Search - October 2010

O C T O B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 27

EDITORIAL

Archana [email protected]

ining sector has been making headlines lately…and it is not even making the other sectors go green with envy, because green, among others, is incidentally one of the reasons why this sector is getting negative publicity from all quarters. Suddenly the focus of media, ministry and the nation is on the mine and mineral sector. Understandably so, the stakes are high for both, the industry as well as the environment, not to mention the natives.

Lately, the minute you blurt out the word mine, all eyes and ears are on you. You are supposed to choose your camp; it is a choice between tight-lipped white collared group or slogan shouting activists. With lot of hardline approach floating around, we are locked in a no-win battle. We cannot ignore the demands for unrestricted and abundant flow of minerals, which is critical for India’s growth… cannot even be less concerned about preserving the nature and the natives. Both are critical for India’s holistic and sustainable growth.

It is a complex situation and there are wheels within wheels. The message from the government to the corporates and investors is loud and clear, the latest rejections of project approvals is not a part of ‘corporates Vs tribals policy’, but it is an action against illegal mining practices. Though the controversies surrounding the mines and mineral sector is not a simple one, there is no denying the fact that all the stakeholders whose fortunes and future is at stake – be it the miners, the natives, the environment conservationists or the rest of the ecosystem – has to work together to light the path of future mining practices, which should be all-enriching.

With this as a backgrounder, the October issue of SEARCH is dedicated to the initiation of a new era of mining and mineral sector, which is cleaner, greener and all-enriching. We have also talked about the synergised growth of mines and material handling industry, with special emphasis on technology and automation.

What is also unique is the fact that we are not forecasting trends and market opportunities in this sector sitting far away from where the action is…we travelled to gather the first-hand information, an experience that was enlightening, and expert opinions that is going to shape the fortunes of this sector and our country.

As a part of this drive, we visited the mining frontrunners, National Aluminium Company (NALCO) and Central Coalfields (CCL). We also managed to get expert views of Mr AK Singh, CMD, Central Mine Planning & Design Institute, and Mr RK Saha, CMD, Central Coalfields… do read the in-depth facility visit report and exclusive interview.

With sustainable mining under spotlight, we also did reportage on how mining equipment industry is fuelling growth with an insightful interview of Mr GK Pillai, CMD, Heavy Engineering Corporation. It is a must-read to know the plethora of opportunities that still remain untapped and the roadmap to tap these hidden growth treasures. It is also time that the industry looks inwards and finds solutions to make India the top mines and minerals producing country, but while we do that, let us not forget to don our green hats.

ENTWINED FORTUNES, UNPARALLEL GROWTH

M

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, Chaitanya Surpur (Cover Illustration)

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

28 SEARCH - THE INDUSTRIAL SOURCEBOOK | O C T O B E R 2 0 1 0

‘If India has to grow at 9-10 per cent, then mining has to contribute in an unprecedented manner’AK SINGH, CMD, Central Mine Planning & Design Institute (CMPDI)

EXTREME MINING

CONTENTS

PPg 60g 60

NATIONAL ALUMINIUM COMPANY | Pg 72

Taking The Path Less Trodden

VIEW FROM THE TOP

Making the impossible possible and overcoming all the challenges requires strong will, determination and a sustainable futurist outlook. Creating history in the bauxite mining in a region with absolutely no basic facilities and connectivity with the outside world, National Aluminium Company (NALCO) has proved this to be true. Standing tall, tackling these extremities for decades is NALCO’s Panchpatmali mine at Damanjodi, Orissa, which has changed the way bauxite mining is being done in India. Because of its high-tech, eco-friendly and socially-oriented business approach, it has earned a high stature and set a precedent for other companies to follow.

SPOTLIGHT80 NALCO Damanjodi Refinery Refining With Excellence

‘Higher economic productivity can make mining products affordable’GK PILLAI, CMD, Heavy Engineering Corporation (HEC)

PPg 66g 66

40 NATIONAL NEWSLatest In The Indian Manufacturing

27 EDITORIALEntwined Fortunes, Unparallel Growth

54 WORLD NEWSSnapshot Of Latest Global Happenings In Manufacturing Domain

TECHNOLOGY TRENDS148 Technology Update Cutting Edge Solutions

NEWS ANALYSIS46 Indian Diesel Genset Market Energising Prospects

50 Business@Orissa High On The Investment Radar

APPLICATION ZONE154 Machine Vision Systems Market On The Crossroads

EQUIPMENT BUYING GUIDE156 Overhead Cranes Sourcing The Best Fit Solution

DESIGN INNOVATIONS161 Innovators’ Outlook ‘Design Success Can Be Achieved By Identifying Features That The Customer Values’ Axel Schmidt, Partner & Head, Roland Berger’s Global Operations Strategy Competence Centre

164 Factory And Plant Equipment Simulating A New World Of Design


PRODUCT UPDATE

CONTENTSSPECIALS IN THIS ISSUE

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

262 PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

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

274 ADVERTISERS’ LIST Advertisers’ List In Chronological Order

PRODUCT UPDATE198 Mining Latest Products In Mining

202 Material Handling Latest Products In Material Handling

210 Engineering Materials Latest Products In Engineering Materials

218 New Launches Latest Products In The Offing

222 General Products Rolling Out The Best-in-class

VIEW POINT168 Profit Mantra

Charting The Blueprint To Success

CASE STUDY182 Statoil Pumping Up Production Levels Through ‘Smart’ Technologies

SMART STRATEGIES174 World-Class Manufacturing Unlocking The Potential To Be The Best

FACTORY FUNDAMENTALS186 Proactive Maintenance Surpassing Conventional Techniques

CURTAIN RAISER197 India Energy 2010 & India Nuclear Energy 2010 Aiming For ‘Power’ful Future

SME ADVANTAGE192 Data Analysis Driving Business Performance Through Visibility

254 International Products Showcasing Product In A Global Arena

PREVIEW180 HiTech Manufacturing Show Envisioning The Future Of Manufacturing190 ENGINEERING EXPO Projecting ‘A Promising Pune’

INDUSTRY UPDATEMining

84 Sustainable Mining Paving The Green Path

90 Spotlight Central Coalfields - Living The Legacy

98 ‘CCL Has Accorded The Highest Priority To Environment Management For Sustainable Mining’

RK Saha, CMD, Central Coalfields

INSIGHTS & OUTLOOKMaterial Handling

107 Mining & Construction Equipment

Excavating Strong Potential

114 Material Handling Equipment

Lifting Up The Competitiveness Quotient

120 Mining Equipment Growing On Strong

Fundamentals

126 Innovative Solution For Open Cast Mines

Reliability And Ease Of Maintenance By Design

ENGINEERING MATERIALS

132 Smart Engineering Materials Unravelling A New World Of

Opportunities

138 Ceramics Creating A New Wave In Energy

Technology

143 New Materials Adding Substance To The

‘Material’ World

Details on pg.177, 190, 195

NATIONAL NEWS


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 June 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-June

10)

% age to total Inflows

(in terms of US $)Mauritius 8,520 42%Singapore 4,245 10%U.S.A. 1,162 7%U.K. 707 5%Netherlands 1,565 4%Japan 1,966 4%Cyprus 486 4%Germany 189 2%U.A.E. 530 1%France 312 1%Total FDI Inflows *

26,418 -

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

2010-11 (Up to June 10) # 26,418 5,807

2009-10 (Up to June 09) 34,211 7,016

% age growth over last year (-) 22.78 % (-) 17.22 %

Sector 2010-11 (April -June

2010)

% age to total Inflows

(In terms of US$)

Services Sector 3,149 21% Computer Software & Hardware

1,427 9%

Telecommunications 4,182 8% Housing & Real Estate 1,595 8% Construction Activities 1,008 7% Power 2,004 4% Automobile Industry * 302 4%Metallurgical Industries 2,602 3%Petroleum & Natural Gas 951 2%Chemicals 404 2%

Note: Cumulative Sector- wise FDI equity inflows (from April 2000 to June 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)

he Indian car m a n u f a c t u r i n g industry is slated to witness an

exponential growth in the next decade and according to projections indicated by the Automotive Component Manufacturers’ Association (ACMA), the Indian auto component industry is expected to grow by over four-fold to $113 billion by 2020.

The total passenger car production in the country will jump four times to reach 9 million cars in the next ten years, ACMA said in its forecast report. Although a major chunk of this will come from the fast growing domestic market, exports are likely to form

around 35 per cent of the total market by 2020. Indian component industry is

expected to clock total revenue of $25 billion in the current fiscal. Given high growth projections, the local component industry is looking to invest $35 billion over the next decade.

Production of two-wheelers

and three-wheelers are expected to double to 2.2 crore units by 2015 and reach

three crore units by 2020 driven by current low penetration levels, expanding rural sales and growth in exports. Commercial vehicles production is forecast to cross the 22 lakh-units mark in the same period.

TAuto component industry to see 4-fold growth by 2020

ujarat is set to save close to Rs 400 crore a year with the Centre revising

its earlier notification of levying custom duty from the power plants that are supplying power from special economic zone (SEZ) into domestic tariff area. The charges for the power project developers have come down to just 10 paisa per unit instead of the earlier 16 per cent duty, which was almost 50 paisa per unit for tariff of Rs 3 per unit. The most beneficial

companies in Gujarat would be Adani Group company, Adani Power and its customer, state utility Gujarat Urja Vikas Nigam (GUVNL). Adani Power operates 990 MW of generation capacity at Mundra SEZ and sells its electricity to GUVNL.

According to an energy expert, players like Adani Power that are catering to domestic tariff areas from SEZ will get major boost on account of revised notification. Adani Power will have to pay only 10 paisa per unit for its current

generation of 20 million units of electricity instead of the earlier duty of 50 paisa. As per the revised rate for 1,000 MW power project, duty would be Rs 100 per 1,000 units in case of imported coal fired generation and Rs 110 per 1,000 units in case of gas-based generation. Similarly, projects below 1,000 MW of capacity will have to pay only Rs 40 per 1,000 units in case of imported coal fired station and Rs 60 per 1000 units in case of gas based project.

GDevelopers of power project in SEZs get duty relief

ndia’s industrial p r o d u c t i o n witnessed an increase of 13.8

per cent in July 2010, surpassing analysts’ forecasts. The official Index of Industrial Production (IIP) grew by 13.8 per cent as compared to 7.2 per cent in July 2009. The rise was powered by a 63 per cent jump in output of

capital goods and 22.1 per cent in that of consumer durables.

