, offers a choice of four technology platforms in colour Laser, LED, solid ink

and inkjet to give customers a wide choice of printing solutions and improve efficiency, enhance productivity and reduce overall cost of ownership. As part of the four technology platforms in colour, Xerox has launched four colour printers and production

equipment. These include Xerox WorkCentre 7120 multi-function system, Xerox ColorQube 9201/9202/9203 multi-function systems, Xerox 7142 & Xerox 8264ETM colour wide format

printers. Solid ink is a proven colour printing technology by Xerox that uses solid sticks (or blocks) of no-mess, non-toxic ink instead of toner or inkjet cartridges. Solid ink is easy to use, produces incredible color print quality, is cost-effective and environment friendly. Xerox also announced its foray in the AO wide format inkjet printer category unveiling the Xerox 7142 & 8264E colour wide format printers.

Xerox India Ltd, Gurgaon 122 018.Tel: 0124-3940 0400, Mob: 09873012762Email: [email protected]: www.xerox.com


NEW LAUNCHES

ANALOGUE FRONT ENDS

Texas Instruments Inc has introduced two new fully integrated analogue front ends (AFEs) with a continuous wave (CW)

doppler mixer for mid- to high-end, spectral doppler ultrasound equipment. The AFE5807 and AFE5808 analogue front ends address ultrasound designers’ need for superior performance and image quality with the best noise performance at 0.75 nV/rtHz.

MULTI-CORE MEDIA PROCESSORS

LSI Corporation has announced that the LSI StarPro SP2600 family of multi-core media processors has been

selected by ZTE Corporation, a leading global network and telecommunications equipment supplier, for integration into their next-generation wireless platform. ZTE chose the SP2600 because it will enable them to develop their next-generation media gateway with minimum risk, cost and time to market. LSI StarPro multi-core media processors are designed to meet the increasingly stringent demands of high-density wireless infrastructure applications. Scalable to 12 DSP cores per SoC, the SP2600 family is designed to cost effectively meet the demands of high-density voice and video processing. The SP2600 provides a single platform for a wide range of telecommunications applications from entry-level multi-service business gateways through wireless carrier-class media gateways. All LSI StarPro media processors support multiple DSP cores, embedded CPUs and co-processing engines.

LSI Corporation, USATel: +1-800-372-2447Email: [email protected]: www.lsi.com


NEW LAUNCHES

In addition, the integrated CW mode measures and displays blood flow velocity in ultrasound images. These new devices are 25 per cent smaller than competing solutions and ensure a compact system footprint for higher channel count. Key features include: integrated CW doppler mixer & summing amplif ier with a very low close-in phase noise better than -155 dBc/Hz; model AFE5807 is a low-power solution with 88 mW/Ch at 1.1 nV/rtHz, 40 MSPS, 12-bit sampling; and model AFE5808 is a high-performance solution with low-noise optimisation of 0.75 nV/rtHz, 149 mW/ch, 65 MSPS & a 14-bit analogue-to-digital converter (ADC) with 77 dBFS SNR (signal-to-noise ratio).

Texas Instruments, Inc, USATel: +1-972-6445580, Fax: +1-972-9276377Email: [email protected], Website: www.ti.com

CONTROL & AUTOMATION PRODUCTS

Amidst global recession where customers are expecting high quality products at low price, Omron has launched new range

of high quality control and automation products. This new range cover products, like temperature controllers, power supplies, timers, sensors, monitoring relays, switches and programmable controllers. The introduction of these new models is a part of Omron’s expansion plan to cater to the needs of Indian customers who want high quality & reliable products but are weighed down by the need for reduction in cost due to intense competition from low cost solution providers.

Omron Automation Pvt Ltd, Bengaluru 560 042.Tel: 080-4072 6400, Fax: 080-4146 6403Email: [email protected], Website: www.omron-ap.co.in


GENERAL PRODUCTS

CIRCLIPS

R K Engineering Co manufactures and offers a wide range of circlips that are used for restraining axial movement of

components of shafts. These circlips are used particularly where space restrictions are applicable and also in small mechanism. External circlips are manufactured as per DIN 471 (IS:3075), internal circlips as per DIN 472 (IS:3075) and E clips as per DIN 6799 (IS:3075). The circlips are manufactured from EN42J high carbon spring steel. They are hardened and tempered. The circlips are also available in SS-304 materials.

R K Engineering Company, Mumbai 400 023.Tel: 022-2267 1141, Fax: 022-2265 5255Email: [email protected]

TRAVEL DRIVES

Trident Precision International offers travel drives that are available as

helical hollow shaft geared motors. All standard drives come with two-speed motors in 1:4 ratios. They have built-in flywheel in all travel drives. All drives unit consist of gearbox, motor and brake. All drives come with special rotor for soft start and stop. These drives have low weight and are highly corrosion-resistant. The drives are also available with ABM frequency controlled drive system.

Trident Precision International, Gurgaon Tel: 011-4142 5326, Fax: 011-2592 7181Email: [email protected], Website: www.trident-precision.com

UNIVERSAL DIE-BENDING MACHINES

Techno Crafts offers CNC universal die-bending presses (model Profi-56) manufactured by Boschert GmbH & Co

KG, Germany. These machines are used for efficient, economical folding, bending & pressing in the workshop and on the production floor. Standard Profi 56 CNC die-bending presses are available in the versions Profi 56/1000 CNC and Profi 56/2200 CNC with working lengths of 1,000 and 2,200 mm. The clearance between the stands is 890 and 2,100 mm respectively. Stroke is 200 mm and the clearance between the folding beams is 310 mm, so that tall tools can also be used, thanks to the maximum installation height of 325 mm. The worktable is 2 mm x 270 mm and accepts correspondingly wide tool systems for universal use as a press system for folding, die-bending or press work of all types. The machines have a stable, rigid design for reproducibly accurate.

Techno Crafts, Pune 411 004.Tel: 020-2542 5551, Fax: 020-2544 6496, Mob: 09422319755Email: [email protected], Website: www.boschert.de

PRESSURE FEED SPRAY GUNS

Jost’s Engineering Company offers pressure feed spray guns (model Bullows 230) that are available with forged aluminum

gun body for strength and durability. These are lightweight and slim body spray guns. The extra side port control in the air circuit making them suitable for various finishes, viz, stipple, hammer tone wrinkle, etc. The pressure feed spray guns have versatile wide range of nozzle setups for different applications and requirements. Other features include: feather light nylon gravity cup; PTFE

packing for extended work life; forged aluminum air nozzles for sturdy lightweight life; and special maintenance kit for spray gun provided along with each spray gun.

Jost’s Engineering Company Ltd, Pune 411 038.Tel: 020-2543 4350, Fax: 020-2543 4393Email: [email protected] , Website: www.josts.com

ABRASIVE BLASTING MACHINES

Carbide inserts of different sizes and shapes after sintering process are required to be cleaned for removal of wax/

foreign materials without effecting surface integrity and finish. MEC Shot Blasting Equipments have developed vapour honing machines based on suction induction principle of blasting. Fine particles are suspended in liquid [usually water] and are then pumped into the blast guns as slurry. At nozzles, the slurry is introduced into air stream & propelled against job. The machines are rotary indexing type

having number of satellites for placing the inserts on the fixtures. Indexing satellite carries the fixtures into the blast chamber where it starts rotating at blasting station. Reciprocating mechanism with multi-blast gun is provided for covering the entire surface of the fixture, thus cleaning the surfaces of the inserts. The machines incorporate precise controls of blasting parameters to achieve high performance.

MEC Shot Blasting Equipments Pvt Ltd, Jodhpur 342 005.Tel: 0291-2740609, Fax: 0291-2742409Email: [email protected], Website: www.mecshot.com

CNC MILL TRAINERS

PowerMill CNC mill trainers (model SS-PM-200) offered by Square Systems are

PC controlled 3-axis CNC mill trainers. These mill trainers are available with Windows-based software with 2D-3D graphics. They have Fanuc compatible programming codes. Other features include: 6-station automatic tool changer; compatible to FMS technology; fully enclosed machine with strong base frame; and powerful cutting on mild steel as

well as on non-ferrous materials.

Square Systems, Pune 411 038.Tel: 020-6528 6482, Fax: 020-2545 2764, Mob: 09326775821Email: [email protected]: www.squaresystemsindia.com


GENERAL PRODUCTS

PROFILE PROJECTORS

Banbros Engineering offers profile projectors (model JT 12 A-Zb) with digital data processors. These profile projectors are

efficient optical measuring instruments that have easy operation. They are suitable for measuring different shapes of workpieces with complicated profiles and surfaces, such as punched pieces, gears, cams, thread cutters, templates, etc, by means of profile compare measure. Technical specifications include: screen diameter Ø300 mm; rotating range 0-360-degrees; rotating indicator scale 1”; work table size 340 mm x 250 mm; X-coordinate 200 mm; Y-coordinate 100 mm; Z-coordinate 90 mm (focusing travel); X-Y coordinate accuracy (2+L/100) μm; motorised movement in Z-axis; magnification of 10x (standard), 20x & 50x (optional); view-field on object Ø30 mm; and working distance 75 mm. Illumination source include contour illumination 12 V, 100W; and surface illumination of 24 V, 150 W. Dimensions are 450 mm x 700 mm x 1150 mm. Weight is 135 kgs.

Banbros Engineering Pvt Ltd, New Delhi 110 092.Tel: 011-2241 8432, Fax: 011-2241 8432, Mob: 09810149486Email: [email protected], Website: www.banbrosengg.tradeindia.com

MITRE CUTTING BANDSAW MACHINES

ITL Industries offers fully-automatic motorised swiveling-type mitre cutting bandsaw machines that are used to cut angles in

the range of 30°-90°-30°. Model LMG mitre series is equipped with swiveling cutting head enabling to cut the job at various


GENERAL PRODUCTS

angles. Swiveling arrangement is available in manual as well as automatic mode. The machines are developed for meeting demands of fabrication industries, construction industries, transmission tower manufacturing and general cutting applications where jobs are required to be cut at various angles. Features include: cutting feed & rapid

reverse of cutting arm; blade tensioning when hydraulic power is on & tension release no sooner the machine is off to minimise fatigue stresses; automatic clamping before cutting arm starts moving down for cutting; shuttle vice release & clamps as the cycle is set/synchronised with length indexing table; apart from fully automatic cycle, manual mode is provided to facilitate initial setting; and automatic machine stop when blade fails.

ITL Industries Ltd, Indore 452 015.Tel: 0731-3044400, Fax: 0731-2721110Email: [email protected], Website: www.itl.co.in

AIR COMPRESSORS

Deep Pneumatics offers single-screw air compressors in joint venture with Shangha FEIHE Industrial Group Co Ltd,

China. The air end is composed of one cylindrical worm and two symmetrical plane star wheels, which are engaged and mounted in a casting. The worm groove, casting and tooth surface form a sealed cavity. When the star wheels moving in the worm groove,


GENERAL PRODUCTS

the air in the groove is compressed and exhausted. The worm has 6 grooves and is separated horizontally by two star wheels into two working cavities; each of realises separately suction, compression and exhaustion. Therefore, one single screw air compressor equals one unit six-cylinder double piston

compressor. When the tooth grooves in the suction end of the worm, all connect with the suction cavity. When the worm rotates to certain position and tooth groove cavity is separated from the cavity by the engagement with convex tooth of star wheel.

Deep Pneumatics Pvt Ltd, Ahmedabad 382 330.Tel: 079-2280 3684, Fax: 079-2280 3684, Mob: 09374635199Email: [email protected]: www.deeppneumatics.in

SINGLE-PASS HONING MACHINES

Khushbu Engineers offers CNC single-pass honing machines (model SP-650)

for higher productivity and accuracy of bore geometry. Very close tolerances can be achieved consistently with required surface finish through single pass honing process. In CNC single pass honing, a rotating diamond impregnated tool is passed once through the bore. High wear resistance of diamond-impregnated tool ensures repeatability of the bore size within 0.001 mm to 0.003 mm.


GENERAL PRODUCTS

CNC single-pass honing operation reduces the cycle time resulting in higher productivity. Features include: 2-axes CNC controller for vertical motion & indexing, Siemens/Fanuc or Mitsubishi controller, CNC index table, ball screw & LM guide, automatic lubrication system, overload sensors, precision class spindle bearing, stroke length 450 mm, variable spindle speed, compact machine base, interlocks, 8 HP power consumption, etc, with one-year warranty. Benefits are higher production rate, low operation cost, low labour cost, quality consistency and bore geometry improvement.

Khushbu Engineers, Kolhapur 416 122.Tel: 0230-2468859, Fax: 0230-2468443, Mob: 09371658016Email: [email protected], Website: www.khushbuindia.com

AGITATOR SEALS

Technomech Engineering manufactures and offers agitator seals that are specially designed for agitators, reactors,

mixers, autoclaves, rotary driers, etc. Special seals are designed for glasslined reaction vessels to handle arrangements of double-mechanical seals and dry seals, depending on temperature, pressure, nature of fluids, etc. For higher temperature application, the seal assemblies have jacketed chamber to circulate chilled water to bring down the temperature. Also normally chilled/plain water is passed through the cooling coil of thermo siphon to bring down the temperature of compatible barrier fluid circulated in seal housing to maintain the continuous cooling. Bottom portion of the seal housing is designed with heat trapping jacketed


GENERAL PRODUCTS

cooling to reduce the temperature around the bottom seal face. Operating limits are: temperature: -30°C to +300°C, pressure of 75 bar (max); and shaft diameter: range from 25 mm to 150 mm, pressure of 75 bar (max).

Technomech Engineering, Mumbai Tel: 022-2678 9468, Fax: 022-2678 9468, Mob: 0986709809Email: [email protected]

LATHE MACHINES

Balaji cone pulley heavy-duty lathe machines (VH series) offered by Vinit Engineering Works, are available in different height of

centres ranging 267 mm to 1000 mm; length of bed ranging from 1675 mm to 12000 mm; admit between centres ranging from 525 mm to 11000 mm; and main spindle hollow ranging from 50 mm to 150 mm. The main spindle nose is threaded-type and

made from alloy steel. Dynamically balanced spindles enable the spindle to run at vibration-free motion at 700 RPM. Norton gearbox is able to cut the any of metric, modules and diametric pitch. Bed is made

from graded cast iron and flame hardened up to 400 BHN. Also available are face plates, carrier plate steady rests, follow rests, motorised coolant pumps with tank & fittings, rear tool posts, quick change tool posts, etc. The machines are maintenance-free & easy-to-use; and come with interchangeable parts.

Vinit Engineering Works, Rajkot 360 004.Tel: 0281-2311734, Fax: 0281-2312091, Mob: 09879022052Email: [email protected], Website: www.balajilathe.com


GENERAL PRODUCTS

CONVEYOR PULLEYS & ROLLERS

Dynamic Rubbers manufactures and offers conveyor equipment and accessories, such as conveyor pulleys duly rubber lined

having dynamic balancing troughing idler, impact idlers, return rollers, self-aligning troughing and return idlers. These are manufactured as per customer’s design and drawing in most of the modernised workshop. All equipments are

supplied subjected to water ingress test, slurry test, ingress test, friction factor test and free rotation test.

Dynamic Rubbers Pvt Ltd, Ahmedabad 380 008.Tel: 079-2272 1567, Fax: 079-2272 1758, Mob: 09824006913Email: [email protected], Website: www.dynamicrubbers.com

CYLINDRICAL GRINDING MACHINES

Universal cylindrical grinding machines (model UC-150) manufactured by Devco Industries are available in eight

different models. Castings are close grained and well ribbed, minimise vibration and distortion. Regulating wheel spindle runs in taper roller bearing. Tailstock, wheelhead and workhead spindle are heat-treated to achieve dimensional stability, and performance roundness of <0.005 mm. Optional accessories

include: mechanical/hydraulic/self-feeding/internal grinding attachments; two-point steady rest, three-point steady rest, wheel balancing stand, etc. Also available are model UC-150 mini grinders that have specifications such as: distance between centre 160 mm, height of centre 102 mm, swiveling angle ±9-degrees, traverse


GENERAL PRODUCTS

speed 140-260-370-700 mm/min, infeed of hand wheel 0.01 division, grinding wheel size of 250 mm (D) x 25 mm (W) x 76.2 mm (B), grinding wheel speed of 2300 RPM, workhead spindle speed of 90-210-360 RPM, and spindle in taper MT-3.

Devco Industries, Wadhwancity 363 035.Tel: 02752-243997, Fax: 02752-240917, Mob: 09825343097Email: [email protected]

AC MOTORS

Oriental Motor offers electromagnetic brake motors, synchronous motors, torque motors, AC speed control motors and

watertight motors to meet specific application requirements. A wide variety of standard AC motors in frame sizes ranging from 1.65 inch to 4.09 inch square with output power of 1 W to 200 W are also available. There are two basic types of AC motors: standard induction motors that run continuously and reversible motors that allow for bi-directional operation. AC motors with additional functionality are also available. These types of motors include: electromagnetic brake motors to hold loads in a power-off situation; clutch & brake motors for quick starts and stops; synchronous motors and low-speed synchronous motors for a fixed speed in synchronisation with the power frequency; watertight motors for applications where the motor is splashed or washed with water; and torque motors for tension control and winding applications.

Essence Engineering, Hyderabad 500 047.Fax: 040-2705 1259, Mob: 09866964469Email: [email protected], Website: www.essenceengineering.com


GENERAL PRODUCTS

VACUUM BOOSTERS

Vulcan three-phase voltage boosters offered by Canary Electricals are applied with an objective of using three-phase

power safely and properly by increasing the voltage as needed in areas where low voltage is a chronically severe problem. All types

of electrical equipments, appliances or gadgets like, submersible pumps, monoblocks, three-phase motors, special electrical equipments used in factories, tubelights, fans and similar items are designed to work properly on a specific voltage level only. The voltage boosters are primarily designed to raise very low input voltage to the required level

of output voltage to be used by other devices like submersible pumps. Normally, one should get 415 V line-to-line AC 3-phase power everywhere. The voltage boosters are basically users own step-up transformers to serve their individual needs and a simple and cost effective way out of the above impasse.

Canary Electricals Ltd, Morbi 363 641 .Tel: 02822-250431, Fax: 02822-250433Email: [email protected], Website: www.vulcanwelding.com

REAR CYLINDER PRESS BRAKES

Rear-cylinder press brakes offered by Kawa Press Systems are available in a wide range of sizes from 2000 mm to 4000

mm length x 2 mm to 20 mm thickness with capacity ranging from 30 tons to 500 tons. These rear-cylinder mounted press brakes offer many superior advantages compared to competition


GENERAL PRODUCTS

like synchronised operation due to superior hydraulic systems; bending operation at slow speed with faster return travel to cut down idle time optional ball-roller tables for easy movement of jobs; quick die changing system; staggered tooling can be used for multiple operations; built-in overload protection systems, etc. Both CNC and PLC-based versions are available. Also offered are hydraulic variable rake angle guillotine shearing machines up to 25 mm thickness; hydraulic deep drawing presses for automotive and utensils industries, hydraulic punch, notching, shearing, and cropping machines for fabrication industries as also large capacity mechanical power presses up to 350 tonnes capacity.

Kawa Press Systems Pvt Ltd, Rajkot 360 002.Tel: 0281-2461102, Fax: 0281-2461665, Mob: 09825389169Email: [email protected], Website: www.kawapresses.com

TRUCK LOADING CONVEYORS

Arvali Engineers manufactures and offers truck loading conveyors for loading/unloading bags, cartons, boxes, crates,

etc, from trucks. These truck conveyors come with completely motorised operation with operator control panel on loading/unloading end. The height of the

Investment Milieu as Rich as its Culture

This December, SEARCH focusses on an undisputed Investment Destination

“WEST BENGAL”. With abundant natural resources, affordable raw material and cheap

labour, West Bengal, offers the best manufacturing environment for investors.

Content highlight.

Present Economic Scenario l Future Growth Opportunities l Investment & Business

Alliances l Role of Research-based Manufacturing l Government Initiatives l Cluster

Development l Hits & Misses and much more…

For advertising opportunities:

Call: 022 3003 4651 OR write to us at: [email protected]

Brought to you by


GENERAL PRODUCTS

loading and unloading ends can be changed, independently. The conveyors are completely mobile, mounted on sturdy wheels for easy mobility. They have telescopic arms for greater reach inside the truck. The truck loading conveyors have: choice of powerised rollers or heavy duty belt; choice of various belts depending on the application; choice of lighting on the conveyor to facilitate unloading/loading of containers; and various customisations of conveyor length, loading/unloading heights possible. Other features are: conveyor speed can be easily varied through the control panel; rough top belt for greater traction; heavy-duty & durable chassis; reputed makes of geared motors used for long trouble-free operation; and heavy-duty hydraulic systems with leakproof seals.

Aravali Engineers, Noida 201 307.Tel: 0120-2401105, Fax: 0120-2402083, Mob: 09810076877Email: [email protected], Website: www.aravaliengineers.com

SUPER BLASTER MACHINES

Surface International offers super blaster machines that are widely used

for sand/shot blasting of automobile components, like aluminium die-casting, precision machined components, castings, forgings, heat-treated components, etc. These machines are also used to provide rough surface on granite tiles for general-purpose finish or for carving on granites. They work on suction principle of lifting abrasives from storage tank. The machines are


GENERAL PRODUCTS

manufactured in three models, namely SSB-606060, SSB-9182, and SSB-12090 to suit different sizes of components and output application. Standard machines can be provided with optional features, like rotary table, tumble basket, and mounted track extension, with/without drive unit. To achieve decorative finish, glass beads can be used in the same machine. Apart from this, alumina, quartz, sand, grits, etc, can be used to achieve a variety of finish. The machines are provided with a cyclone dust collector/reclaimer with fabric bags. They are pollution-free and warranted machines that are easy-to-operate.

Surface International, Jodhpur 342 008.Tel: 0291-2787749, Fax: 0291-2721778, Mob: 09413329749Email: [email protected], Website: www.surfaceint.com

CONDENSATE DRAINS

Beko Compressed Air Technologies offers the 3rd generation of condensate drains: Bekomat 20, 21, 12, 13, 14 and 16.

Together they represent the standard programme of Bekomat condensate drains. These models are designed for operating pressures up to 16 bar, and the programme is rounded off by a 25 bar pressure version of the Bekomat 13 and 14, a 40-bar version of the Bekomat 13 as well as by a 63-bar high-pressure version of the Bekomat 12 device. In addition to the aluminium version for normal condensates, the devices can also be provided with hard coating for handling aggressive condensates. These devices have a triple LED display for indicating the


GENERAL PRODUCTS

different operating states. A potential-free contact can be used for relaying an alarm signal to a control centre. The condensate drains are designed for compressor performances up to 1,400 m³/min (temperate climate), depending on the type.

Beko Compressed Air Technologies Pvt Ltd, Hyderabad 500 037.Tel: 040-2308 0275, Fax: 040-2308 0274, Mob: 09393002464Email: [email protected], Website: www.beko.de

ULTRASONIC THICKNESS GAUGES

India Tools & Instruments Co offers ultrasonic through-coating thickness gauges. Some of the technical specifications include:

range from 0.8 mm to 300 mm in steel (depending of the probe); through coating range from 2.5 mm to 18 mm (depending on the probes); tolerance of ±0.05 mm in steel; and display resolution of 0.01/0.1 mm. Also available are digital ultrasonic thickness gauges, digital coating thickness gauges, portable digital hardness

tester and other related instruments.

India Tools & Instruments Co, Mumbai 400 003.Tel: 022-2342 8862, Fax: 022-2341 2578, Mob: 09819345050Email: [email protected]: www.indaitools.net


GENERAL PRODUCTS

PH TESTERS

Waterproof pocket pH testers offered by Hi-Tech Engineers have large display screen

with dual display LCD for enhanced readability, providing comprehensive meter information. The waterproof & dustproof housing that are IP67 rated, maintain the integrity of the testers even in harsh conditions. Double junction sensors offer longer lasting usage. User-replaceable sensors reuse the same meter body many times. The pushbutton calibration with auto buffer recognition gives quick & easy

UNIVERSAL TESTING MACHINES

Sinewave Engineering offers universal testing machines that are ideal for tensile and

compression testing applications. The accurate and rigid test frame is powered by Windows-based sophisticated and user-friendly software to perform almost every test in tensile and compression mode. Key features include: wide range from 10 kg up to 10 ton capacity; ball screw based test frames ensure excellent length accuracy; variable speed stepless speed servo drive; extremely quiet operation; high accuracy load cells; and auto load cell recognition/configuration.