Among the major constituents of the IIP, the index for manufacturing has registered an annual growth of 15 per cent for July 2010 as compared to 7.4 per cent in the corresponding month in 2009, while mining grew at 9.7 per cent for July 2010 in comparison

to 8.7 per cent in July 2009 and electricity logged a growth of 3.7 per cent in July 2010.

Till July 2010 in the current fiscal, the economy witnessed a cumulative industrial growth of 11.4 per cent, with the figures working out to be 12.2 per cent for manufacturing, 10 per cent for mining and 5.2 per cent for electricity.

IIndustrial production rises by 13.8 per cent in July 2010

As per the estimates of ACMA, the local component industry would create an additional employment for over 10 lakh people in the next decade. To meet the increased requirement of skilled hands, the government has decided to set up a dedicated skill development body for the auto industry to train 25

million people in the next decade.

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

NATIONAL NEWS


EVENTS In India

rundfos India has recently launched ‘The Incredible Indian Pump Yatra’

- a fully equipped business lounge on wheels, equipped with a series of interactive displays of a wide range of industrial pumps.

The journey that started from Ahmedabad on September 10, 2010 will cover various cities of Gujarat enabling visitors to gain hands-on experience of Grundfos products & solutions. Commenting on the initiative, Ranganath NK, MD, Grundfos Pumps India, elaborates,

“Grundfos India has been directly associated with the Indian industrial market for over 10 years. Our intensive research in the market has revealed that in many engineering industries, there exists a great potential for energy savings, even in the small and medium range pumps. To address this gap, Grundfos has a wide range of energy efficient pumps.”

Highlighting on energy efficient technologies, Ranganath adds, “For decades, Indian industrial end-users were used to conventional low cost

but inefficient pumps. Further, the pump recommendations and selections were made more on historic assumptions. Grundfos has the distinction of introducing pump and pump technologies that are very efficient and reliable and did not exist in India. These pumps and systems not only conserve energy but also save space. Moreover, the cost of installation/maintenance and the overall life cycle cost are far lower than the pumps that were in the market. The payback in most cases was a year or lesser.”

GGrundfos launches ‘Incredible Indian Pump Yatra’

he Union Commerce & Industry Ministry is in the process of

formulating a draft policy to attract investments for setting up mega manufacturing hubs in the country.

Anand Sharma Union Commerce & Industry Minister said, “The Ministry is in the final stages of formulating the policy,

which is most likely to be placed before the inter-ministerial group by the end of October this year. This policy will facilitate timely approval and clearances of investments needed for large manufacturing hubs.”

The Minister stressed that engineering and manufacturing need to go hand-in-hand to have a meaningful impact on

the economy. “India has tremendous potential in manufacturing though our share in global exports is just 1 per cent,” he remarked. However, Sharma said that before these investments are made, efforts should be directed towards skill training and up-gradation of the workforce, given that millions are going to join the labour pool in the near future.

T

Govt plans policy to attract funds for building manufacturing hubs

Concurrent Shows

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.

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

MaharashtraFebruary 17-19, 2011

Bombay Exhibition Centre

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 4649/4651Fax: 022 30034499Email: [email protected]: www.engg-expo.com

odrej Material Handling has joined hands with IMER International for

their Iteco range of powered access equipment in India. Godrej will offer powered scissor lift from Iteco’s full product range.

Iteco’s range of powered access equipment is known for its innovative design and features which no other manufacturer offers. For instance, Iteco’s scissor platforms are drivable at full platform height. The platform

capacity remains maximum even on deck extension. Iteco powered access equipment is known for its design and rigidity.

The powered access equipment market has been g r o w i n g consistently in the last few years in India. Godrej and IMER have decided to cater to this growing demand by

offering the Indian customer a wide range of powered access equipment.

Godrej and Iteco both have a long-term vision towards this business in India. Initially, Godrej will be marketing and

servicing the Iteco products, followed by rapid steps to manufacture popular models of the range in near future.

GGodrej and IMER Group tie up for powered access equipment

NATIONAL NEWS


oday, with the requirement of large finances in s o l a r

project development, project financing seems to be one of the major barriers to this market. To address this issue, Confederation of Indian Industry (CII) and Indian Renewable Energy Development Agency (IREDA) recently organised an exclusive interactive session on ‘Enabling

Financing of Solar Power Projects in India’ in Mumbai.

A major point put forth at

the meet was that banks funding renewable energy projects will require long-term resources,

for which they should be allowed to float tax-free solar bonds. S Sridhar, CMD, Central Bank of India, said “Bankers are concerned, but not averse to financing these projects. Banks should be allowed to float tax-free solar bonds, of about 10-15 years duration. This will enable them to raise long-term resources.

PROMACH 2010Focus: Tools and Tooling EquipmentWhen: October 1-4, 2010Where: Bangalore International Exhibition Centre, BangaloreTel: 080-80-65833234Email: [email protected]

INDIA ENERGY 2010Focus: Technologies in renewable energy When: October 7-9, 2010 Where: Bombay Exhibition Centre, Mumbai Tel + 91 22 6612 2644Fax: + 91 22 6612 2626-27Email: [email protected] Website: http://www.ubmindia.com

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]

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

EVENTS In India

SMEs (Micro, Small and Medium Enterprise) are widely

regarded as the growth engine of the Indian economy.

The sector constitutes 95 per cent of the overall industrial units and contributes 40 per cent of the industrial output along with 40 per cent of the exports in India. With their expansion and exposure to international markets, the sector has been evolving its entrepreneurial skills over the years.

In view of the magnitude of this imperative sector, the

Maharashtra Economic Development Council (MEDC) & Indian Education Society’ IES

Management College had recently organised a two day

business conference ‘MSMEs – Gearing up to Global Competitiveness’ in Mumbai. The event focussed on the importance of MSMEs in India’s economic growth and delved in depth into various challenges faced & ways to overcome them.

Rajendra Darda, Minister for Industries, Maharashtra, announced the launch of the new industrial policy for the

MSME sector during his inaugural speech at the conference.

MMEDC hosts MSME Global Conference

We are planning to have 30 per cent extra land reservations of plots for MSMEs in MIDC. The state government will also have a new industrial policy, next year, which will have a special section for the

MSME sector.

RAJENDRA DARDA,Industries Minister, Maharashtra

TCII supports solar power projects financing in India

We have completed first phase with power purchase agreements signed for 100 MW. Apart from this, expressions of interest

for another 700 MW are with us.

DR FAROOQ ABDULLAH,Minister for New & Renewable Energy,

Government of India

merging dynamics of the Indian power market make it pertinent for the

industry players to realign their strategies and operating models to the changing sectoral trends. Buoyed by incentives & support from the government as well as advancements in the

technology, the Indian T&D sector is all set to play a critical role in defining the future of the industry and in ensuring sustainability of the Indian energy sector.

To tap this market, CII with SEARCH as its media partner are organising a seminar on ‘Challenges in Transmission and

Distribution’ on October 1 in New Delhi. This seminar will bring together the industry, policy makers, and service providers all under one roof to derive and arrive at consensus on vital issues and plan to leverage on emerging opportunities and face upcoming challenges boldly.

ECII to host seminar on transmission & distribution

INDIAN DIESEL GENSET MARKET


he growth in manufacturing and construction activities has intensified the need for continuous supply of power in India. Several studies reveal that at

present there is a demand-supply gap of about 17 per cent when it comes to power generation in the country. This has opened up huge market opportunities for players in the power and allied sectors. And one instance of this is the creation of a highly competitive market space for the generator set manufacturing companies. The boost in diesel genset sales in the country is attributed to growth spurt in industrial sectors and peak power deficit being faced in India. Amol Kotwal, Deputy Director – Energy & Power Systems, South Asia & Middle East, Frost & Sullivan, avers, “The diesel genset market is estimated to be around 1.5 lakh units in FY 2009-10. The genset market witnessed a growth rate of 15 per cent in revenue terms, chiefly driven by demand from retail and telecom sector, during the period.”

DEMAND TRENDSDiesel genset market can be broadly divided into three segments. Namely, small diesel generators (15-75 kVA), medium diesel generators (75.1-375 kVA), and large diesel generators (375.1-2000 kVA). Acute power shortages coupled with high growth in manufacturing, infrastructure, telecommunication, information technology (IT), and IT-enabled services, retail segment, etc., has triggered market growth for all the diesel genset segments.

In the recent past, telecom sector was the key growth driver for the small diesel generator set market. Even though, the 15-75 kVA diesel generator set market witnessed a slight slowdown in the last few years on account of saturation in certain telecom circles, industry experts predict that with the advent of 3G services in 2010, the small diesel generator market will revive and witness a high growth rate. According to industry estimates, the DG set market in India (15-2000 kVA range) was estimated at `60,253 million with 1,47,040 units in the financial year 2006-07. That is now projected to grow

to `12,2230 million with sales of 2,05,450 units.

D Srinivasa Reddy, Managing Partner, Reddy Generators, says, “During recession, the diesel generator market was witnessing a low market growth. However, in 2010 the genset market has started to pick up and currently, it is having a high growth rate mainly due to the boost in telecom sector. Following this, real-estate, manufacturing, construction, retail and consumer market are driving the growth of this segment.”

TAPPING THE MARKETObserving the current trend and demand rise, Indian diesel genset manufacturing companies are adopting innovative practices to tap this potential market. Major players like Mahindra & Mahindra, Kirloskar, Cummins, etc have introduced new brands for specified users. For example, foreseeing the huge potential, Mahindra & Mahindra has launched Powerol brand for the Indian market. Company report says that this new brand has helped to grow their business to `1,010 crore in 2009 from its earlier revenue of `51 crore in 2005. For

With the increasing demand-supply gap in power generation, diesel genset segment has bounced back riding on growing need for uninterrupted power for telecom and manufacturing sectors. Making smart moves, this segment is tapping emerging opportunities to enhance business prospects for the long run.

T

KTP RADHIKA JINOY

ENERGISING PROSPECTS

INDIAN DIESEL GENSET MARKET


the retail and consumer market, Cummins India announced its entry by introducing small power generator sets of 7.5 kVA and 10 kVA in the beginning of this year.

Sources reveal that the company plans to set up a separate retail channel for marketing these small generators through 300-400 retailers in the next 18 months. Kotwal says, “Indian diesel genset manufacturers have already geared up to take advantage of the current growing demand. However, adequate engine manufacturing and sourcing is required to address the market demands. In addition, the emphasis on sales and services network is important.”

Manufacturing companies are also developing new technologies and designs to augment growth. The emission norms in India are being continuously updated to match international standards. New technologies and designs will help the companies reduce emission and improve efficiency. “Previously, Indian diesel generators were causing high pollution and their carbon footprint was high. However, today, due to advancements in technology and design, emissions have reduced to a great extent,” says Reddy. Adding to this,

Kotwal says, “Stricter emission norm is expected in 2013. However, all major genset OEMs already have or are in process of enhancing the engine technology to meet emission norms. Hence, as per major genset manufacturers, change in emission norms is not expected to affect them. However, new norms may affect the unorganised engine manufacturers.”

THE FLIP SIDEEven though market is growing, the Indian diesel genset industry is still facing major challenges, which need to be addressed on priority. Import of low-cost diesel generators and the competition from unorganised players are some key constraints that have slowed growth of late. Reddy says, “Low-cost imports, especially from China, are impacting the domestic manufacturers & suppliers. This is also hurting the profit margin.” Another threat is the hike in diesel price. Industry experts predict that the global price hike of crude oil will result in the rise of diesel prices significantly, thereby causing huge losses to the end-users. This necessitates shutdown of diesel-based generation that will negatively impact the demand for new diesel generators in the

future. Supporting the point, Kotwal points out, “Shortage of diesel engine manufacturing capacity in India and lack of availability of skilled manpower, who are shifting to other lucrative professions, are posing as major challenges to the Indian diesel genset industry.”

BRIGHT FUTURELooking forward, the degree of competition in small and medium genset market is expected to increase significantly. Kotwal asserts, “In the near future, the genset industry in India is set on a robust growth path, fuelled by power supply deficit and investments in industrial and commercial activities, where reliable back-up power is a necessity. The market is expected to witness a CAGR of 8.4 per cent for the period 2010-14.”

Noticing the demand trend, several new participants, both domestic and international suppliers are planning to venture into the diesel genset market. However, the players in this space have to focus on product positioning, service strategies and better customer service in order to win the competition and enhance their business prospects in the long run.


his year, Orissa grabbed the highest number of investments in the country. Emerging as a preferred business destination, the state has outrun

Maharashtra and Gujarat in major sectors like mining and power. With this development, the above-mentioned states and those in Western India seem to have lost their status of the most preferred destination for investment in India.

According to a Reserve Bank of India (RBI) study on corporate investment, which considered 796 projects in FY10, involving bank/FI fundings, Orissa attracted the highest investments of Rs 74,757 crore in 31 projects, accounting for 13.4 per cent of total investment intentions during the year. Maharashtra ranked a distant second with investments worth Rs 49,480 crore in 124 projects. Gujarat, which used to be a top investment destination earlier, managed to attract only Rs 16,572 crore in 72 projects

during FY10 compared to Rs 59,887 crore in 77 projects in the previous year. The other top investment destinations were Andhra Pradesh and Chhattisgarh. According to an economist, “Much of these investments are in mining projects that are coming up in Orissa, with the state opening up this sector and addressing a number of hurdles faced by it. Most of them are high value projects. This could result in investments picking up in projects that are already cleared.”

REASONS BEHIND THE DEVELOPMENTOrissa, a state which was not known to be very investor-friendly till date, managed to grab maximum amount of investments, thanks to the largely capital-intensive mining projects coming up in the region. However, many believe that these investments are three-fold. Nilesh B, MD, Orange Financials, elaborates, “Orissa is attracting major investments in power, mining and

steel. Of these, the major chunk is focussed on mining as the state has abundant natural resources in the form of iron ore, aluminium, platinum, precious metal and base metals. Companies like Mittal Group, POSCO and Vedanta have already entered this space, but are facing multiple problems due to regulatory issues.”

Highlighting the issues that companies entering this region are facing, PK Mohapatra, Executive Director, Mines & Refinery, NALCO, avers, “All the major aluminium companies like Utkal Alumina, Hindalco, Vedanta are already in Orissa, but so far these companies could not initiate the mining process because of local resistance and other issues. Companies need to give due consideration to the people’s needs and sentiments, and consider it as a part of the investment. Unless these companies do something for the people, the issues would not get resolved.”

According to the RBI report, the

T SUMEDHA MAHOREY

HIGH ON THEINVESTMENT RADARWith investments worth over Rs 74,757 crore in 31 projects in FY10, Orissa has emerged as the undisputed leader in total investment intentions, a total turnaround to its previous image of not being a very investor-friendly state. With mining and power companies making a beeline for Orissa, more investments are slated to come into this state in the years to come.

BUSINESS@ORISSA

BUSINESS@ORISSA


location of high value projects tends to change the spatial pattern from year to year. The location, in turn, depends on a host of other factors like the nature of the project, market size, growth prospects, availability of skilled labour, suppliers, adequate infrastructure, etc.

Another notable feature on the pattern of project investments is that the geographical distribution of the projects was seen to be broad-based in FY10. There are growing investment prospects in Chhattisgarh, Orissa, Tamil Nadu, Arunachal Pradesh and Rajasthan as reflected in the increasing share of project expenditure intentions in these states in relation to last year.

POWER GENERATIONDuring the last decade, the power generation in Orissa had been adversely affected by widespread criticism. Taking note of this, the state government has started pursuing the companies that have signed MoUs to complete their power plant as per the deadline.

Soon after this decision, many private players had evinced keen interest to set up power plants, mostly coal-based as the state has huge coal deposits. Elaborating on this, Narendra Nainani, Chairman & MD – Bullet Advice for Indian Stocks, points out, “Natural resources in Orissa are in plenty, but they have not been explored by the government as yet. With aggressive companies making the entry, 8-10 per cent growth in investment can be witnessed in mining in this region. Also, with the surge in power companies in the state, mining production is bound to increase.”

Around 26 power companies from the private sector have signed agreements with the state government to set up thermal power plant with an installed capacity of 32,000 MW. Besides, the state has agreed to host three of the five new ultra mega power projects of 4,000 MW each. Apart from this, after confining itself to mining since the last two decades, the state-owned Orissa Mining Corporation is now diversifying into power and coal mining sector by setting up 2,000 MW thermal power plant near Rengali in a joint venture with Orissa Hydro Power Corporation, with an investment of Rs 8,000 crore.

INCREASING COMPETITIONWith multiple projects coming up in the mining and power sector, more investments are projected to come up in this state. This would lead to intense competition and open up more opportunities for Orissa. Commenting on the future market scenario, Nilesh avers, “With these developments, competitive growth is evident. Competition in any industry is both, investment- and consumption-driven, thereby creating a win-win situation for all.”

FUTURE INVESTMENT DESTINATIONThe government initiatives in opening up the state for further investments have created a conducive environment for companies looking forward to enter mining and power sector in the future. Opining on the same, Nainani says, “Investments in both mining and power will rapidly go up in the future. Amidst this, the government needs to create a green channel for companies, which are planning to invest in the state. It also needs to fasten the resolution of the increasing number of applications, which are coming in from the mining and power sectors. Wastage of time should be decreased as much as possible.”

WORLD NEWS


rench industrial output beat forecasts and experienced a

good growth of almost 0.9 per cent in July compared to the level in June. This growth was powered by a sharp rebound in the auto sector, the national statistics institute INSEE reported. This growth in July came after there was a decline of 1.7 per cent in June compared to the previous month.

The overall manufactured production, which excludes the mining and construction sectors, registered a rise of 1.4 per cent in July compared to the fall of 1.2 per cent experienced in June. The July performance is clearly much better than expected, said analyst Laurence Boone, Barclays Capital, noting that her bank had foreseen a gain of around 0.2 per cent.

However, at research group Xerfi, economist

Alexander Law cautioned that there is no clear trend that has emerged. “Given the weak state of industry order books, the end of the year could be rather complicated.” he explained. Although following the drop of 6.5 per cent in June, and with the July output in the auto sector surging6.5 per cent in July,“The volatility that has characterised this industry for several years is far from over,” said Law.

Intertool MoscowFocus: Tools & Tooling EquipmentWhen: October 5-8, 2010Where: Crocus Expo International Exhibition Center, Moscow, RussiaTel: + (1)-(203)-8404800Fax: + (1)-(203)-8404801

BIMUFocus: Tools & Tooling EquipmentWhen: October 5-9, 2010Where: Fiera Milano, Milan, ItalyFax: + (39)-(2)-26255214

EMCW Expo 2010Focus: Electrical manufacturing and coil windingWhen: October 18-20, 2010Where: Gaylord Texan Convention Centre Grapevine, TexasTel: 619-435-3629Fax: 619-517-3707

MM LiveFocus: Manufacturing & RepairWhen: October 19-20, 2010Where: Ricoh Arena, Coventry, United KingdomTel: + (44)-(1829)-770037Fax: + (44)-(1829)-770047

2010 Advanced Manufacturing & Technology ShowFocus: Manufacturing and Machinery When: October 20-21, 2010 Where: Dayton Airport Expo Center, 2900 McCauley DrVandalia, OH 45377 USTel: 937-512-3862Fax: 937-512-3224

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

EVENTS Abroad

hina, the world’s second largest economy has now become the fifth

biggest global investor even though Foreign Direct Investment (FDI) into the country is set to cross $100 billion this year. “Bucking international trends in both outbound and inward investments, China stepped up its outbound direct investment (ODI) to $56.5 billion, jumping from 12th position in 2008 to 5th in 2009. Also, FDI in the country this year was set to surpass $100 billion compared to $90 billion last year,” said Shen Danyang, Vice-Director of the Ministry.

During the first half of the year, China’s ODI to the US and the European Union went up by almost 360 per cent and

107.2 per cent, respectively, on a year-on-year basis. Its investment in ASEAN and Russia also grew by 125.7 per cent and 58.5 per cent. Jinny Yan, Economist, Standard Chartered Bank, Shanghai, predicts that the EU would continue to be a hotspot for China’s outbound investment

in the coming months, thanks to the ongoing European debt woes.

“The growth in both outbound investment from and inbound investment to China reflects the nation’s rising economic power and attractiveness as an investment destination,” adds Shen.

CChina emerges as fifth largest global investor

FFrench industrial output grows in July

In 2009, global ODI volume reached $1.1 trillion, and China contributed about 5.1 per cent of the total. This is just a beginning. Although the figure is already quite amazing, the volume is not large enough considering China’s economic growth and local companies’ expanding demand

for international opportunities.

SHEN DANYANG,Vice-Director of the Ministry, China

s exports reached their highest level in two years, the US trade deficit

dropped more than expected in July, official data showed. The Department of Commerce de-clared that the trade deficit dropped to $42.8 billion in July,

a 14 per cent decline from the previous month’s revised figure of $49.8 billion-its highest level in almost 20 months. The total exports in July increased by 1.8 per cent to $153.3 billion from June to its highest level since August 2008. A major reason for this was the strong sales of

aircraft, industrial machinery,computers and telecommuni-cations equipment.