Sinewave Engineering Pvt Ltd , Pune 411 041.Tel: 020-6523 4870, Fax: 020-2439 0916, Mob: 09763719531Email: [email protected]: www.sinewaveengineering.com


GENERAL PRODUCTS

calibration with no calibration mistakes. The pH testers are ideal for quick & accurate pH checks in pools and spas, aquariums & hydroponics operations, or wherever frequent pH testing is required. They are also used for cooling towers, food processing water testing & process/wastewater testing in metal f inishing, photo development, printing and chemical industries.

Hi-Tech Engineers, Thane 400 606.Tel: 022-6523 3952, Fax: 022-2588 3965, Mob: 09821255016Email: [email protected]: www.hi-techengineers.com

THERMIC FLUID HEATERS

Alankar Boilers & Pressure Vessels manufactures and offers thermic fluid heaters (model TFH) that are made from

premium quality materials, which ensure durability and strength of the heaters. Technical specifications of these thermic fluid heaters include: horizontal heli-coil type, multi-pass package; fuel (on GVC): wood (12 per cent moisture) of 2800 kcal/kg, lignite of 3500 kcal/kg, coal of 4800 kcal/kg; fuel consumption: wood 82 kgs/hr, lignite 66 kgs/hr, coal 48 kgs/hr; capacity of 6,00,000 kcal/hr; working/outlet temperature 120/150°C; heating surface 82 sq mt; induced type of draught; maximum flue gas 200 ±20; heater circulating media quality: hitherm 500 oil/synthetic 230; thermal efficiency: 72 ±3 (with a H unit); and overall size (horizontal): 2000 mm (L) x 2000 mm (W) x 4000 mm (H). The thermic fluid heaters are widely used in process houses, sugar paper mills,


GENERAL PRODUCTS

textiles, rubber industries, pharma industries, wooden pallets, rice mills, food industries, etc.

Alankar Boilers & Pressure Vessels Pvt Ltd, Ahmedabad 382 445.Tel: 079-2584 0242, Fax: 079-2584 2613, Mob: 09427030365Email: [email protected], Website: www.alankarboiler.com

LABORATORY DISSOLVERS/MIXERS & MILLS

Khushboo Scientific offers Dispermill laboratory dissolvers, mixers and mills manufactured by ATP Engineering BV, The

Netherlands. These are universal machines meant for all laboratory and pilotplant needs. With the Dispermill, one can mix, disperse, homogenise, emulsify and mill. The machines perform almost any

mixing task in the modern laboratory, whether gentle stirring or where high shearing is required. They can produce outstanding results on most applications, and have low noise drive system with continuous adjustable speed. High-tech PID electronics ensures constant speed even when viscosity changes. All

Dispermill dissolvers are complete with safety protection according to CE. Salient features include: adjustable quick fit clamping device, integrated adjustable timer 0-100 min, automatic stop, emergency main switch, continuous readout of speed & time on digital display, immersible parts made from stainless steel, multiple choice of mixing heads, such as propeller & rotor/stator, etc.

Khushboo Scientific Pvt Ltd, Mumbai 400 002.Tel: 022-2203 2174, Fax: 022-2208 1346, Mob: 09820230835Email: [email protected], Website: www.khushbooscientific.com


GENERAL PRODUCTS

REFLECTIVE PHOTOELECTRIC SENSORS

Lubi Electronics offers Sunx-make (model EQ-34W) dual output adjustable range reflective photoelectric sensors

that are specialised for detecting two different levels or surfaces for up to 2-meter sensing range. These sensors contain two individual outputs for two sensing distances: far (main) and near (sub). Hence, only one sensor is sufficient enough where earlier two were required. Detectability of the sensors is very stable even if the lens is contaminated by dirt, dust, mist or smoke under an unclear environment. The sensors have IP67 protection and therefore they can also be used in places splashed with water. Main benefit of the sensors is non-contact type detection of the object with two different level outputs, which is most suitable for packaging, pharma and food processing industries. Typical application includes detection of level (upper & lower) in hopper etc.

Lubi Electronics, Ahmedabad 380 025.Tel: 079-2220 5471, Fax: 079-2220 0660, Mob: 09327497006Email: [email protected], Website: www.lubielectronics.com

POWER SHEARING MACHINES

Godson Bending Systems offers power shearing machines that are constructed sturdily and designed for accuracy

& dependability by employment of the latest technology and experience. Sidewalls are designed from mild steel to take heavy loads. Beds and upper beams are fabricated from mild steel to withstand and absorb heavy loads designed specially to adjust


GENERAL PRODUCTS

the blade clearance as required. Pressure plates are fabricated from mild spring loaded. Clutches, brakes and drives include revolving key clutch, linked with

the main gear that engages every time when the foot pedal is pressed. Back gauges in GSH-1-2-3-4 are screw drives whereas in GSL1-2-3-4 and GSL1-2-3 they are of rack pinion type designed. Blades are generally four-edged and grade-I with single segment. Lubrication oil cups provided are connected with various pipes rendering supply of oil. Standard equipments include: back gauge, front gauges, wheel & gear guards, foot pedal and pulley.

Godson Bending Systems Pvt Ltd, Rajkot 360 002.Tel: 0281-2361467, Fax: 0281-2361873, Mob: 09879079267Email: [email protected], Website: www.godson-india.com

ONE-WAY CLUTCHES

NMT Group manufactures and offers one-way clutches (freewheels) that have no driving contact between inner

and outer ring in one direction of rotation and there is driving contact between inner and outer ring in the other direction of rotation which transmit torque. Three types of freewheels, viz, sprag (standard, indexing, centrifugal lift off ), roller, and


GENERAL PRODUCTS

cam-roller combined, are available with bore diameter of 12 mm to 150 mm. For mounting, clutches are provided with tapped holes on face, with flanged outer diameter with clear holes, with lever arm or key slot on face/outer diameter. Key attributes include: indexing & feeding, over-running, backstopping & holdback, and safe & automatic operations. Applications are in all industries: general drives, hoisting & conveying devices/inclined conveyors, leather, packaging, paper & printing, rubber & plastic, textile, wire processing, fishing net machinery, etc.

NMT Group, Ahmedabad 382 330.Tel: 079-2282 1527, Fax: 079-2282 0214Email: [email protected], Website: www.nmtgindia.com

SURFACE GRINDING MACHINES

Pinnacle Engineering Enterprise offers surface grinding machines in a full range from 450 mm x 150 mm table size manual

machines; to 1000 mm x 300 mm table size hydraulic machines; and 800 mm x 400 mm and GSH-8 Jumbo with table size of 1000 mm x 500 mm in hydraulic as well as NC/CNC versions. The Sumo series of machines have robust base structure and have internationally accepted fixed column design. Heavy box-type column casting with honeycombed ribbing is rigidly clamped to heavy base casting. The spindle housing supports cartridge type spindle unit and is fitted with super precision bearings grease packed with imported grease to have long trouble-free service. Automatic electronic cross feed is variable from 0.5-6 mm at


GENERAL PRODUCTS

each table reversal with a facility of rapid power positioning and additional safety manual to auto interlocking device. These machines are tested as per IS test-chart.

Pinnacle Engineering Enterprise, Surendranagar 363 002.Tel: 02752-231167, Fax: 02752-231913Email: [email protected], Website: www.pinnaclegrinder.com

LASER DISTANCE SENSORS

The AR200 laser measurement sensor is Acuity’s value distance-measuring sensor. Using laser triangulation

measurement principles with high-speed CMOS detection arrays, these sensors delivers high accuracy in a very compact model. This model includes both serial and analogue outputs for simple integration. Measuring 54 x 20 x 70 mm the sensor head fits anywhere. With integrated digital, analogue and discrete output signals, the sensors require no external controller or signal conditioner. Simply plug it directing into your PC or PLC. It has

sharp resolution. Specifications begin at 1.8 microns. The AR 200 sensors are equipped with RS232, 0-10V analogue, 4-20 mA current loop and NPN and PNP discrete outputs for alarm triggers. AR200 can be used for measuring steelstrip thickness, measuring defects on sheets, positioning silicon wafers etc.


GENERAL PRODUCTS

LATHE MACHINES

Premier Lathe Manufacturing Co offers lathe machine that are rigidly designed and suitable for bulk production. These

machines combine all the features, which are expected in heavy-duty production lathes with great efficiency and are ideal for all sliding, surfacing and screw cutting operation. Various special features of these machines include: lathe hardened & ground bedways; raw materials used are selected and grade quality raw materials are used; main spindle is hardened & ground with double grinding; and all screws made from bright steel with gun metal screw nut. Some of the technical specification are: length of bed 1675-6100 mm, admit between centre 555-4950 mm, centre height available at 330/380 mm, spindle bore available at 55/80/104/130 mm, etc. The lathe machines also have a variety of attachments, like fully or semi Norton gearbox, taper turning attachment, rear tool post and coolant pumps, etc.

Premier Lathe Manufacturing Co, Rajkot 360 003.Tel: 0281-238 7556, Fax: 0281-238 9248Email: [email protected], Website: www.premierlathe.com

SBS Precision Systems (India) Pvt Ltd, Kolkata 700 053.Tel: 033-3292 0078, Fax: 033-2400 3097, Mob: 09331140202Email: [email protected], Website: No website


INTERNATIONAL PRODUCTS

WIRELESS DATA TRANSMISSION SYSTEMS

Jay Electronique offers TI series wireless data transmission systems. These are of interest for applications where transmission

cables cannot be used or generate too high operating costs. The manufacturers point out the possible advantages of these systems, such as a lowering of installation costs and an increase in the reliability of mobile equipment by eliminating the need for wear parts. Also, the flexibility of installations can be increased and operating costs due to maintenance decreased. Applications can include the status indication of isolated detectors to control room as well as the remote control from machine to machine. The systems are mounted in metal housings with protection index IP65 to operate in most harsh environments.

Jay Electronique, FranceTel: +33-476-414400, Fax: +33-476-414444Email: [email protected], Website: www.jay-electronique.fr

BENCH WIRE TWISTERS

The Eraser Company, Inc manufactures and offers bench wire twisters (model G10S) that are used for many diverse

twisting needs. These units can twist pre-stripped stranded wires, twist strands of two or more wires together, twist wrapped shields on coaxial cables and tighten the twist of already twisted wire. They are supplied with one set of three twist length spacers to vary the twist length, depending on the application needs. Twisting inserts can be ordered depending on the wire size to be twisted. Technical specifications are as follows: wire sizes: 12-18 AWG (2.06-1.02 mmø), 18-24 AWG (1.02-0.51 mmø), 22-26 AWG (0.64-0.41 mmø); twist length up to 1” (25.4 mm) depending on the spacers used; twisted pairs do not exceed 2 18 AWG (1.02 mmø); three size spacers: 1/2” (12.7 mm) thick, 1/4” (6.35 mm) thick, 1/8” (3.18 mm) thick; and power of 115 V, 60 Hz or 220/240 V, 50 Hz.

The Eraser Company, Inc, USATel: +1-315-4543237, Fax: +1-315-4543090Email: [email protected], Website: www.eraser.com

WORK PROCESS MANAGEMENT SOLUTION SOFTWARE

GE Intelligent Platforms has announced the availability of the latest version of its Proficy Workflow work process

management solution software. This new software features validated system support capabilities allowing companies to create a more secure and regulatory compliant environment, ultimately saving time and reducing cost. Proficy Workflow 1.5 also features 64-bit support and better scalability. Furthermore, ISA-95 model additions allow users to manage inventory with materials in lots and sublots. New service method activities permit creating, incrementing, decrementing, querying, reading, changing the status or location of, deleting, and closing lots and sublots. The ISA-95 model additions also offer new resource utilisation feedback for improved business

reporting, material planning and process optimisation. Version 1.5 features comprehensive response models for reporting resources used/consumed and allows recording of actual people, equipment and materials used during a process.