On the other hand, imports fell 2.1 per cent from the previous month to $196.1 billion in July. The July deficit beat most analysts’ expectations of $47.3 billion.

AUS trade deficit pins down in July

WORLD NEWS


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

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

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

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]

EVENTS Abroad

heet Metal is a vital p r o d u c t i o n requirement for various products,

be it consumer goods or even heavy machinery. In an endeavour to tap this growing demand, the 21st International Sheet Metal Working Technology Exhibition ‘EuroBLECH 2010’, will open its doors in Hanover, Germany on October 26-30, 2010. The trade exhibition, this year, will

focus on innovative technologies of sheet metal working for the future. Enhanced fabrication processes for adapting to changing demand; intelligent systems for energy-saving and environmentally sustainable production; new materials and the latest trends in R&D will be on display. “The current situation, a period of economic regeneration, demands a great deal of innovative capacity from every company. After a difficult

time, it is important to now set the course by sourcing the right equipment. For industry experts from all over the world, EuroBLECH 2010, with its theme ‘Time for Innovation’, is therefore, the first choice to gain a comprehensive overview of trends and innovative technology, and to find suitable machinery and tailor-made solutions”, explains Nicola Hamann, Exhibition Director EuroBLECH.

SEuroBLECH 2010 to be held in Germany this October

ecently, Daimler,a leader inheavy truck m a n u f a c t u r i n g ,

announced that it will build a popular Mercedes-Benz model in Brazil to meet the fast growing demand in Latin America. The Actros truck, designed for long-distance transport is likely to be produced in Juis de Fora,

southern Brazil. “The move will enable Mercedes-Benz to respond more quickly and flexibly to the growing demand for trucks in Latin America, particularly in the rapidly expanding heavy-duty segment,” say officials.

With sales of 21,700 vehicles from a global total of 56,300, Brazil emerged as the truck unit’s biggest market in

the first half of 2010. Mercedes was surprised by

strong growth in Brazil, even though it had announced an extension of its biggest truck factory outside Europe, in Sao Bernardo do Campo, southern Brazil in March this year.

Building its trucks close to foreign markets will allow Daimler to significantly reduce costs.

RDaimler to build Mercedes truck in Brazil

ugust saw a growth in the manufacturing sector in China and Russia owing to

the constant rising domestic demand. Purchasing managers indexes (PMIs), which measure changes in business activity across thousands of private sector companies, showed diverging fortunes among Euro zone manufacturers which expanded at their slowest pace since February. The Markit Eurozone Manufacturing PMI for August dropped to 55.1 from 56.7 in July, marking its 11th month above the 50 mark.

Though recent data showed that Germany, Europe’s biggest economy is

expanding fast, the manufacturing growth in Germany slowed in August. Also, business in France accelerated but Italy and Spain experienced a drop in their manufacturing indexes. “We are at a delicate juncture of the global business cycle. Globally

there is a slowdown in the trade cycle which first affects the economies which are reliant on it,” averred Silvio Peruzzo, RBS. In addition, led by weakest expansion in new orders for more than a year, growth in Britain’s manufacturing sector was slower than

expected. On the other hand, markets in China and India picked up at a good pace. A pair of China’s manufacturing surveys showed activity picked up last month, recovering from a government-engineered slowdown designed to calm an overheating economy. Also, Indian factories expanded rapidly in August, although slightly slower than in July.

AManufacturing grows in India and China, drops in Europe

We are at a delicate juncture of the global business cycle. Globally there is a slowdown in the trade cycle which first affects the economies

which are reliant on it.

SILVIO PERUZZO,Economist, Royal Bank of Scotland


REREQUISITES FOR EXPLORATION AND SETTING UP OF A MINEExploration and setting up of mines are two different concepts involving different processes. The exploration precedes the setting up of a mine. Once the exploration is successful and viable deposits are

found, only then the mining process starts.In the case of public sector units, for starting the exploration

process, a company has to take prospecting license and notify under section 4 of the Coal Bearing Areas (A&D) Act. Moreover, if the forest land is involved, then permission has to be obtained from the Ministry of Environment and Forest (MOEF), under the Forest Conservation Act. Even the private companies have to go for prospecting licenses. Once that is sought, the company requires licenses from the respective state departments under MMRD Act. The procedure for forest land is the same as that for public sector units. Nevertheless, as per the current norms, companies need to also ensure that they do not have more than 15-20 bore hole per 10 sq km.

After the completion of exploration process, the companies have to obtain acquirable land and then the mining can start. Companies like Coal India have been given the right to mine under section 11 of

the CBA Act. The land has to be acquired under LA Act with respect to non-forest land and through the help of state governments.

Local conditions and demands are considered by state governments for paying compensation. In order to kickstart the mining process, after the acquisition, clearance of environmental management plan is also required. Furthermore, permission under Forest Conservation Act, DGMS and controller of mines is also obligatory. All these formalities are necessary for setting up of mines. For setting up of explosive magazines, companies need permission from chief controller of explosives.

MINERAL EXPLORATION AND GEOLOGYCurrently, there are several new technologies available for the exploration process, which have brought down the cost and time factors. Most of these technologies are based on geophysical methods. However, in India, we are applying these technologies only for broad mapping of an area. Once the coal bearing areas are found, perspective exploration is done in two parts – regional exploration and detailed exploration.

Regional exploration is done by a central committee called Geological Promotion Council. The Council comprises representatives from Geological Survey of India (GSI), Ministry of Mines, Ministry of

“Considering the vast and untapped resources in the coal sector, I believe that India has a huge mining potential,” avers AK Singh, CMD, Central Mine Planning & Design Institute (CMPDI), during an exclusive interaction with Sandeep Pai. Providing insights on the various aspects

of coal mining and its future growth prospects in India, Singh shares his expertise on mine planning and development. Excerpts…

P

IF INDIA HAS TO GROW AT 9-10 PER CENT, IF INDIA HAS TO GROW AT 9-10 PER CENT, THEN MINING HAS TO CONTRIBUTE IN AN THEN MINING HAS TO CONTRIBUTE IN AN

UNPRECEDENTED MANNERUNPRECEDENTED MANNER

CMD, CMPDI


CMD, CMPDI

Coal, Mineral Exploration Corporation (MECL), CMPDI and the respective state governments. It decides the availability of coal in a particular area and prepares an annual programme based on it.

The Ministry of Mines & Ministry of Coal provides the funding for exploration. For the regional exploration, samples are collected from every 1-2 km spacing to obtain a broad idea, and once some evidence of minerals is found, then detailed exploration is done. In case of Coal India, detailed exploration is done by CMPDI. However, some captive coal blocks allottees are also doing it themselves. Detailed exploration is required for examining the reserve, strata, geological structure and quality, etc. It is done intensively by mechanical wireline coring drilling. We, at CMPDI, have also started using hydrostatic drills. Nonetheless, the quality of coal is determined by coal core samples generated during drilling.

GEOPHYSICAL METHODS TO SUPPLEMENT CORING DRILLINGUnder geophysical methods to supplement the coring drilling, CMPDI is using the following methods depending on the specific geological complexities in a particular area: Multi parametric geophysical logging High resolution shallow seismic Resistivity surveys Magnetic surveys

Keeping the future programme of exploration in view, CMPDI has initiated efforts to introduce some advanced geophysical methods to enhance coal exploration further, like 3D seismic survey and acoustic imaging system.

R&D IN COAL MINING So far in coal sector, only a limited effort has been made over R&D. However, recently the emphasis on R&D activities has increased significantly. This is majorly done under the S&T grant, provided by the Ministry Of Coal.

Standing Scientific Research Committee (SSRC), headed by Secretary to the Government of India, Ministry of Coal, oversees the research work. Under SSRC, there is a technical sub-committee headed by CMD, CMPDI, which is responsible for analysing the proposals submitted by scientists / engineers from CSIR labs or technical institutes like ISM (Dhanbad), CIMFR, IIT(Kharagpur), IT(BHU), etc. After the screening by the technical sub-committee, it is put up to the SSRC for final approval.

It should be noted that S&T grant is an ongoing system and newer projects are being taken up time and again. Recently, we have approved a few projects on identification of trapped miners in underground mines and development of a mobile goaf-edge support system. Apart from S&T grant, even Coal India has got its own R&D programmes. It performs research work on different aspects of mining and has come out with exceptional results. Till date, we have completed 312 research projects including 287 S&T projects and 25 R&D projects.

CHALLENGES FOR CMPDI Our greatest challenges involve working in remote and difficult

terrains, unapproachable areas especially during the monsoon season. Moreover, mining changes the land use pattern of any area. Thus, we have to be more conscious about environment preservation and bringing the land back to its original state. Furthermore, CMPDI is faced with the challenge of retaining its expertise. Previously, the pay scales were low and private mine operators comparatively offered attractive remuneration, so there was a sort of exodus from CMPDI. Although the attrition rate has decreased after the revision of pay scale, it still exists.

MONITORING LAND USE PATTERN OF OPENCAST PROJECTSThrough remote sensing and satellite information, CMPDI has been monitoring all the major opencast projects of Coal India. Every year, we conduct surveys about the land use information regarding the opencast mines and reclamation and plantations done there. Strikingly, we have found that the vegetation cover has actually increased post- mining. Thus, by way of analysing the reclamation aspects, we ensure that the land use environmental issues are taken care of.

ENVIRONMENTAL AND REHABILITATION FACTORS We have to conduct base line survey before setting up of any mine. This includes land use pattern, air quality, water quality, noise, reabilitation & resettlement (R&R), demographic survey, etc, which are presented in the Environmental Management Plan (EMP). Coal India has a R&R policy, which stipulates compensation package to the Project Affected Persons (PAPs). Along with compensation, it provides employment as well. For instance, Coal India provides one job for each 2 acre of land acquired. It is given in the form of a package. There are R&R schemes notified by the state governments also. So, the best compensation package is given by Coal India for acquiring land for its projects.

EXPLORATION OF ALTERNATIVE ENERGY Exploration services offered by CMPDI are till date limited to coal and coal-based energy sources. Apart from the conventional coal mining, alternative coal-based sources are being sought for exploration to meet the increasing energy demand in the country. Methane trapped in coal beds is an important additional clean energy resource, akin to natural gas.

With technological advancements, coal bed methane (CBM) along with its subsets coal mine methane (CMM), abandoned mine methane (AMM) (for recovery of methane during and after mining)

and ventilation air methane (VAM) (for recovery of methane from ventilation air of mine) have proved to be alternative resources of energy. In this regard, we have successfully implemented one demonstration project under UNDP in one of the mines in

Bharat Coking Coal (BCCL). Apart from this, development of the technology for underground coal gasification (UCG) is another non-conventional, coal-based energy that is being focussed upon. For UCG, 9 blocks that include 7 outside CIL and 2 in CIL have already been identified by us. Thus, we are exploring every possible way of energy generation.

Coal bed methane is an unconventional form of natural gas. Within next 15-20 years, CBM will contribute significantly to India’s energy requirement. About 33 blocks have been awarded for production of CBM, and

work has started in a few of them.


CMD, CMPDI

CBM AND ITS FUTURE IN INDIA CBM is an unconventional form of natural gas. Within next 15-20 years, CBM will contribute significantly to India’s energy requirement. About 33 blocks have been awarded for production of CBM, and work has started in a few of them. For example, Great Eastern Energy in Raniganj is laying a pipeline to start the supply of CBM gas to IISCO plants at Burnpur. Essar is developing a CBM block to supply gas to consumers in Durgapur and nearby areas.

Similarly ONGC-CIL block in Parvatpur is being developed and it may supply gas to Bokaro expansion steel project. They have already started compressing and selling it in cylinders. Ultimately their plan is to lay a pipeline and supply it to various industries. Going by the development activities shaping up in this domain, it can be said that various projects related to CBM have been initiated in the country.

LAND RECLAMATION AND BEST USE OF RESIDUESUnder Environmental Protection Act, a company has to leave the mining site in a safe condition. Thus, mining companies have to prepare a Mine Closure Plan. A Progressive Mine Closure Plan alongwith tentative detailed Mine Closure plan has to be submitted at the beginning of the mining process and every year some amount has to be deposited, which will be released during the closure of the mine. Moreover, some activities have to be done concurrently during the operation of the mines such as the back filling of the area once the mining has been done in that area.

A detailed Mine Closure Plan has to be submitted five years before the final closure of the mine for approval by MoEF. The company has to ensure that the land used is filled properly and revegetated. If refilling is not possible, then it has to be turned into a water body.

They have to make sure that the water body not only recharges the ground water but also be usable for fishing and other allied activities.

Coming to the residue part, for coal washeries where rejects are dumped or mineral processing plant where wastes are dumped, companies have to take special care of these dumps. They need to ascertain that leaching or the heavy metals present in the residue do not contaminate either the ground or surface water. Worldwide, there are numerous examples regarding the best use of land. In Spain, for instance, the old dump areas have been reclaimed beautifully and have been given to other industries to set up their base. By doing so, the skill of the local population is also utilised.

GROWTH PROSPECTS OF MINING IN INDIAConsidering the vast and untapped resources in the coal sector, I believe that India has a huge mining potential. Nevertheless, the contribution of mining to the overall GDP has been less, and if India has to grow at 9-10 per cent, then mining has to contribute in an unprecedented manner.

While scope of growth is huge, land acquisition has to be done in an effective manner taking the local people into confidence. This can be done by having a liberal compensation and land acquisition policy in place.

EXTREME MINING: NALCO

Taking The Path Less Trodden

on pg. 72

OLE OF EQUIPMENT IN INDUSTRIAL GROWTH Industries like steel, mining, automobile, etc, provide business to capital equipment manufacturers, who in turn provide competitive edge to these industries.

Manufacturing sector and other industries are interdependent. Each of them has to undertake some improvement and innovation in a continuous manner; otherwise there is a risk of getting eliminated.For instance, if an auto manufacturer plans to improve its welding quality which they think will sharpen their competitive edge, the equipment manufacturing companies have to shape a device that can satisfy this need. Again, if an equipment manufacturing company works on a furnace design for steel plant that can cut one per cent fuel cost for the steel plant operator, it will give the manufacturing company an edge over other companies working in the same segment. Thus, we can safely say that both manufacturing and core industrial sectors work in close co-ordination.

CONTRIBUTION OF EQUIPMENT IN MINING Equipment in mining sector plays a vital role in increasing the mining output and at the same time increasing economic productivity. Due to an ever-increasing demand for new products as a result of increasing population, the demand pressure is ultimately passed onto the mining sector. For instance, when there is more demand for power, the pressure is on coal mining; when there is demand for new car or machinery, better infrastructure etc, the pressure is on steel sector, ultimately resulting into higher demand for mining of iron ore, coal and alloying material.There has been tremendous demand on quantum of mining product. The needs could be met only through mechanisation of the mining process and improvement in mining technology coupled with better management to result in higher economic productivity. Higher economic productivity can

make mining products affordable and make our vision projects viable. So, both quantum and productivity are important; and use of advanced technology, mechanisation and automation is the way forward to achieve both.

In India, almost 75-80 per cent of mining activity revolves around coal and lignite, so in the Indian context if I am making reference to coal, it gives a relevant representation of the total mining sector.

“Innovativeness in design, considering the local conditions, will result in a win-win situation for both equipment manufacturers and the industry,”

opines GK Pillai, CMD, Heavy Engineering Corporation (HEC). In an exclusive interview with Sandeep Pai, he highlights the crucial role played

by equipment in mining and its interdependency with other industry verticals.

R

HIGHER ECONOMIC PRODUCTIVITY CAN MAKE MINING PRODUCTS AFFORDABLE

CMD, HEC

SEARCH - THE INDUSTRIAL SOURCEBOOK | O C T O B E R 2 0 1 066


CMD, HEC

POLICY INITIATIVESIn 1946, just before independence, India was producing around 30 MT of coal, almost entire quantity of which came from underground mining.During the first Five-Year Plan period, it was felt that mechanisation is essential to boost coal production by way of systematic and scientific development of the coal industry. This led to the setting up of the National Coal Development Corporation (NCDC), a Government of India undertaking in 1956 with the collieries owned by the Railways at its nucleus – the first major step towards planned development of the Indian coal industry. At the same time, the Singareni Collieries that was already in operation since 1945 became a government company under the control of Government of Andhra Pradesh in 1956.

Incidentally, in 1964, HEC started its operation and within 2 years rolled out the first ever 4.6 CuM Electric Rope Shovel forBhurkunda Colliery. This was one of the initial instances of mechanisation at Indian mines. The equipment has undergonemany design improvements since then and over 552 of the same have been supplied to coal and iron ore mining industries. The speciality of such equipment lies in its rugged structure that giveslong operating life and simple design, making its maintainability easy, resulting in high availability, thereby making these machines dependable for the Indian mining sector.

Nationalisation of coal mines in 1971-73 was the second policy decision of the Government of India that encouraged the second phase of mechanisation.

DEPENDABILITY ON COALTwo major industries that depend on coal are steel and power. Coking coal is required particularly for steel, while other grades are required by the power sector (and other industries like cement, engineering etc). More than 70 per cent of power is coal-based and to meet the requirements, much higher capacity mines were planned particularly in the mining areas of Northern Coalfields (NCL), South Eastern Coalfields (SECL). These new generation mines needed higher capacity equipment. HEC pitched in and came out with higher size excavators (10 CuM) and dragline with 20 and 24 CuM bucket capacity as a solution to meet these demands. These types of equipment had a great supportive role in boosting mining product. Along with main excavating equipment, there was a need for higher size hauling machines like dump trucks, dozing and their grades. Companies like HM, BEML contributed significantly towards this end. Many of these companies subsequently manufactured excavating equipment also.

COAL PRODUCTION: STATISTICSThe production of coal maintained an impressive growth as a result of these developments – 72.95 MT (1970-71); 114.01 MT(1980-81); 213.86 MT (1990 91); 313.7 MT (2000-01);382.62 MT (2004-05). At present, the production stands at 500 MT. In 1990s, mining companies took one major step towards mine management and optimisation. This resulted in the adoption of information technology in mine planning, equipment selectionand operation monitoring. All these developments have

helped in the phenomenal growth of mining output, which in turn has supported the economic growth.

TECHNOLOGY TRENDS Technological advancements can be discussed in two parts, first the open cast (above-ground mining) technology, and second underground mining technology. Owing to the hazardous nature of underground mining, safety considerations and regulatory measures are more stringent. This leads to longer time periods in the development of a mine.

As a result, quantum jump in technology based on underground mining is difficult. Comparatively open cast mines have more flexibility in equipment selection, deployment of equipment and workforce. Even, control during operation is better due to visibility of action. So, mining of coal through open cast route was more preferred to meet the increasing demand of coal, and today almost 88 per cent is

produced through open cast route.

In case of open cast mining, the present emphasis is on development of further advanced equipment mainly for higher productivity and less deployment of manpower. Target machineries have higher degree of automation

that can be hooked to mine management system using global positioning technique for continuous monitoring and control of operation.

Mines are planning to use 20/42 CuM excavator for their operations. In some areas, this is likely to increase the production substantially, with much reduced workforce. But application of such huge machinery will depend on geological conditions and other supporting infrastructure.

Open cast mine again has certain limitations. There is a depth limit in open cast mines beyond which mining with the conventional shovel or dumper is not feasible on account of longer hauling distance. In India, the near surface reserves are fast-depleting. As a result, the plan is to focus on underground mining.

For increasing productivity, mechanisation was introduced in underground mining during 80s with long wall mining technique. But mechanisation remained limited to a few and major parts of the underground mines that are semi-mechanised, limited to loading and transportation of coal from face after blasting. Technology level and mechanisation of underground mining did not get proper attention in the era of over-emphasising open cast mining.

Currently, however, due to difficulty in land acquisition for open cast mining and environmental reasons, the interest in underground mining is increasing. A survey suggests that around 49.07 billion tonne coal reserves are spread over 213 coal blocks in India. Of this, around 22 billion tonne of extractable coal under CIL are at a depth of 450-500 m, which will need increased level of mechanisation to extract by underground mining.

MINING TECHNOLOGIESCurrently, the two main technologies available are long wall process and continuous mining. Long wall process is more popular in China and Russia and has limited application in Indian coal seam due to geological disturbances. Therefore, more inclination is towards continuous mining technique, which uses package of

Undoubtedly, India has the strongest technical base among the developing nations with the manufacturing capacity. But it lacks design and technology capabilities. Most of the products manufactured are as per the

drawings developed by overseas organisations.

Bos

ch R

exro

th (I

ndia

) Ltd


CMD, HEC

equipment and system like: Continuous coal cutter with roof bolting Coal conveying by shuttle car, which are commonly operated

electrically (diesel operated are also under implementation) From shuttle car discharge to feeder breaker for crushing

In developed countries, various information technologies for continuous monitoring of mining operation and synchronisation of sub-systems are used. In the wake of these technological developments, HEC is trying to tie up with companies that manufacture higher capacity excavators and explore the possibility to enter into underground mining equipment market.