GE Intelligent Platforms, USATel: +1-508-6987456Email: [email protected], Website: www.ge-ip.com

CONNECTORS

Harting KGaA offers the new Han EEE series that feature highest contact density up to 16 A. Thanks to a very space-

saving and compact design, the Han EEE series impresses with the highest contact density that has ever been possible in a monoblock

with Han E crimp contacts. The Han EEE series combines reliability and versatile application possibilities thanks to the combination of the simplest handling, as in the proven Han E series, and the new space-saving contact arrangement. Features include: available in two sizes: Han 40 EEE (40

crimp contacts/size 16 B) and Han 64 EEE (64 crimp contacts/size 24 B); 500 V at 16 A; can be inserted into the housing series: Han B, Han EMC, Han M & Han HPR; and control cabinet assembly with Han-Snap.

Harting KGaA, GermanyTel: +49-577247-244, Fax: +49-577247-400Email: [email protected], Website: www.harting.com

OVERVOLTAGE ARRESTERS

The triple socket TAE-TRAB-FM-NFN from Phoenix Contact GmbH protects analogue telecommunication interfaces against

over-voltages. The connecting socket is N-F-N coded so that for instance a telephone, a fax machine and an answering machine

can be protected at the same time. These arresters are available both for surface- and flush-mount assembly. Three-electrode gas arresters work as coarse protection in both normal and common mode direction. They are able to arrest a

surge current of 5 kA. Quick responding Transorb diodes offer a normal mode fine protection with a residual voltage of only 95 V. The high arresting capability and low values of the limiting voltage offer the biggest protection possible for the interface connected and in so doing, ensure the availability of the telecommunication devices for the exchange of information and data.

Phoenix Contact GmbH & Co KG, GermanyTel: +49-5235-341512, Fax: +49-5235-341825Email: [email protected], Website: www.phoenixcontact.com

STEP MOTION CONTROLLERS

Low-cost IC-based step motor controllers (series MC2502), offered by Performance Motion Devices, Inc, are the addition

to the Navigator Family 2500 series of motion processor chips. Available in one (MC2512), two (MC2522) and four (MC2542) axis configurations, the MC2502 series consist of two components, a 132-pin processor and a 100-pin logic device. Both components are surface-mount CMOS technology and powered by 5 V. The



motion processor is driven by a host microprocessor, via an 8-bit or 16-bit bus interface or through an asynchronous bi-directional serial port, giving users the ability to offload resource intensive motion control functions from the applications host.

Performance Motion Devices, Inc, USATel: +1-781-6749860, Fax: +1-781-6749861Email: [email protected], Website: www.pmdcorp.com

CLAMPING SYSTEMS

Clamping and machining of small parts has always been a big problem in manufacturing industries. Witte Bleckede,

manufacturer of different clamping systems now offers a further item in their freeze technology range. With a clamping surface of 40 x 40mm ice vice light is especially suitable for machining small parts. Ice vice light enables secure and plane-parallel freezing of flat workpieces onto its clamping surface using only a little water and in just a few seconds. An even holding force is effective over the whole surface. Applications include: clamping of small parts, clamping of workpieces with special geometries, and especially suitable and economically viable in modelling, sample machining, prototype machining and single series machining. Preparations for use are kept to a minimum. After the chuck is cooled down to +3°C, some water is sprayed onto the clamping surface and a part is positioned.

Witte Far East Pte LtdTel: +65 6248 5961, Fax: +65 6898 4542Email: [email protected], Website: www.witteasia.com



ACCU-LINE LASERS

Z-Laser Optoelektronik offers accu-line lasers (model Z3A). The power supply of these small lasers is provided by a

standard accumulator and is equipped with an on/off switch. There is no transformer or annoying cable any more. The accu-line lasers are developed for small machines like band saws, radial saws, mitre circular sawing machines, etc; and are therefore easy to use and to install. These semiconductor lasers are able to project a very sharp red line of approximately 1 m length. The very precise accu-line laser make the user work a lot easier and help to achieve good quality.

Z-Laser Optoelektronik GmbH, GermanyTel: +49-761-2964432, Fax: +49-761-2964455Email: [email protected]

AFTERCOOLERS

Hankison International manufactures and offers aftercoolers in air-cooled

& water-cooled types. Air-cooled models use ambient air to lower compressed air temperature, & generally 5 to 20°F, 3 to 11°C above the ambient air temperature. Water-cooled models use cooling water to lower compressed air temperature generally 10 to 20°F, 6 to 11°C above the cooling water temperature. These



aftercoolers cool the high temperature compressed air exiting a compressor to safe, usable levels. They can be sized as a single source cooler or as a trim cooler for use with an air-cooled aftercooler during hotter weather. By lowering the temperature of the compressed air in downstream airlines, the risk of fires is reduced and the need to insulate piping is eliminated. Also, it is typically necessary to cool the air to a maximum of 120°F (49°C) before introducing it into a dryer or filter for further treatment.

Hankison International, USA Tel: +1-724-7451555, Fax: +1-724-7456040Website: www.hankisonintl.com

MULTI-WIRE WIPERS

Contact technology today is advancing the miniaturisation of components while continuously increasing the reliability and

quality of the signal produced. In this field of modern contact technology, W C Heraeus GmbH offers multi-wire wipers to meet these high requirements. The multi-wire brush contacts have proven their worth as contact elements in position sensor applications in the automotive, industrial electronics and consumer

electronics industry. In all these applications, it is required that the sensor has always a stable and reliable electrical signal under all operating conditions. Electrical noise levels and noise potential decrease by a power of two with the increased number of parallel contact points. As it can be recognised in the name itself, multi-wire wipers offer a much higher amount of contact points compared to conventional stamped wipers (claims the company).

W C Heraeus GmbH, GermanyTel: +49-6181-35051, Fax: +49-1681-353131Email: [email protected], Website: www.wc-heraeus.com

BIMETAL THERMOMETERS

Dwyer Instruments offers bimetal thermometers (series BTO) transmitter output. These bimetal thermometers are

designed to take remote readings along with measurements, via a bimetal helix, making them the ideal choice to take accurate

temperature measurements in the toughest environments. They eliminate the need for a separate thermometer and transmitter. By only needing one connection, the BTO series reduces installation cost and saves space. The head-mount transmitter is located in a weatherproof thermal head located on the side of the stem. The BTO series is ideal for use on power generating boilers, skid mounted compressors, and thermal oxidation systems.

Dwyer Instruments Inc, USATel: +1-219-8798000, Fax: +1-219-8729057Email: [email protected], Website: www.dwyer-inst.com

FUSING MACHINES

VEIT manufactures and offers fusing machines (MultiStar EX series) that are custom-designed and suitable for a wide application of

fabric & interlining combinations. Of utmost importance in a fusing machine is control of the fusing parameters. Standard control functions include: set/actual temperature; VEIT power management; standby mode saves energy during downtimes; integrated timer to



cool belts after use; minimised power peaks during machine warm-up; pressure displayed in bar or N/cm²; belt speed displayed in m/minute & seconds; on/off function; and diagnostic system for heating elements, compressed air supply and belt tracking.

VEIT GmbH & Co, GermanyTel: +49-8191-479204, Fax: +49-8191-479199Email: [email protected], Website: www.veit.de

FLEXIBLE EPOXIES

Cotronics Corporation offers Duralco 4538 super flexible epoxies that are so flexible that one can even tie it in a knot. Unlike ever

before, there is a solution for applications requiring the ultimate in thermal shock and vibration resistance, sound absorption and excellent adhesion to dissimilar substrates. This completely variable system can be tailored to meet any application requirement just by varying the mix ratio of resin to hardener resulting in the exact degree of flexibility required for any application. Easy to use, one has just to choose the mix ratio desired, dispense resin and hardener, mix to a uniform colour and apply. The epoxies have excellent adhesion to most plastics, metals, ceramics, glass, rubber



The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

SEARCH

and even treated Teflon and cure at room temperature without any objectionable odors. They can be used from -100°F to +450°F.

Cotronics CorporationTel: +1-718-7885533, Fax: +1-718-7885538Email: [email protected], Website: www.cotronics.com

VISUAL CODE PROGRAMMING SYSTEMS

Haas Automation Inc offers visual quick code programming system designed to make operating CNC machines easier

and faster for the both the novice operator and experienced machinist alike. Visual quick code is a conversational programming system with a graphical interface that makes creating simple G-code programs nearly effortless. Once the operation is selected, a series of graphical part templates is displayed along with an English description of the operation to be performed for each template. Complex parts can be programmed a piece at a time by selecting individual graphical templates to generate G-code for each feature, then inserting the G-code into the same programme. The visual quick code option also includes standard quick code that allows operators to use a split-screen format to create G-code programmes without having to memorize G and M modes.

Haas Automation, Inc, USATel: +1-805-2781800, Fax: +1-805-9886918Email: [email protected], Website: www.haascnc.com

PRODUCT INDEX


To know more about the products in this magazine, refer to our ‘Product Index’ or write to us at [email protected] orcall us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to

the advertisers directly to help you source better.

SOURCE AUTOMATION & INSTRUMENTATION PRODUCTS @www.engg-expo.com

2D to 3D conversion 1792-wire transmitters 103D modelling 1794-column hydraulic presses 247Abrasive blast rooms 221Abrasive blasting machines 202, 221Absorption drying machines 13AC geared motors 239AC motors 59, 215, 239AC/DC panels 243Acoustic enclosures 125Actuators 169Adapter sleeves 68Adhesives 109Adjustable adaptors 79Adjustable shock absorbers 55Agitator seals 209AGVs 147Air compressors 95, 113, 119, 206, 227Air dryer & filters 119Air nozzles 143Air purifiers 173Air receivers 227Air treatments 129Air-cooled reciprocating compressors 95Airport passenger baggage trolleys 209All-geared auto-feed pillar drilling machines 137, 174All-geared auto-feed radial drilling machines 137All-geared pillar drilling machines 208, 209All-geared radial drilling machines 208Alloy wheels 209Alu-cera polymers 9, 15Aluma coat 9, 15Aluminium oxide ceramic composites 9, 15Aluminium worm geared motors 176Aluminum extrusions 174Ammeters 219Analogue & digital panel meters 17Analogue front ends 199Analogue panel meters 17Appliance switches 29Apron conveyors 230Area sensors 77, 121Assembly technology 67Auto drains 216Auto feeder hydraulic presses 247Auto-feed radial drilling machines 174Automated guided vehicles 147Automatic back spot facing tools 189Automatic rolling shutters 23Automation & process controls 107, 145, 253Automation & security systems 251Automation & storage systems 49Automation 85, 266Automations 10Automotive paints 184Auxiliary equipment 231Aviation cog wheels 143Back-geared auto-feed radial drills 137Back-geared fine-feed machines 137Bags bailing presses 247Baling presses 247Ball & roller bearings 8Ball bearings 229Ball joints 60Ball screws 183Ball transfer units 209Ball valves 169, 191, 205Balls 201Basket strainers 191Batteries & chargers 107, 145, 253Battery-operated pallet trucks 81Bearing bushes 143

Product Pg No

Bearings 8, 140, 229Bellow couplings 183Bench grinding machines 212Bending machines 171Best CAD 179Billet shearing machines 14Blasting media 221BLDC motors 239Bollards 23Boring machines 209Brake motors 41, 59, 176, 182Brass castor wheels 209Breather valves 191, 210Brine chillers 219Bronze wheels 209Brushless DC motors 20Brushless DC systems 239Brushless motor controls 20Building automation 266Bust preventives 172Butterfly valves 205Cable carriers 140, 183Cable connectors 140Cable glands 47Cable reeling drums 52Cable tray-cable ladders 230Cables & leads for fixed instaction 49Cables for bus systems 49Cables handling & processing systems 49Cables scanps 49Cables 41, 86, 93, 107, 145, 253CAD programs 179CAD software 179CAE software 179Calendaring Front gatefoldCalibrators 10CAM express 179CAM 179Carbide rods 71Carbon fibre re-enforced products 143Cast/extruded products 225Castor wheels 209Castors 209CED coating machines 266Centralised lubrication systems 198Centreless grinders 229Centreless grinding machines 245Centrifugal blowers 95Centrifugal compressor package 95Centrifugal fans 211Centrifugal pumps 39Ceramic adhesive cements 9, 15Ceramic electrical heater parts 9, 15Ceramic processing furnaces 231C-frame power presses 14Chain hoists 222Chain pulley blocks 182Chain wheels 162Chains 140Chair castors 209Channel magnets 177Check valves 191Chemical pump vanes 143Chemical pumps 210Chemical-resistant paints 184Chemicals & adhesives 107, 145, 253Chemlok coating machines 266Chillers 58CI castings 209Circlips 202Circuit protection 107, 145, 253Circular motion vibratory screens 52Circular vibratory screens 52