SURGE IN ADOPTION OF AUTOMATED EQUIPMENTDifferent types of automated equipment are also being introduced in phases in Indian mining, but the full benefit will be derived when interphasing with other operating modules will be completed. Individual equipment use sophisticated PLC-driven system that prevents accidental mal-operation. Further, it ensures machine condition monitoring and alarm system, etc.

COAL HANDLING PLANTS, WASHERIES AND DIRECT REDUCTION PLANTS Handling of coal in huge quantity received from various mines, processing the same and routing to use points is equally a challenging task. While mine reserves get exhausted and the mine faces keeps on shifting, the decision about location, capacity technology level of CHP/ washery is important from long-term economic point of view.

HEC has developed expertise in designing and execution of CHP from concept to commissioning. Over the years, it executed CHPs at Jayant, Bina, Nigahi for Northern Coalfields. In addition, a number of CHPs and bulk material handling plants has been executed by HEC for steel plants and power plants.

Indian coal has high ash content and low calorific value. Washery is an important area for value-addition to the product mined. A washery set up near the mine helps in avoiding transportation of unsuable products (ash), while reducing the threat of polluting the environment by the ash content during transportation.

In India, washing of coal was not given priority for a long time. Thankfully, the mindset has now changed and Coal India has decided to add 20 washery projects of around 111 million tonne per year aggregate capacity, with an estimated investment of Rs 2,500 crore. This will be further increased to cover almost the entire coal production by CIL. Even, the new mode of tendering by CIL is highly productive and environment-friendly.

Furthermore, the direct reduction of iron ore (DRI) process, for iron making is considered as a popular means of intermediate product, sponge iron, in the beginning of this decade. During those times, HEC supplied tyre casting and other components for sponge iron projects. Moreover, in late the 70s, SAIL R&D and HEC had set up a pilot sponge iron plant adjacent to foundry forge plant of HEC to study feasibility of technology.

SELF-RELIANCEUndoubtedly, India has the strongest technical base among the developing nations with the manufacturing capacity. But it lacks design and technology capabilities. Most of the products manufactured are as per the drawings developed by overseas organisations.

ROLE OF DESIGN AND ENGINEERING Unfortunately, most Indian companies have not yet achieved design and engineering capability. Earlier, design and technology were being transferred to Indian companies through technical collaboration, which involved manufacturing drawings along with technology for one or few models of particular equipment. With this, manufacturing of identical equipment was possible, but changing of design based on Indian conditions or customers requirements was not possible. As a result when the equipment design becomes obsolete, there is need for fresh technical collaboration to get the drawings.

R&D ACTIVITIES SHAPING UP IN THIS SEGMENT Shortcomings in design and engineering for Indian companies are based on two reasons: Indian companies primarily focus on domestic market – low

output level Customers’ acceptability

The multinational companies having a wider market and larger sale of same/similar products facilitate them to invest more in R&D and its outcome is used in commercial products for gaining an edge over competitors. But Indian companies, most of whom focus on domestic market, have low business volumes resulting in low investment in R&D. This scenario appreciably does not add to product design working successfully. So, even if in-house product designs are prepared, they are not readily marketable. The real capability of manufacturing sector cannot be realised until customer collaboration is taken into account and there is a policy framework to encourage Indian designed products.

LEVERAGING OPPORTUNITIES The rate at which the core sectors are growing will have to be supported by the manufacturing sector in terms of quality supply and service. The product features and quality have to be further improved, if we want a global industrial culture. Innovativeness in design considering the local conditions will result in win-win situation for both equipment manufacturers and industry. It not only entails mechanisation and automation, but also the safety, hazard handling and environmental considerations to be inbuilt in the product feature. Equipment manufacturers and plant operators also have to ensure comfortable and good working environment in the shop-floor that will ensure a longstanding healthy industrial culture in India.

Priority factors to rate a machine Applicability/capacity along with secondary features Operating factors Machine availability Maintainability and availability of spares Prompt service support Life of service Price


NATIONAL ALUMINIUM COMPANY

TAKING THE

PATH LESS

TRODDEN

E SANDEEP PAI AND SUMEDHA MAHOREY

Making the impossible possible and overcoming all the challenges requires strong will, determination and a sustainable futurist outlook. Creating history in the bauxite mining in a region with absolutely no basic facilities and connectivity with the outside world, National Aluminium Company (NALCO) has proved this to be true. Standing tall, tackling these extremities for decades is NALCO’s Panchpatmali mine at Damanjodi, Orissa, which has changed the way bauxite mining is being done in India. Because of its high-tech, eco-friendly and socially-oriented business approach, it has earned a high stature and set a precedent for other companies to follow.

astern Ghats, a beautiful stretch of mountains spanning over a thousand kilometre from Visakhapatnam in Andhra Pradesh to Kalahandi in

Orissa, is renowned as the bauxite belt of the country. Four thousand feet high, extending roughly parallel to the coast, this belt is also home to one of the most successful mining endeavours in Indian history.

THE BAUXITE STORYAround 40 years ago, it was estimated that more than 2 billion tonne of bauxite was present in this hilly region. Today, with over 4.8 million tonne of this estimate being extracted annually, this figure just constitutes a speck in the ocean of abundant resources that still lies untouched in this vast expanse.

Back then in the 70s, the bauxite deposit from this belt was not considered economically-viable because of its low alumina and high silica contents. Another

reason was the reluctance to mine in a region that was located in one of the most backward districts of Orissa, with no rail-road connectivity and deep forest cover as the roadblock .

With next to negligible logistical support, it had become a humungous task even for the Railways to set up infrastructure in this region. This region was impenetrable for any mining company, as it almost had no connectivity with the outside world. Apart from logistics, lack of adequate power



required to run a mine and the subsequent refinery was another major constraint.

Besides the basic infrastructural bottlenecks, there were issues related to availability of human resource. The villagers inhabiting these hills were tribals in true sense. With meagre living resources, reluctance to change and the highest illiteracy rate, communicating with these tribes and convincing them was a Herculean task.

Under such extreme conditions, companies were not too keen to invest, as they were unsure about the returns. In fact, many believed that mining was next to impossible in these regions. However,

National Aluminium Company (NALCO), a public sector enterprise incorporated in 1981, went against the preset notions and demonstrated to the world as to how sustainable and profitable mining can be achieved even under such extremities.

While the company had to overcome a lot of challenges for carrying out mining activities efficiently, with sheer determination and perseverance to achieve the so-called ‘impossible task’, NALCO sailed through the storms successfully. Providing an in-depth account on the challenges faced by the company in its earlier days, PK Mohapatra, Executive Director–Mines & Refinery,

NALCO, elaborates, “During those years, there was no road even to Damanjodi. Thus, for bringing in equipment and materials to start the exploration process, we had to make alternative kuccha road. For years, we had operated relying on that road before the pucca road came into being.

Another challenge confronting the company was to keep the workforce motivated under such harsh circumstances. “Those were the toughest times that the employees had faced. There was no proper shelter, water or food available to them. We started from scratch and now have reached a stage where we have our township with adequate facilities,” adds Mohapatra.

THE SURVIVAL INSTINCTSurviving through that phase, Panchpatmali open cast mine now stands as Asia’s largest bauxite mine located at Koraput district in the southern part of Orissa. Moreover, with an annual capacity of 4.8 MT and under expansion to 6.8 MT shortly, it is the only deposit from the two billion tonne east coast bauxite reserves, which has been mined so far. Over the years, it has bagged certifications to ISO 9001, ISO 14001, OHSAS 18001 and SA 8000 standards. Along with the mine, NALCO currently has Asia’s largest integrated aluminium complex, encompassing bauxite mining, alumina

refining, aluminium smelting and casting, power generation, rail and port operations.

TRACING THE SUCCESSFUL JOURNEY A visit to Damanjodi reveals the legacy of more than 25 years of sustainable mining, maintaining perfect peace and harmony with its environment and surroundings. From the foothills of Panchpatmali mine, a camera zoom shows a green tabletop mountain with a white coloured rope bisecting it. A further zoom clears the view… it’s not a ropeway but a uniformly covered man-made conveyor. S Sameer

Latest technologies deployed A semi-mobile in-pit crusher is

under development in the far North block.

A surface miner to eliminate drilling and blasting.

N

S

W E

Top view of Panchpatmali hill



Majhi, Junior Manager, NALCO, explains, “This is a 14.6 km single flight long distance conveyor. We use this conveyor stretch to transport bauxite ore from Panchpatmali mine to NALCO’s 1.575 MT capacity alumina refinery located at the foothill.”

During the journey to Panchpatmali mine, one travels close to the conveyor belt. The plantations are ubiquitous and conspicuous all along. After a while, as the mercury level drops and fog sets in, Panchpatmali hill emerges as a beautiful hill station. Before the mining commenced, this hill was practically barren except for sparse and stunted growth of amla, bushy date palms, ban tulasi and giant grass. However, because of the massive plantation drives taken up by NALCO, the place is wrapped up by lush greenery.

Surprisingly, the central portion of the hill has more plantation cover than even the (unmined) southern part. When asked, SK Patnaik, Sr Manager-Mining, NALCO, states with evident pride, “While we pursue mining, we also ensure land reclamation and afforestation simultaneously. Our way of working is different from other miners. There the mining is done first, and reclamation & rehabilitation is done towards the end of the mine life. But here, mining and reclamation are concurrent processes. We carry out extensive plantation not only inside the mine but also in the surrounding valleys. Because of this, today, the hill is witnessing the return of a green lustrous forest on its top.”

In future, NALCO is planning to take up huge plantation drives. The vision of the

company is best described by Patnaik. He asserts, “We have given this barren hill a forest cover. After the completion of mining, we would like to see this place becoming an attractive hill station in the future.”

The mining area of the hill (or the tabletop) is divided into three parts – north, central and south. While, the company has mined the central portion for around 25 years, it has just started mining in the north. The southern part of the hill has not been mined as yet. The hill characteristically has

sharp escarpments mostly on the eastern side and steep gradient slopes on the western side.

Moreover, in order to prevent flow of surface run off water from mining areas to the valleys, rolling of mining equipment from slopes, spreading of dust and noise to surrounding, a 15 m width of bauxite has been left on both sides of the hill and trees have been planted well in advance to act as a peripheral green barrier.

This peripheral barrier is one among the

many features of this mine. Company officials give credit to the initial mine planners and executors, who had followed a systematic and scientific approach while designing this mine and its mining methods. Several computer simulated ore body models were experimented in those days to design a suitable mining method, which would not only protect, but also help in enhancing the environment during mining. Over the years, what has evolved is sustainable mining with efficient

environment-friendly operations. With latest equipment and technologies

ensuring high profitability and environment conservation in all aspects, here is an intriguing process that the company follows for sustainable mining.

MINING PROCESS A typical bauxite mine is formed in-situ by weathering and lateritisation of parent rock, which is known as ‘khondalite’. The cross-section of the reserve would show the top

Sl.No Vertical profile offormation

Thickness in Mtr.

Rock Type Broken by Remarks

1 Top soil 0-1 Soft Wheel loaders Blast-free2 Laterite 3-4 Hard Drilling & blasting --3 Top bauxite 8-10 Medium hard Drilling & blasting ---

Hard ferruginous Big boulders by rock breakers to prevent Secondary blasting

Blast-free

4 Sub bench 2-3 Medium hard Ripping instead of blasting, using ripper dozers

Blast-free

5 Bottom bauxite 3-4 Soft Backhoe shovel instead of loosening by blasting.

Blast-free

14.6 km single fl ight long distance conveyor used for carrying bauxite ore

Rock breaking techniques implemented by NALCO



being covered with an average soil thickness of 0-1 m, followed by ferruginous lateritic overburden of about 4-5 m, and below that lies about 14-15 m thickness of bauxite formation. The partially lateritised khondalite (PLK) is seen below the bauxite layer. The deposits are highly heterogeneous with wide variations in grades and thicknesses.

Analysing these conditions, NALCO has come out with a unique way of mining. Explaining the process, A Chakraborty, GM–Mines states, “Conventional mining method is not effective in this type of deposits, and hence, the trench method of mining was adopted. This method provides staggered working fronts, effective quality control system, maximum ore recovery from undulated floors, fast land reclamation concurrent with mining, etc.”

In this trench mining method, the fertile top soil is removed by wheel loaders and then the hard laterite is drilled and blasted. When the blasted laterite is removed

bauxite gets exposed. The top slice of bauxite i.e. about 8-10 m thickness is loosened by drilling & blasting and also by ripping where bauxite is soft. The bottom bauxite of 3-4 m thickness is removed using backhoe shovels, as this does not require either blasting or ripping.

The mining machineries used by the company are mostly wheel-mounted, diesel-powered and hydraulically operated. Equipments include wheel loaders, backhoe

shovels, dumpers, blast hole drills, ripper dozers, water sprinklers, motor graders etc.

NALCO has increased its production capacity from 2.4 MT to 4.8 MT per annum and is under further expansion to 6.825 MT. Patnaik points out, “We increased the mine production by introducing higher capacity machines, an in-pit crusher in far off north block and drawing a flexible long distance conveyor from north to present crusher location in the central block such that equipment fleet size remains minimum but the average mine productivity goes very high. The speed of the only conveyor belt has been increased to carry higher tonnage in each hour. Had we continued with the same size of equipments, we would have required large size of equipment fleet leading to high traffic congestion and increased pollution load onto environment.”

While the previously aimed target has been achieved, the company is now determined to make this mine blast-free. Currently, the blasts are limited to overburden and top bauxite only. Patnaik says, “We aim to make this mine ‘Totally blast-free’ by resorting to mechanical means of mining in place of blasting. Since surface miner is one of the best alternatives, we conducted several rock analysis studies with the help of IIT Kharagpur and the results were very encouraging. Accordingly, a Surface Miner ‘T1255’ of Vermeer (USA) make has been hired and put under trial operation to actually see its performance in our mine.”

By deploying surface miner, NALCO

has become the first bauxite mine in the country to try this technology. Elaborating on this, Mohapatra avers, “Surface miner is an advanced way of performing blast-free mining. It also curbs environmental hazards arising out of a blasting operation considered as the key factor for pollution.”

Surface miner technology eliminates: Blast Hole Drilling machine, its

operations & maintenance Explosives procurement and storage Security arrangements during

transportation & storage of explosives Crushing of ore and operation &

maintenance of crusher.

MOVING TOWARDS ROBUST MECHANISATION While the company is deploying technologically advanced equipment, it is also ensuring that these are being utilised to the fullest. A GPS-based truck dispatch system installed few years back takes care of these requirements. The system is placed on the trucks and on loading equipment as well. They are monitored by a centrally located control room. Illustrating the system, Vikash Mohanty, Engineer, Truck Dispatch System-Mining, highlights, “With this, we are able to e-log the equipment performance, productivity and establish communication with the operators.”

The mine has a pit head primary crusher of double roll tooth crusher type which receives 1cubic metre size input and reduces it to-150mm size. The crushed ore is transported through a 14.6 km-long single flight cable belt conveyor to refinery at the foothill.

Even the conveyor belt has unique features. Describing it in detail, Patnaik articulates, “It can move in curvilinear paths unlike other belts, which move only in vertical plane. Moreover, the whole conveyor belt is completely covered, leaving no scope for spillage or dust emission.”

Adding to this, a PLC controlled auto sprinklers has been installed all along the main haul road to prevent dust generation during the movement of dumpers. Dry fog system has been installed inside the crusher and conveyor system to arrest dust before becoming air borne.

Water requirement for the mine is pumped from two reservoirs made out of tapping streams at Jholaguda located at the foothill. The company has also installed five

A drilling machine in operation in the Panchpatmali mine

Social polices and business should go hand-in-hand. Amalgamation of technological upgradation, which reduces the cost of production, enhances efficiency and productivity and a good environment policy with an attitude for social development, would lead to major achievements in

the future.

PK MOHAPATRA,Executive Director–Mines & Refinery,

NALCO



rainwater harvesting structures, which fulfill additional water requirements.

Another commendable initiative for environment protection is the Zero Discharge System(ZDS). Patnaik expounds, “We ensure that there is no discharge from the mine to the surrounding valleys. Effluents, mostly oil-mixed water from the workshops, waste water from canteen etc. are routed through a scientifically designed zero discharge system and reused for dust suppression measures. These waste water are regularly sampled and analysed.”

Further, the striking feature of the Panchpatmali mining is that it does not affect the ground water resource. Patnaik clarifies, “It has been more than 25 years, but we have never found that groundwater has been affected by any means. The different hydro-geological studies conducted in the past have established that mining does not affect groundwater table present below 150 m from the surface. Most of the springs originate from the hill below this level and they never dry during the year.”

The steps undertaken by the company have worked phenomenally towards its commitment for sustainable mining. Taking the legacy forward, the company has also

made special provisions to ensure the safety of its workforce. Mohapatra avers, “All dumpers are fitted with rear view cameras and have AC cabins; all machines coming from behind can be seen and monitored. Moreover, we have a separate health monitoring system for the employees, wherein doctors examine them periodically for occupational hazards, if any. Till date no employee has suffered occupational hazards on account of dust, silica or other substances.”

UNMATCHED APPROACH Starting at a time, when bauxite mining along the east coast was seen with a lot of scepticism, NALCO today, has reached a remarkable stature that has become a case study for many in mining. Its eco-friendly, well-planned and social approach to one of the toughest processes in the industrial history has helped the company achieve more value than plain profit.

Today, standing at the pole position in bauxite mining in the country, NALCO’s business policy is highly people-oriented. Highlighting the fact, Mohapatra remarks, “Industries have exploited the environment to an extent that they need to pay a price

for it today. Companies cannot think of the past and claim to work on similar lines even today. They need to devote some percentage of their success to their surroundings. It is not possible that only they earn the benefits and in the bargain the society at large suffers. At least 4-5 per cent of its profit should be reserved for the society.” Adding further, he says, “Social polices and business should go hand-in-hand. Amalgamation of technological upgradation, which reduces the cost of production, enhances efficiency and productivity and a good environment policy with an attitude for social development, would lead to major achievements in the future. Thus, our focus remains in this direction and the government is supporting us in this endeavour.”

Going by the unique practices the company has adopted to ensure safe and secure mining as well as its surroundings, it would be worth claiming that India has achieved sustainable mining to a certain extent. NALCO, with its mission to develop a people-friendly mine, has become a trendsetter of best practices for those who plan to venture into this so-called unexplored territory.


NALCO DAMANJODI REFINERY

arrying the legacy of Panchpatmali mine forward in every sense is NALCO’s Alumina complex located at the foothill of Damanjodi, Orissa. With a production capacity of 21,00,000 tonne per annum, the unit is able to generate high quality alumina out of the low content bauxite ore found in this region.

To accomplish this, the company has adopted unique measures to extract alumina from the bauxite ore mined from Panchpatmali.

NALCO’s Damanjodi refinery is equipped with state-of-the-art processes and technologies. Apart from this, robust mechanisation has helped the company in producing alumina at a faster rate. Here’s a snapshot of the systematic process followed by NALCO to refine bauxite ore into alumina.

PROCESSING UNITThe bauxite coming from Panchpatmali mine is stored in open yard stack piles and reclaimed at specific rate by bucket wheel reclaimers. The raw material is then crushed by hammer crushers to 30 mm size and stored in storage tanks called silo. As alumina processing involves solid bauxite and liquid sodium hydroxide reaction, fine size of solid is necessary to have better reaction and higher yield. To achieve this, bauxite stored in the silo is extracted at a measured rate and fed into ball mills, which grinds the material to 63 micron size.

Each of the four ball mills has a grinding capacity of 200 tonne per hour and is loaded with about 100 tonne of hyper steel spherical balls. At this stage, silica is present in the bauxite ore in the form of reactive silica (kaolinite), which needs to be removed.

For this, the ground bauxite in caustic soda solution, also known as ‘mill slurry’ is pumped to a subsequent process called pre-desilication. This process converts harmful reactive silica to non-reactive sodium aluminium silicate by heating the mill slurry with steam to react kaolinite with sodium hydroxide, which in the end forms sodium silicate. After that, the slurry is passed to the tanks where sodium silicate is converted into sodium aluminium silicate or sodalite.