Product Pg No

Circular/gyrator vibro machines 177Cistern type manometers 191Close frame hydraulic presses 247Clutch & brakes 20CNC cutting machines 266CNC hydraulic turret punch presses 181CNC laser cutting machines 266CNC lathes 165, 175CNC machine solutions 158, 186CNC machines Back inside coverCNC mill trainers 202CNC oxyfuel cutting machines 266CNC plasma cutting machines 181, 266CNC press brakes 181CNC synchro press brakes 181CNC tap chucks & tap adaptors 79CNC tap holders & pull studs 79CNC toolings 73CNC tools holders & pulley studs 79CNC turning centres Back inside coverCNC vertical machining centres 19, Back inside coverCNC Back inside coverCNC/VMC machines 135Coating machines 266Coating plants 266Coating systems 266Coin presses 247Cold storage dockhouses 23Cold storage doors 23Collecting electrodes 230Colour printers 198Command panel systems 43Compressed air division 185, 245Compressed air filters & regulators 157Compressed air systems 50Compression fittings 180Compressor valve plates 143Compressors vacuum pumps & air motors 170Compressors 50, 95, 104, 113Concrete vibrators 52Condensate drains 13, 221Conduits & connector systems 29Cone pulley heavy-duty lathe machines 163Cone pulley light-duty lathe machines 163Cone pulley medium-duty lathe machines 163Connector accessories 49Connectors 6, 24, 47, 107, 140, 145, 253Console systems 43Contactless in-cylinder transducers 183Contactless technologies 183Container cranes 111Control & automation products 201Control & automation 93Control cables 86Control panel accessories 29Control valves 205Controllers 10Conventional & monoblock pumps 177Conventional precision lathes 165Converter planomillers 189Conveyor castor wheels 209Conveyor pulleys & rollers 212 Conveyor trolleys 209Conveyors & automation systems 23Coolant accessories 177Coolant pumps 177Coolant rotary unions 55Coolant separators 170Cooling tower motors 176Cooling towers 129Cooling water treatments 265Cordless rechargeable grease guns 241Coromill 103Corothread 103

Product Pg No

PRODUCT INDEX


Corrosion preventives 172Corrosion-resistant paints 187Counter balanced pallet trucks 81Counters & power supplies 5Counters rate products 10Counters 121Couplings 167Crab hoists 182Crane-duty motors 41, 176, 182Cranes 18, 182, 201Crimp contacts & tools 49Cross belt-inline magnetic separators 52Crystals & oscillators 107, 145, 253Cushion dock shelters 23Custom-made cables 49Cutting machines 266Cutting tools 71, Front gatefoldCylinders 45, 228Cylindrical grinders 175, 245Cylindrical grinding machines 212Data acquisition modules 192Data cables 49DC motors 59DC power packs 185DC power supplies 192Deep drawing hydraulic presses 247Dehumidifiers 189, 191Demagnetisers 170Dessicant dryers 95Diamond core drilling machines 195Diamond setting 195Diaphragm switches 110Digital almen gauges & almen strips 159Digital mark sensors 77Digital multimeters 17Digital panel meters 121, 206, 219Digital pressure switches 239Digital soft starters 215Dip spin coating machines 266Disc brakes 239Discharge electrode assemblies 230Discharge electrodes 230Discharge frames 230Discrete semiconductors 107, 145, 253Display units 121Distribution boards 16Dock levellers 23Dock shelters 23Door runners & tracks 209Door side sensors 121Doors 23Dosing feeders 52Double drum & triple drum magnetic separators 189Down shop leads 208Drawer magnets 177, 189Drill chucks 185, 245Drill machines 137, 180, 208Drill sleeves 79Drilling machines 174, 216, 228Drilling-cum-milling machines 228Drilling-cum-vertical milling drill machines 196Drills 174Drive motors 210Drivers & controllers 121Drives 21, 217Drum trolleys 209Drum-type magnetic separators 52, 177Dry vane pumps 125Dryers 13Duplex deburring tools 189Dust collectors 212, 221Dust resistance motors 239Earth resistance testers 192Electric controls 67Electric drives 67Electric forklift trucks 23Electric wire rope hoists 18, 182, 188Electrical actuators 199Electrical connectors 60

Product Pg No

Electrical measuring instruments 219, 243Electrical products cable ties 47Electrical systems 93Electrical transducers 17Electricals 107, 145, 253Electro hydraulics 227Electromagnetic bin vibrators 52Electromagnetic chucks 170Electromagnetic disc brakes 239Electromagnetic ferrofilters 52Electromagnetic vibratory feeders 177Electronic pressure switches 239Electronic speed switches 215Electronic timers 30, 32, 34, 36Electronics For You Expo-2011 226Electronics products 47Electrostatic liquid cleaners 72Embossing rolls Front gatefoldEmergency shock absorbers 55Enclosure cooling units 43Enclosure systems 43Enclosures 107, 145, 253Encoders 5Energy efficient motors 176Energy efficient pumps Front inside coverEnergy saving gas burners 231Engineering plastic plugs/sockets 30, 32, 34, 36Engineering plastics 225EngineeringExpo 203, 213, 223EOT cranes 18, 182, 188EOT jib cranes 201Everdry 13Everything About Water Expo-2011 200Exhibitions 115, 190, 200, 203 213, 223, 226, 242, 246Explosion-proof valves 227External & in-cylinders linear position sensing 183Extra heavy-duty lathes 196Extra hi-cut lathes 196Extra-duty lathe machines 196Fabtec India-2011 115Factory automation 85, 206Failsafe brakes 239Fan & filter units 43Fans 107, 145, 253Fasteners & mechanical 107, 145, 253Fasteners 215Feed units 228Femap 179Ferrous casting 174Fibre sensors 77Fibreoptic sensors 121Filters 13, 45Filtration technology 13Filtration 265Fine & auto feed radial 228Finishing machines 177Fire shutters 23Fittings 45Fix frame hydraulic presses 247Flame arresters 191, 210Flameproof motors 59, 176Flameproof products 10Flange flacers 189Flange motors 41Flange mounting motors 59Flanging machines 171Flat cables for submersible pumps 49Flat high-tension single-twin igniting electrodes 9, 15Flexible cables & wires 49Floating holders 79Floor plates 209Floor scrubbers & driers 259Flooring 231Flow instruments 197Flow rate indicators 10Flow switches 191Fluid dispensing parts 143Fluid seal systems 65

Product Pg No

Fluidised bed coating machines 266Fluids 122Flush bottom valves 191Flux generators 52Foot mounting motors 41Force actuation 169Force feed lubricators 228Forged components 174Forging presses 14Forklift trucks 57FPGA design flow systems 195Frequency meters 219, 243Friction drop hammers 14, 179, 205Friction screw presses 14FRL spares valve spares 216Front casing 210Funnel magnets 177Furniture castor wheels 209Furniture castors 209Fuse boxes 198Gantry cranes 182, 201Gas control & regulators product 205Gas distribution plates 230Gas distribution screens 230Gas springs 55, 188Gas trains 205Gauge accessories 197Gear couplings 162Gear motors 20, 117, 122, 176, 178, 182, 188Gear seals 143Gearboxes 20, 117, 122, 162, 178, 187, 188Geared & flexible couplings 122Geared head heavy-duty lathe machines 163Geared head medium-duty lathe machines 163Geared motors 59Geared radial drilling machines 228Geared drilling machines 228Gears 122, 162 Glass processing furnaces 231Glass 151Glide coating machines 266Global cam indexers 149Globe valves 191Goliath cranes 182Goods lifts 201Graphic panels 121Grill magnets 177Grinding machines 151, 212Grinding media 9, 15Grinding tools for hard materials 151Haconan-free cables 49Hammers 14, 179, 205Hand magnets 177Handheld vibratory motors 52Hannover-2010 242Head screws 210Head washers 210Heat shrink tubings 47Heat sinks & HVAC 107, 145, 253Heat transfer equipment 211Heat treatment salts 172Heating elements 247Heavy job turning & boring machines 196Heavy-duty castor wheels 209Heavy-duty castors 209Heavy-duty drill machines 180Heavy-duty industrial castors 209Heavy-duty lathe machines 222Heavy-duty lathes 196Heavy-duty radial drill machines 180Heli-bevel geared motors 176Helical gearboxes 188Helical geared motors 18Helical gears 162Helical inline geared motors/reducers 178Helical-worm gear units 20Heli-worm geared motors 176H-frame power presses 14Hi-cut lathes 196

Product Pg No

COMPLETE ENGINEERING UNDER ONE ROOF @www.engg-expo.com

PRODUCT INDEX


SOURCE ELECTRIC & ELECTRONICS PRODUCTS @www.engg-expo.com

High-alumina wear resistant ceramic tiles 9, 15High-carbon chrome 201High-carbon steel balls 201High-discharge pumps 177High-efficiency standard motors 176High-intensity induced roll magnetic separators 52High-intensity rare earth magnetic separators 177High-intensity roller type magnetic separators 177High-performance plastics 143High-pressure ball valves 169High-pressure blowers 20, 211High-pressure cleaners 259High-pressure switches 239High-pressure transmitters 239High-speed doors 23Hi-tech Manufacturing Show 246HMM technical guidelines 176HOC dryers 95Hollow shaft worm gear motors 20Hooper magnets 177, 189Horizontal boring & facing machines 208Horizontal boring machines 208Horizontal CNC machines Back inside coverHorizontal facing machines 208Horizontal hydraulic presses 247Horizontal machining centres Back inside coverHorizontal pipe & tube bending machines 207Hose clamps 196Hoses & flexible tubings 45Hoses 167, 222Hot oil rotary unions 55HRC fuse bodies 9, 15Hump magnets 52, 177, 189Hydraulic & pneumatic applications 217Hydraulic and pneumatic valves & fittings 180Hydraulic centerless grinding machines 245Hydraulic cylinders 168, 171, 185Hydraulic cylindrical grinders 168, 245Hydraulic cylindrical grinding machines 245Hydraulic dampers 55Hydraulic dock levellers 23Hydraulic dock shelters 23Hydraulic floor cranes 170Hydraulic floor jib cranes 169Hydraulic forging hammers 232Hydraulic gear pumps 185Hydraulic hand pumps 228Hydraulic hoses 8Hydraulic internal grinding machines 245Hydraulic manual pallet trucks 81Hydraulic pallet pumps 168, 228Hydraulic power packs 169, 206Hydraulic power units 185Hydraulic press brakes 181Hydraulic press machines 207Hydraulic presses 168, 232, 247Hydraulic pumps & valves 185Hydraulic pumps 185, 227Hydraulic punching machines 171Hydraulic rotary unions 55Hydraulic seals 133Hydraulic servo actuators 227Hydraulic shearing machines 181, 207Hydraulic shock absorbers 55Hydraulic splitters 195Hydraulic steel working machines 171Hydraulic systems 185Hydraulic tank accessories 168Hydraulic valves systems 228Hydraulics 67IC counterbalanced forklifts 23ICS semiconductors 107, 145, 253Imaging & vision systems 266Impellers 210Inclined tube manometers 191In-cylinder sensors 183In-cylinder transducers 183Indexers 149Indexing machines 221

Product Pg No

Indicators 10Inductive proximity switches 29Industrial automation 85Industrial batteries 93Industrial ceramics 9, 15Industrial connectors 49Industrial control & sensing devices 5Industrial coolers 129Industrial cooling systems 219Industrial cranes 111Industrial electric AC motors 20Industrial electric power distribution systems 16Industrial floorings 231Industrial heating elements 247Industrial hoses 157Industrial ovens & dryers 231Industrial overhead doors 23Industrial paints 188Industrial pumps 150Industrial shock absorbers 55, 188Injection moulding components 198Inline drum-type magnetic separators 177Inline helical geared motors 176Inline shaft mounted helical geared motors/reducers 178Instrumentation & controls 27Instrumentation made cables 49Instrumentation 217Insulated conductor systems 208Insulated doors 23Insulated power rails 208Insulation testers 17Interlocking doors 23Internal grinders 245Internal grinding machines 245Internals for electrostatic precipitators 230Inverter duty motors 176Inverter/variable frequency drives 5Investment destination - West Bengal 218IPVS-2010 190Isolators 12Jacks 228Jib cranes 18, 182Joinings 169Kamlok & drylok couplings 150Kilns & baths 231Laboratory dissolvers/mixers & mills 228Laboratory testing rerods 52Large bearings 8Large enclosures 43Large helical & heli-bevel gearboxes 176Laser distance meters 196Laser distance sensors 232Laser markers 77Laser sensors 77Laser shaping 151Lathe machines 210, 239Lathes 163, 195, 196, 209, 222Leak detectors 45LED signal tower lights 30, 32, 34, 36LEDs 29Level controllers 5, 199Level gauges 191Level indicators 199Level switches 199Level transmitters 199Lift & conveyor cables 49Lift trucks services 111Lifting magnets 189Light lifting 111Light-duty castors 209Light-duty lathe machines 222Light-duty lathes 196Limit switches 29, 30, 32, 34, 36Linear motion vibratory screens 52Linear motion 67Linear position transducers 183Linear potentiometers 183LM guideways 183

Product Pg No

Load break switches 29Loaders 57Loading arms 150Loading bay equipment 23Lock nuts 68Lock washers 68Long travel machines 228Loop powered indicators 10Loop powered isolators 10Lorry loaders 57Low lift pallet trucks 23Low vacuum dehydration & degasification 72Lubricants 45Machine tool accessories 79, 183Machined components 174Machines 171Magna roll 52Magnet cups 210Magnet drive pumps 210Magnet pumps 210Magnetic concentrators 52Magnetic coolant separators 177Magnetic floor sweepers 52, 177Magnetic pulleys 52, 189Magnetic racks 189Maintenance sprays 7Manometers 191Manual hydraulic crushers 195Manual pallet trucks 23Material handling equipment 18, 81, 182MCBs 12MCC & PCC enclosures 43MCCBs 93Measurement & inspection 107, 145, 253Measurement sensors 77Measuring & monitoring relays 5Measuring instruments 17, 219, 243Mechanical & hydraulic press brakes 207Mechanical press brakes 181Mechanical/hydro-mechanical section bending machines 207Medical & surgical devices 143Medical air compressors 227Membrane drying 13Metal cutting tools 139Metal diaphragm pressure switches 239Metal scrape baling presses 247Metal treatment chemicals 172Metallurgical furnaces 231Metering solutions & relays 93Meters 93, 219, 243Micro-milling beads 9, 15Micro-switches 30, 32, 34, 36Microwave level switches 110Mighty tiny series 20Mill lining blocks 9, 15Milling cutters 71Milling grades 103Milling-cum-drilling machines 137Miniature modular systems 45Mitre cutting bandsaw machines 205Mobile control valves 206Mobile cylinder hydraulic presses 247Modernisations 111Motion controls 5Motion solutions 149Motor control centres 93Motor protection circuit breakers 29Motorised boom barriers 23Motorised control valves 205Motorised vibratory feeders 177Motors 41, 59Multi-angle right angle universal milling attachments 189Multi-core media processors 199Multi-functional tools 71Multi-speed motors 176Multi-stage pumps 177MV switchgears 93Needle roller bearings 8Needle valves 191

Product Pg No

PRODUCT INDEX


FINALIZE SUPPLIERS @www.engg-expo.com

Non-ferrous casting 174Nozzles 150Nuts 68Office & computers 107, 145, 253Ohms meters 243Oil coolers 58Oil removal 13Oil seals 172Oil/coolant coolers 219On/off controllers 10One-way clutches 230Optical touch switches 77Optoelectronics & displays 107, 145, 253Oriental motors 239O-rings 133, 210Overband magnetic separators 177Overcrank shearing machines 181Overhead doors 23Oversize lathe machines 222Oxyfuel cutting 181Paint removers 184Paint shop equipment 266Paint shop machines 266Paint spray booths 221Paint systems 191Paints & allied products 184Paints/thinners & allied products 189Pallet pumps 228Pallet stackers 23Pallet trucks 81Panel air-conditioners 219Panel coolers 58Panels 243Paperless recorders 206Parallel cam indexers 149Parallel shaft helical geared motors 176Part ejectors 127Parts for pollution control equipments 230Passive components 107, 145, 253PC enclosures 43PD blowers 95Pedestrian & rider operated counter balanced pallet trucks 81Pedestrian low lift pallet trucks 23Pedestrian pallet stackers 23Peeing machines 159Perforated metal screens 230Peripheral explorer kits 192Permanent magnetic chucks 170, 189Permanent magnetic drum pulleys 177Permanent magnetic drum-type separators 189Permanent magnetic lifters 52pH testers 225Photoelectric sensors 5, 77, 121Pick & move cranes 57PID controllers 10PID temperature controllers 121Pillar drill machines 174, 180Pillar-type hydraulic presses 247Pilot lights 29Pipe bending machines 171Piston rings 143Piston rods 222Planetary gear heads 183Planner machines 209Planners 195Planning machines 229Plano millers 209, 195, 229Plastic hose pipes 157Plastic mould products 143Plastic products 143Plate bending machines 171, 181, 207Plate castor wheels 209Plate magnets 52, 177, 189Plat-trucks 209PLC-operated hydraulic presses 247PLCs 217Plugs & sockets 29Pneumatic & electric on/off valves 205Pneumatic clutches & brakes 177

Product Pg No

Pneumatic control valves 205Pneumatic cylinders 179, 222Pneumatic fastening tools 183Pneumatic feeders 180Pneumatic nailers 172Pneumatic piston pumps 184Pneumatic plug valves 177Pneumatic products 157, 216Pneumatic rotary actuators 172Pneumatic rotary unions 55Pneumatic seals 65Pneumatic stirrers 180Pneumatic valves 174Pneumatic vices 183Pneumatics 8, 67Polishing machines 212Polyacetal 225Polyaryletherketone 143Polyetheretherketone 143Polypropylene 225Polyurethane thinners 185Polyurethane 225Portable blasters 221Portable coolant purifying systems 127Portable oil skimmers 127Portable turning machines 189Powder coating & speedy painting equipment 241Power & line protection 107, 145, 253Power cables 86Power chucking cylinders 175Power controllers 121Power distribution components 43Power factor meters 219Power magnets 189Power pack units 228Power packs 228Power presses 181, 207Power quality management systems 93Power shearing machines 229Power supply for cranes/hoists 208Power supply for stem material handling 208Power transducers 17Pre treatment systems 266Precision locknuts 183Precision roll turning lathe machines 196Precision rolling bearings 8Precision steels 151Precision switches 29Precision universal cylindrical machines 245Press technology 169Pressure blasters 221Pressure boosting 265Pressure control valves 210Pressure feed spray guns 202Pressure gauges 10, 197Pressure sensors 77, 121Pressure switches 239Pressure transducers 239Pressure transmitters 239Process controllers 206Process cranes 111Process gas blowers 211Process water treatment 265Product assemblies 174Profile projectors 205, 243Programmable logic controllers 5Programmable terminals 5Prong magnets 52Proportional valves 227Protective-conduit systems 49Proximity sensors 5, 30, 32, 34, 36, 77, 121Proximity switches 215PTFE/Teflon products 225Pulleys 162Pumps 11, 39, 125, 131, 210, Back coverPunching machines 171Push buttons 29PVC flap & strip doors 23Quick connects 45

Product Pg No

Quick release couplings 180Quick-change tapping chucks/tap adaptors 79Racks & cabinets 107, 145, 253Radial drill machines 137, 180, 208, 216Radial drilling 174, 209Rapid flexible doors 23Rapid roll-up doors 23Rapping bar assembly 230RCCBs 12Reach trucks 23Reaming & tapping 79Rear casings 210Rear cylinder press brakes 216Receptacles 150Reciprocating air compressors 119Re-crystallised allumina tubes 9, 15Rectangular lifting magnets 52Re-drawer magnets 52Reflective photoelectric sensors 229Refrigerated dryers 13, 95Regulators 45Re-hopper magnets 52Reliable flooring 231Relief valves 191Re-magnetic rods 52Reversible motors 239Reversible tapping attachments 79RFIDs 5Rigging solutions 99Right-angled helical bevel geared motors/reducers 178Right-angled helical worm geared motors/reducers 178Robotic cables 49Robotic demolition 195Rod ends 60Roll forming machines 207Roller-type magnetic separators 177Roots blowers 125Rotary cam switches 29Rotary clean flow magnets 52Rotary dry vacuum pumps 211Rotary encoders 121Rotary indexing tables 149Rotary joints 55Rotary screens 52Rotary screw air compressors 95, 119Rotary shaft seals 133Rotating unions 55Round glasses 191RTD sensors 10Rubber products 172Sack trucks 209Safety laser scanners 77Safety light curtains 5Safety protection devices 29Safety relief valves 191, 210Safety shock absorbers 55SCADA & DCS implementation 266Scanners 10Scissor lifts 23Scrap-circular lifting magnets 52Screw air compressors 119Screw compressors 227Screw presses 232Sealants 45, 109Sealing systems 222Seals 8, 172Section bending machines 207Sectional overhead doors 23Security & audio visual 107, 145, 253Security systems 173Self-opening die-heads 79Semiconductor modules 107, 145, 253Semiconductor tools 107, 145, 253Semiconductors 107, 145, 253Sensitive part loading/unloading 127Sensor controllers 121Sensors & transducers 107, 145, 253Sensors 77Serial converter modules 121

Product Pg No

PRODUCT INDEX


SOURCE HYDRAULICS PNEUMATICS EQUIPMENT @www.engg-expo.com

Shaft loading 127Shaping machines 209Sheet metal components 198Sheet metal machines 171Shipyard cranes 111Shock & vibration isolation 225Shoe brakes 239Shot blasting hoses 221Shot blasting machines 205Shot blasting 159Shrouded DSL systems 208Shunts 243Sight flow indicators 191Sight flow meters 150Signal isolators 10Silence flow packages 211Simplair anodised aluminum piping 95Single/multiple precision switches 29Single-pass honing machines 208Slab demolition 195Sleeves 68Slipring crane-duty motors 59SLS linear displacement sensors 183Small junction/distribution boxes 43Sockets & switches 24Solar water heating systems 231Solderless terminals 47Solenoid valves 205, 216Solid carbide drills & mills 139Solid carbide reamers 139Solid carbide special drills & mills 139Solid carbide special reamers 139Solid edge 179Special application motors 176Special refrigeration equipment 219Specialised grooving & parting tools 71Special-purpose machines 195Speed control motors 239Spindle nose toolings 71Spiral bevel gearboxes 20Spiral cables 49Spiral-cum-helical gearboxes 122Spray guns 185, 245Spur gears 162Squeezing rolls Front gatefoldSSM nuts 79Stacker pumps 228Stainless steel valves 227Stainless steels 201Standard pyramid-type plate bending machines 207Static control & site safety 107, 145, 253Static control devices 77Steam rotary unions 55Steel balls 201Steel working machines 171Stepper motors 121, 239Stepping motors & systems 239Straightening machines 229Submersible hydraulic presses 247Suction blasters 221Super blaster machines 219Surface grinding machines 231Surface plates 209Surface treatments 109Suspension magnets 52, 177Sweeping machines 259Switchboard meters 243Switches & relays 107, 145, 253Switches 12Switchgear products 93Switching power supplies 121Switching relays 5Swivels 150Synthetic enamels 188System integrators 217Tacho/speed/pulse meters 121Tail lifts 23Team centres 179Technical ceramics 9, 15

Product Pg No

Teflon bushes 210Telescopic doors 23Temp/humidity transducers 121Temperature controllers 5, 206Temperature instruments 197Temperature-resistant cables 49Tension springs 188Testers 243Tests 107, 145, 253Thermic fluid heaters 227Thermocouples 10Thread whirling tools 103Timers 5, 10, 121Timing belts 162Timing pulleys drives 162Timing pulleys 162Tool holders 73Tool post belt grinders 212Tooling solutions 93Toolings 73Tools & production supplies 107, 145, 253Torque motors 20, 176Totalisers 10Touchup spray paints 185Toughened glasses 191Tower cranes 57Tower lights 121Trade fairs-2011 220Transducers 219Transformers 107, 145, 243, 253Transmitters 10Trap magnets 177Travel drives 202Traveling machines 18Trims 198Triple drum-type magnetic separators 52Trolley castor wheels 209Trolleys 209Truck blowers 211Truck loading conveyors 217Truck-dumper body vibrators 52Tube magnets 52Tube sheet assemblies 230Tubing & tube accessories 45Turned components 174Turning holders 71Turrets 175Twin spin bearing reducers 183UF exiter vibratory screens 52UHMW-PE products 225Ultrasonic flow meters 206Ultrasonic thickness gauges 222Unbalanced vibratory motors 52Uni-force exciters 52Unigraphics 179Universal die-bending machines 202Universal drilling machines 163Universal quick-change chucks & adaptors 79Universal radial drilling machines 228Universal testing machines 225U-tube manometers 191Vacuum blasters 221Vacuum booster pumps 125Vacuum boosters 216Vacuum cleaners 173Vacuum pumps 227Vacuum systems 125Valve position transducers 183Valve seats 143Valves 45, 169, 180, 191, 216 Variable speed drives 20Variable speed pulleys 20VDI tool holders 73Ventilators 221Vertical boring machines 209Vertical machining centres 175Vertical order pickers 23Vertical turning machines 195, 209Vertical turning-cum-boring machines 195

Product Pg No

Vibrating motors 177Vibrating reed type 243Vibrating screen machines 177Vibrating tables 192Vibration motors 20Vibratory bin activators 52Vibratory bowls 177Vibratory conveyors 52Vibratory feeders 52Vibratory fluidised bed dryers 52Vibratory furnace chargers 52Vibratory grizzly feeders 52Vibratory knockout tables 52Vibratory spiral elevators 52Vibratory tables 52Vices 185, 245Vision sensors 5Voltmeters 219Wall sawing 195Washers 68Wastewater treatments 265Water analysers & combustible & toxic gas detectors 217Water chillers 219Water exhibitions 128Water faucet & tap parts 9, 15Water purifiers 173Water rotary unions 55Water treatments 265Water-cooled reciprocating compressors 95Waterjet cutting Front gatefoldWaterproofing & decorative outdoor paints 187Watertight motors 239Wattmeters 219Wear parts 71Welding equipment 185, 245Welding systems 45Wet & dry vacuum cleaners 259Wet drum-type magnetic separators 52Wheel assemblies 188Wheel barrows 209Winches 201Wire & assemblies 107, 145, 253Wire connectors 47Wire rope drums 188Wires 86Wiring connectors 198Withdrawal sleeves 68Worm gear speed reducers 20Worm gears 122, 162Y-type strainers 191Zirconia polycrystal ceramics 9, 15

Product Pg No

Accu-line lasers 243Aftercoolers 243Analogue front ends 199Bench wire twisters 240Bimetal thermometers 244Clamping systems 241Connectors 240Flexible epoxies 245FPGA design flow systems 195Fusing machines 244Hydraulic dock levellers 187IS interfaces remote 171Motors 114Multi-core media processors 199Multi-wire wipers 244Overvoltage arresters 240Screw compressors 22Step motion controllers 240Switches 171Transmitters 171Truck tailgate lifts 187Visual code programming systems 247Wireless data transmission systems 240Work process management solution software 240


ADVERTISERS’ LIST


Our consistent advertisers

AC Automation 188T: +91-11-27674839E: [email protected]: www.ac-automation.com

Action Construction Equipments Ltd 57T: +91-11-40549900E: [email protected]: www.ace-cranes.com

Actuators India Pvt Ltd 199T: +91-22-26736864E: [email protected]: www.tscindia.com

Aglow Engineers Pvt Ltd 198T: +91-120-3917070E: [email protected]: www.aglowengineers.com

Allied Electronics Corporation 6T: +91-22-26616619E: [email protected]: www.aecconnectors.com

Amsak Cranes Private Limited 201T: +91-44--26273486E: [email protected]: www.amsakcranes.com

Applied Engg Services 241T: +91-20-24448165E: [email protected]: www.appliedengg.in

Ashok Industry 172T: +91-22-61504150E: [email protected]: www.ashokindustry.com

Atlas Copco (India) Ltd 104T: +91-20-30722222E: [email protected]: www.atlascopco.com

Atos Spa 227T: +91-80-23613840E: [email protected]: www.atos.com

Autonics Automation India Pvt Ltd 121T: +91-22-27814305E: [email protected]: www.autonics.com

Avcon Controls Pvt Ltd 205T: +91-22-28221505E: [email protected]: www.avconindia.com

To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at [email protected] call us at +91-22-3003 4640 or fax us at +91-22-3003 4499 and we will send your enquiries

to the advertisers directly to help you source better

Advertisers’ Name & Contact Details Pg No

Awwa (I) Technologies 187T: +91-80-25360784E: [email protected]

B S Hydro-Pneumatic Pvt Ltd 180T: +91-22-26861361E: [email protected]: www.bshydro.com

Ballkings 201T: +91-161-2534501E: [email protected]

Beko Compressed Air Technologies Ltd 13T: +91-40-23080275 / 23081107E: [email protected]: www.beko.de

Bhagirath Heavy Transmission 188T: +91-11-32222661E: [email protected]

Boge Compressed Air System 50T: +91-44--43009610E: [email protected]: www.boge.in

Bonfiglioli Transmissions (Pvt) Ltd 21T: +91-44--24781035E: [email protected]: www.bonfiglioliindia.com

Bosch Rexroth (India) Limited 67W: www.boschrexroth.co.in

Buildcon Consultants Pvt Ltd 231T: +91-141-4012629E: [email protected]: www.buildcon.in

C&S Electric Ltd. 12T: +91-11-30887520-29E: [email protected]: www.cselectric.co.in

Cenlub Systems 198T: +91-129-4113771E: [email protected]: www.cenlub.com

Ceratizit India Pvt Ltd 71T: +91-33-24947146E: [email protected]: www.ceratizit.com

Champion Industries 170T: +91-2752-231741E: [email protected]


Chemical & Industrial Engineers 191T: +91-22-28822740

Classic Polymers & Resins 225T: +91-22-24465251E: [email protected]: www.classicpolymers.com

Coatec India 266T: +91-172-5063436E: [email protected]: www.coatecindia.com

Connectwell Industries Pvt Ltd 24T: +91-251-2870636E: [email protected]: www.connectwell.com

Cosmos Impex (India) Pvt. Ltd. 158, 186T: +91-265-3927000E: [email protected]: www.cosmos.in

CRI Pumps (Pvt) Ltd 11T: +91-422-3260011E: [email protected]: www.cripumps.com

Darling Pumps Pvt Ltd 131T: +91-731-2720558E: [email protected]: www.darlingpump.com

Deep Pneumatics Pvt Ltd 119T: +91-79-22803684E: [email protected]: www.deeppneumatics.in

Delair India Pvt Ltd 191T: +91-124-4091111E: [email protected]: www.delair.com

Diamond Metal Screens Pvt. Ltd. 230T: +91-831-2441295E: [email protected]: www.diamondscreens.com

Digital Marketing Systems Pvt Ltd 217T: +91-731-3046800E: [email protected]: www.digitalcontrols.org

Dixon Asia Pacific Pvt Ltd 167T: +91-22-40931555E: [email protected]: www.dixonvalve.com

Dongguan Dacheng Machinery Make Co., Ltd. 187T: +86-769-8321-7777E: [email protected]: www.taillift.net


ADVERTISERS’ LIST



Essence Engineering 239T: +91-09866964469E: [email protected]: www.essence-india.blogspot.com

Eureka Forbes Limited 173T: +91-80-30251500E: [email protected]: www.eurekaforbes.com

Everest Transmission 125T: +91-11-45457777E: [email protected]: www.everestblowers.com

Fabtec India 2011 115T: +91-422-2221582E: [email protected]: www.fabtecindia.codissia.com

Farnell Electronics India 107, 145, 253T: +91-80-40003800E: [email protected]: www.farnell.in

Ferrocare Machines Pvt Ltd 72T: +91-20-26830655E: [email protected]: www.ferrocare.com

Fluid Energy Controls Inc 150T: +91-44--42083536E: [email protected]: www.fecindia.com

Fontus Water Ltd 265T: +91-11-43100536E: [email protected]: www.fontuswater.com

Forging Machinery Manufacturing Co 14T: +91-161-5011755E: [email protected]: www.nkhhammers.com

Frank Technologies 227T: +91-422-2646490E: [email protected]: www.frankcompressors.com

Freeze Tech Equipments Pvt Ltd 58T: +91-44-42152387E: [email protected]: www.freezetechequip.com

G A Industries 239T: +91-79-25895577E: [email protected]: www.gaindustries.net

G L Brothers 245T: +91-22-66047000E: [email protected]: www.pilotindia.com

Dowel Machinery Pvt Ltd 247T: +91-281-2362465E: [email protected]: www.thedowel.com

Dynascan Inspection Systems Co 243T: +91-80-41102747E: [email protected]: www.dynascan.info

EA Water Pvt Ltd 200T: +91-11-43100519E: [email protected]: www.eawater.com/expo

East India Bearing Co. (P) Ltd. 8T: +91-22-40939200E: [email protected]: www.eibc.in

EFY Enterprises Pvt Ltd 226T: +91-11-26810601E: [email protected]: www.efyexpo.com

Elecon Engineering Company Ltd 122T: +91-2692-236469E: [email protected]: www.elecon.com

Electro Magnetic Indus 52T: +91-265-3241361E: [email protected]: www.electromagneticindia.com

Electrocraft (Asia) Limited 114T: +852-3163-2250E: [email protected]: www.electrocraft.com

Electronica Hitech Engineering Pvt Ltd 135T: +91-20-30435400E: [email protected]: www.electronicahitech.com

Empire Cable Industries Pvt Ltd 86T: +91-11-23874632E: [email protected]: www.empirecables.com

Endeavour Engineering 143T: +91-79-65123263E: [email protected]: www.endeavourengineering.com

Engineering Expo 203, 213, 223T: +91-9920401226E: [email protected]: www.engg-expo.com

Entech Consultancy Bureau (Madras) Pvt. Ltd. 110T: +91-44--24421024E: [email protected]: www.entechconsultancy.com

Advertisers’ Name & Contact Details Pg No Advertisers’ Name & Contact Details Pg No

G W Precision Tools India Pvt Ltd 139T: +91-80-40431252E: [email protected]: www.gwindia.in

Gandhi Automations Pvt Ltd 23T: +91-22-66720200E: [email protected]: www.geapl.co.in

Gem Equipments Ltd 129T: +91-22-3267800E: [email protected]: www.gemindia.com

Global Sleeve Solutions 68T: +91-09501040477E: [email protected]: www.globalsleeves.com

Godson Bending Systems Pvt Ltd 207T: +91-281-2361467E: [email protected]: www.godson-india.com

Goliya Electricals Pvt Ltd 243T: +91-22-24120456E: [email protected]: www.goliya.com

Goliya Instruments Pvt Ltd 219T: +91-22-24149657E: [email protected]: www.goliyainstruments.com

Grundfos Pumps India Pvt Ltd .BCT: +91-44--24966800E: [email protected]: www.grundfos.in

H G Shah & Co 162T: +91-79-25621431E: [email protected]: www.timingpulley.in

Hannover Fairs India Pvt Ltd 242T: +91-22-40050683E: [email protected] W: www.mda-india.com

Havells India Ltd. 41T: +1800-11-0303;’+91-11-41660303E: [email protected]: www.havells.com

Heattrans Equipments Pvt.Ltd. 174T: +91-79-25840105E: [email protected]: www.heattrans.com

Henkel Adhesives Technologies India 109T: +91-80-25357771E: [email protected]: www.loctite.com


ADVERTISERS’ LIST



Hensel Electric India Pvt. Ltd. 16T: +91-44--24541669E: [email protected]: www.hensel-electric.de

Hindustan Motor Mfg Co 176T: +91-22-42500500E: [email protected]: www.hindmotors.com

Hitachi India Trading Pvt Ltd 113T: +91-11-40605252E: [email protected]: www.hitachi.com.sg

HiTech Manufacturing Show 246T: +91-09820373804E: [email protected]

Hi-Tech Robotic Systemz Ltd 147T: +91-124-4715100E: [email protected]: www.hitechroboticsystemz.com

Igus India Pvt Ltd 140T: +91-80-39127800E: [email protected]: www.igus.in

Ingersoll Rand (India) Ltd 95T: +91-79-22820123E: [email protected]: www.ingersollrand.co.in

Inter Ads - Brooks Exhibitions Pvt Ltd 128T: +91-09810042500E: [email protected]: www.india.aquatechtrade.com

Jagdeep Foundry (Regd.) 209T: +91-1871-242750E: [email protected]: www.jagdeepfoundry.in

Jaibalaji Controlgears Pvt. Ltd., 30, 32, 34, 36T: +91-44--26251279E: [email protected]: www.jaibalaji.firm.in

Jayashree Electron Pvt Ltd 215T: +91-20-46768998E: [email protected] W: www.jayashree.co.in

Jaykrishna Magnetics Pvt Ltd 177T: +91-79-22970452E: [email protected]: www.magneticequipments.com

Jyoti Ceramic Industries Pvt Ltd 9, 15T: +91-253-2350120/338E: [email protected]: www.jyoticeramic.com


Jyoti CNC Automation .BICT: +91-2827-287081E: [email protected]: www.jyoti.co.in

Jytra Engineering Services 179T: +91-40-66663747 / 9246553857 E: [email protected]: www.jytra.com

Kapasi Fastners / Inc 215T: +91-80-22279217E: [email protected]

Keman Enterprises Ltd 195T: +91-22-25902283E: [email protected]: www.kemangroup.com

Klipco Pvt Ltd 196T: +91-22-28684221E: [email protected]: www.klipcohoseclamps.com

Knowell International Pvt Ltd 229T: +91-33-22304627E: [email protected]: www.knowell.co.in

Konecranes India Pvt Ltd 111T: +91-20-40047470E: [email protected]: www.konecranes.com

Kryfs Power Components Ltd 99T: +91-22-67859999E: [email protected]: www.slingset.com

Kushal Udyog Manufacturers & Engineers 221T: +91-291-2720072E: [email protected]: www.kushaludhyog.com

Lapp India Pvt Ltd 49T: +91-80-7826000E: [email protected]: www.lappgroup.com

Larsen & Toubro Ltd 93T: +91-22-67525656E: [email protected]: www.larsentoubro.com

Lubi Electronics 77T: +91-79-39845300E: [email protected]: www.lubielectronics.com

Maco Corporation India Pvt. Ltd. 55T: +91-33-40224129E: [email protected]: www.macocorporation.com.com


Macro Tech Equipment Pvt Ltd 81T: +91-33-24666261E: [email protected]: www.macrotechcal.com

Makson Machines Pvt Ltd 174T: +91-278-2446437E: [email protected]: www.makwanaeng.com

Manmachine (India) Private Limited 259T: +91-120-2422727E: [email protected]: www.manmachine.in

Mather And Platt Pumps Ltd .FICT: +91-20-27442100E: [email protected]: www.matherplatt.com

Micromatic Machine Tools 175T: +91-80-41492285E: [email protected]: www.acemicromatic.com

Millenium Instruments Ltd 197T: +91-11-22456571E: [email protected]: www.miepl.com

Mitsubishi Electric Asia Pte. Ltd. 85T: +91-124-4630300E: [email protected]: www.messung.com

N K Forging & Rolling Industries 179T: +91-161-2223666E: [email protected]: www.nkhhammer.com

Nanfang Pumps India Pvt Ltd 39T: +91-22-25425540E: [email protected]: www.nanfangpumps.com

Ni Systems India Pvt Ltd 27T: +91-80-41190000E: [email protected]: www.ni.com

Ningbo Xinda Screw Compressor Co., Ltd 22T: +86-574-8833-6868E: [email protected]: www.augustcompressor.com

Oil Seals Mfg Co Pvt Ltd 172T: +91-22-22047943E: [email protected]

Omron Automation Pvt. Ltd. 5T: +91-80-40726400E: [email protected]: www.omron-ap.com


ADVERTISERS’ LIST



Orbitz Corporate & Leisure Travels (I) Pvt. Ltd. 220T: +91-22-24102801E: [email protected]: www.visittradefairs.com

Orbitz Exhibitions Pvt Ltd 190T: +91-22-24102801E: [email protected]: www.ipvs.in

P Parmar Mechanical Works 180T: +91-278-2447409E: [email protected]: www.parmardrill.com

Packam Controls Pvt Ltd 149T: +91-22-28771293E: [email protected]: www.packam.co.in

Pathak Machines International 171T: +91-161-2510401E: [email protected]: www.pathakeuromachines.com

Pidilite Industries Ltd 7T: +91-22-33087544E: [email protected]: www.pidilite.com

Pilot Pneumatics Pvt Ltd 185T: +91-22-66047000E: [email protected]: www.pilotindia.com

Pitroda Utility Industries 245T: +91-2752-243795E: [email protected]: www.pitrodautilityindia.com

Poly Kraft Machines 208T: +91-79-22743639E: [email protected]: www.polykraftmachines.com

Power Build Ltd 178T: +91-2692-231070E: [email protected]: www.pbl.co.in

Precise Engineering Works 73T: +91-278-2470868E: [email protected]

Prem Brothers 212T: +91-11-28117456E: [email protected]: www.powermaster-india.com


Premier Enterprise 196T: +91-281-2387556E: [email protected]: www.premierlathe.co.in

Premium Transmission Ltd 117T: +91-20-27488886W: www.premiumtransmission.com

Procon Technologies Pvt Ltd 206T: +91-79-27492566E: [email protected]: www.procon.co.in

Radix Electro Systems Pvt Ltd 10T: +91-22-42537784E: [email protected]: www.radix.com

Rajamane Industries Pvt Ltd 177T: +91-80-43659000E: [email protected]: www.rajamane.com

Rajindra Machines (P) Ltd 195T: +91-1871-242763E: [email protected]: www.rajindra.net

Rattan Hammers 205T: +91-161-2685235E: [email protected]: www.hammersindia.com

Reality Automation And Security Systems Pvt Ltd 251T: +91-20-32922630E: [email protected] W: www.vighnaharta.in

Regulateurs Georgin 171T: +33-01-46126000E: [email protected]: www.georgin.com

Reva Industries Ltd 18T: +91-129-4185400E: [email protected]: www.revacranes.com

Rexello Castors Pvt Ltd 209T: +91-22-4091777E: [email protected]: www.rexellocastors.com

Riat Brothers (India) 229T: +91-9815934018E: [email protected]: www.riatgrinders.com


Rightvision (India) Pvt. Ltd. 232T: +91-120-4261026E: [email protected]: www.rightvision.biz

Rishabh Instruments Pvt Ltd 17T: +91-253-2202202E: [email protected]: www.rishabh.co.in

Rittal India Pvt Ltd 43T: +91-80-23519792E: [email protected]: www.rittal-india.com

Roto Linear Systems 183T: +91-080-23572855E: [email protected]

S&T Engineers 19T: +91-422-2590810E: [email protected]: www.stengineers.com

S.B. Pumps 210T: +91-22-25784069E: [email protected]: www.machbow.com

Sahyog Enterprise 228T: +91-278-2446848E: [email protected]: www.siddhapuradrills.com

Sameer Linkages Pvt. Ltd. 60T: +91-265-2638941E: [email protected]: www.sameerlinkages.com

Samson Extrusion Ind Pvt Ltd 157T: +91-22-23422238E: [email protected]: www.samson-grp.com

Sandvik Coromant India 103T: +91-20-27104725E: [email protected]: www.sandvik.coromant.com/in

Satyabhumi Machine Tools 137T: +91-278-2438241E: [email protected]: www.prakashmachines.co.in

Satyaprakash Machine Tools 216T: +91-278-3012407W: www.spdrills.com

Seal Jet Seals 217T: +91-20-27121581E: [email protected]


ADVERTISERS’ LIST



Search - Investment Destination-West Bengal 218T: +91-22-30245000E: [email protected]

Shavo Technologies Pvt Ltd 170, 225T: +91-20-26059641E: [email protected]: www.shavogroup.com

Shenoy Engineering Pvt Ltd 189T: +91-80-28361767E: [email protected]: www.shenoyengineering.in

Shikovi Heat Gen Technologies Pvt Ltd 231T: +91-22-27607758E: [email protected]: www.shikovi.com

Shilpa International (Impex) Pvt Ltd 183T: +91-40-27849020, 27840698E: [email protected]: www.shilpagroup.com/si

Shree Prayag Air Controls (P) Ltd 216T: +91-120-4733333E: [email protected]: www.spacpneumatic.com

Shree Saikrupa Hydro Marketing 185T: +91-79-22800836E: [email protected]: www.bosspumps.in

Shreeram Engineers 169T: +91-79-22901542E: [email protected]: www.shreeramahmedabad.com

Shridhan Automation Pvt Ltd 199T: +91-80-28431847E: [email protected]: www.shridhan.com

SKF Economos India Pvt. Ltd. 65T: +91-11-41098880-89E: [email protected]: www.economos.com

Sonal Magnetics 189T: +91-79-22872349E: [email protected]: www.sonalmagnetics.com

Spareage Seals Ltd 133T: +91-22-25800972E: [email protected]: www.spareage.com

Sreelakshmi Traders 221T: +91-44--24343343E: [email protected]: www.sreelakshmitraders.com


Statfield Equipments Pvt. Ltd. 241T: +91-20-22922180-82E: [email protected]: www.statfieldequipments.com

Sumitron Exports Pvt Ltd. 47T: +91-11-41410631E: [email protected]: www.sumitron.com

Sunil Enterprise 222T: +91-281-2926239E: [email protected]

Surface International 159T: +91-09413329749E: [email protected]: www.surfaceint.com

Susheel Engineering Corporation 208T: +91-22-25007976E: [email protected]

Swagelok Manufacturing Company 45T: +91-22-66625984E: [email protected]: www.swagelok.com

Swam Pneumatics Pvt Ltd 211T: +91-120-4696222E: [email protected]: www.swamatics.com

Tandem Hydraulics Pvt. Ltd. 206T: +91-120-4159611E: [email protected]: www.tandemhydraulics.com

Techaids .FGFT: +91-172-4379995E: [email protected]: www.techaids.in

Teknic 29T: +91-22-26592392 / 94E: [email protected]: www.teknic.co.in

The Indian Electric Co 59T: +91-20-24474303E: [email protected]: www.indianelectric.com

Theeta Electricals Pvt Ltd 247T: +91-124-4387400E: [email protected]: www.theeta.com

Tools & Appliances Corp 79T: +91-2764-233983E: [email protected]: www.imitoolsindia.com


Tox Pressotehnik India Pvt Ltd 169T: +91-20-66538300E: [email protected]: www.tox-de.com

TPG Motors & Drives (India) Pvt Ltd 20T: +91-44--23634199E: [email protected]: www.tpg-tw.com

Trident Precision International 222T: +91-11-41425326E: [email protected]: www.trident-precision.com

Trident Products Pvt Ltd 230T: +91-124-4300626E: [email protected]

Tussor Machine Tool Ind Pvt Ltd 165T: +91-422-3200183E: [email protected]: www.pinachoindia.com

U-Tech Associates 127T: +91-80-23390309E: [email protected]: www.u-techindia.com

Venus Engineers 182T: +91-11-32222661E: [email protected]: www.venusengineers.com

Vinit Engineering Works 163T: +91-281-2312091E: [email protected]: www.balajilathe.com

VKE Valves Industries Pvt Ltd 210T: +91-22-26763764E: [email protected]: www.vkevalves.com

Weldor Engineering Pvt Ltd 181T: +91-281-2360242E: [email protected]: www.weldor.com

Wendt India Ltd 151T: +4344-405500E: [email protected]: www.wendtgroup.com

Werner Finley Pvt Ltd 219T: +91-80-23289889E: [email protected]: www.wernerfinley.com

Zenith Hydromatic 228T: +91-79-22812945E: [email protected]: www.hydraulicsystemsindia.com


Vo

l 13 No

11

No

vemb

er 2010

Reg. No: G2/MH/MR/NMD/81/2008-2010 RNI Reg. No: 67827/98WPP Licence No: MR/TECH/WPP – 355/Navi Mumbai/2008–2010

Licence To Post Without Pre-Payment at Mumbai Patrika Channel Sorting Office, Mumbai G.P.O., Mumbai 400 001. Date Of Posting: 22nd & 23rd Of Every Previous Month/English & Monthly.

268

search - november 2010

Documents