The slurry is then mixed with concentrated caustic soda solution and pumped to cyclones for classification. The particles having size bigger than 63 micron are recycled back to the ball mills for further grinding. Subsequently, the fine particles slurry proceeds to the digestion process. Digestion Here, fine bauxite slurry in caustic soda is heated in tanks to achieve 105°C. Sodium hydroxide reacts with alumina tri-hydrate to form sodium meta-aluminate. The non-reactive components such as iron oxide, bohemite and silicon dioxide remain in suspended form in the slurry. For about 2.3 hours, the slurry remains in digestion tanks and

C

Showcasing operational excellence, deploying best-in-class practices and state-of-the-art technologies, with due importance to environmental protection, NALCO’s Refinery at Damanjodi, Orissa stands out as one of the best refineries for alumina production in India with unmatched

quality. Here’s how the company has been able to set inspirational benchmarks in becoming the country’s leading alumina producer…

REFININGWITH EXCELLENCE

SANDEEP PAI



is then pumped to separating cyclones for removal of coarse particles called ‘sand’. Sand separation Digested slurry having about 100gm/litre solid is fed tangentially into small conical tanks called cyclones. Due to tangential feeding, the particles experience centrifugal force and are thrown towards periphery and collide on the wall of the cyclone. With this, heavier particles fall under gravity and get separated from bottom. The slurry having very small particles come out from top of the cyclone and are moved forward to a dilution tank. The separated sand is washed with water to extract soda from it. The washed liquor is then fed into a dilution tank. Here, the slurry which contains solid is separated in subsequent stages and washed with water for recovery of soda. The washed liquor thus derived from there is partly mixed in dilution tank to get the desired soda concentration of 167gm/litre. After this, the diluted slurry is pumped to post desilication tanks.Post desilication process The remaining amount of reactive silica, which had earlier remained inactive in the pre desilication process, now reacts in the digestion stage and forms sodium silicate. This sodium silicate has to be converted to non-reactive sodalite in precipitation. For this, diluted slurry is heated in post desilication tanks to 105°C and retained for about 8 hours. The slurry is then slowly agitated in post desilication tanks to facilitate sodalite formation. At the end of this process, the outlet is pumped to settler for solid waste separation.

SettlerThese are 6m high, 40 m diameter tanks in which desilicated slurry is fed. Here, the mud settles down at the centre. A slow speed rake mechanism then drives the settled mud from centre to periphery. The settler overflows containing about 400 mg/lt of solid and 165gm/lt soda is then collected in an overflow tank. The underflow of settler containing 500 gm/lt of settled mud is washed in six stages with water to recover maximum amount of soda. Part of that wash liquor is mixed with the settler overflow liquor to attain 148 gm/lt of soda concentration i.e. favourable condition for alumina precipitation. The liquor thus, achieved is pumped to security filter feed tanks for third and last stage of solid impurity removal. Security filtration Since 400 mg/litre of solid impurity in the liquor will make the alumina impure in precipitation up to unacceptable limit, further separation of solid is being done by means of filtration. For this purpose, settler

overflow liquor is filtered in security filter or Kelly filter to bring down the solid from 400 mg/lt to below 30 mg/lt. Here quick lime solution is used as filter to aid in filtration. The liquor from here onwards is called ‘aluminate liquor’ and is ready for alumina production by

precipitation. Precipitation

Aluminate liquor is cooled down to about 65°C in plate heat exchangers to

achieve better precipitation. As per quality demand of precipitated products, small hydrate particles are mixed with aluminate liquor so that alumina hydrate precipitation takes place on those particles and their size increases.

At the end of precipitation process, the particles are classified as per size and coarse particles are taken out as final product hydrated alumina. The fine particles are mixed with fresh aluminate liquor to allow precipitation on the surface to make them grow further. In this manner, coarse products are taken out and fines are recycled to precipitator after mixing with aluminate liquor.

After classification of the precipitated products, slurry containing coarse particles is filtered in product filter to remove the mother liquor called ‘spent liquor’. The spent liquor received from both product and seed filters is then heated up in plate heat exchangers, while cooling aluminate liquor, and dispatched to evaporation area.

The seed hydrate is not only mixed in aluminate liquor for agitation but also for increasing the rate of precipitation as auto precipitation rate of aluminate liquor is very low.

The bauxite ore is being stored in open yard stack piles and reclaimed at specifi c rates.

A closer view of the NALCO’s alumina refi nery at Damonjodi

82


Low concentration of soda in aluminate liquor, low precipitation temperature, high surface area of seed hydrate, high amount of seed hydrate are favouring factors for better precipitation. The unit has 16 precipitators of 4200 cubic metre. They are cooled in between to decrease the temperature to get more yields. After this, the spent liquor is pumped to evaporation area and product hydrate to calcinations area.EvaporationThis unit has six evaporator batteries, each having six effects. Any one of the first five effects can be bypassed for maintenance purpose. In this process, steam is used for heating the spent liquor and boiled to get vapour, so that the liquor gets concentrated. The steam is generated by back pressure turbine in the steam and power plant (SPP). Talcher Coalfield, under Mahanadi Coalfields provides coal for SPP. Required evaporation: 800 tonne/hour

of water Steam used: 260 tonne/hour

The steam condensate from these multiple effect evaporators is sent back to steam plant. Generated vapour is condensed in different effect and the condensate is used in different area as sodic condensate. CalcinationThe hydrated alumina received from precipitation is washed in drum filters to reduce impregnated soda. In order to remove bound or chemically combined moisture from the hydrate, it is subjected to a temperature of 1000°C in the furnace.

SOLID WASTE MANAGEMENT While NALCO generates 5500 tonne of alumina per day, the company also effectively utilises major solid wastes – fly ash and red mud – generated during the process. There are red mud and fly ash ponds, where these wastes are sent in the form of slurry with water. Fly ash is a residue generated as a result of burning of coal in boilers for generation of steam and power. Once the water is reclaimed from the ash pond, it is reused for ash slurrying. Moreover, ash is used for cement making, concrete brick making, filling of low lying area and even for agricultural purposes.

For red mud handling, the environment and safety department has introduced Thickened Tailend Disposal & Thickened Red Mud Tailend Disposal (TTD & TRMTD) package. As per NALCO’s earlier system, red mud generated from alumina plant was

pumped to red mud pond at a solid concentration of 28-30 per cent. But with the introduction of the new system, the slurry concentration has been increased to 55 per cent, thereby increasing the pond life. In the present system, the deposit takes place conically instead of flat thereby reducing dusting issues.

While generated solid waste is disposed off efficiently, the extracted alumina is either sent to Angul for smelting and further processing or Visakhapatnam Port to be exported directly. The company has a tie-up with the Indian Railways, which runs its dedicated freight service. Apart from alumina transportation, it also helps in the logistics of coal used to feed the SPP unit.

PERSISTENT THRUST ON QUALITY NALCO refinery at Damanjodi has created a distinct identity for itself in alumina production in the country. A visit to

NALCO’s Alumina refinery clearly emphasises this notion. Moreover, a detailed understanding of the refining process involved in the refinery demonstrates the emphasis that company places on quality control and effective utilisation of all the generated solid wastes. While the refinery is the exact reflection of the kind of precision maintained at the mine, it is itself an iconic brand to reckon with.

High quality alumina produced after the rigorous refi ning process

Ash generated from the steam plant is slurried to the ash pond.

Best practises adopted Highly advanced atmospheric pressure

digestion process Pre-desilication and inter-stage cooling

for higher productivity Energy efficient fluidised bed calciners Advanced red mud disposal system Effective utilisation of ash generated.

SEARCH - THE INDUSTRIAL SOURCEBOOK | O C T O B E R 2 0 1 0

INSIGHTS & OUTLOOK : Mining & Construction Equipment

Excavating strong potential

on pg. 107


SUSTAINABLE MINING

SUSTAINABLE MINING: Paving The Green Path .............................................................................84

SPOTLIGHT: CENTRAL COALFIELDS - Living The Legacy ............................................................90

INTERVIEW

RK SAHA, CMD, CENTRAL COALFIELDS: ‘CCL Has Accorded The Highest Priority To Environment Management For Sustainable Mining’ ..........................................................................98

MINING & CONSTRUCTION EQUIPMENT: Excavating Strong Potential ...................................108

MATERIAL HANDLING EQUIPMENT: Lifting Up The Competitiveness Quotient ......................114

MINING EQUIPMENT: Growing On Strong Fundamentals ...........................................................120

INNOVATIVE SOLUTION FOR OPEN CAST MINES: Reliability And Ease OfMaintenance By Design ..............................................................................................................126


SUSTAINABLE MINING

ndia is a mineral rich country and boasts of about 4 fuel, 10 metallic, 46 non-metallic, 3 atomic and 23 minor minerals spread across the country.

India has the world’s fourth-largest coal reserves, the fifth-largest iron ore reserves, and a significant proportion of reserves of bauxite and several other minerals. Given the large infrastructure deficit the country faces, these resources play an important role in the economic and social development.

Indian mining and mineral sector has recorded a strong growth of 8.29 per cent during 2009-10 over the previous year. The growth recorded this year is significant

over the historical growth, which was modest at about 4 per cent over the last five years. The sector today is valued at $28.8 billion in production, of which coal and iron ore contributes more than 50 per cent. The pace of growth is expected to accelerate, keeping in view the fact that the country has sizeable potential for mineral wealth and demand from manufacturing sector continues to expand.

While mining operations impact the local ecosystems, the business operations are in turn dependent on the ecosystem for sustained and continued operations and are in turn impacted by degradation of these natural resources. These effects could result from physical scarcity of the natural resources or other reputational, regulatory

or litigation risks arising as a result of ecosystem degradation due to business operations.

GROWTH STORY The gross budgetary support for Indian mineral industry (coal and metallic minerals including steel) has been increasing each year and has recorded an annual compounded growth rate of around 25 per cent. This indicates the expanding nature of mining industry and the Indian economy in general. The significant growth in mining has been registered due to increasing consumption pattern resulting in the development of various industries.

Currently, the total coal production stands at about 550 million tonne against

I


SUSTAINABLE MINING

demand of more than 600 million tonne. By the end of Twelfth Five-Year Plan, the coal production is projected to be more than 1 billion tonne. Similarly, iron ore production has been growing in the country.

The production of coal and iron ore is concentrated in the eastern regions of India, i.e. Jharkhand, Orissa, West Bengal and Chhattisgarh. These four states account for more than 78 per cent of the total coal production of the country. Though rich in mineral resources and the largest producers of minerals, these four states score low in per capita income and living standards. This indicates the disparity between the growing mining sector and poor state of local economy. The benefits of growth have not accrued to the locals and pose serious

socio-economic challenges. Some of these are discussed below, which call for developing a sustainable development framework by the Government of India to pass the benefits of growth to all and give appropriate recognition to local interests.

SUSTAINABILITY CHALLENGESThe mining sector is accountable to their stakeholders for financial performance as well as with respect to social and environmental issues that are increasingly becoming critical to the successful operation of mining operations. The need has further increased in India due to lack of local, community and environmental development in the mineral rich areas in the past.

The ‘license to operate’ is based on the responsiveness of mining companies to various stakeholder expectations including issues related to health and safety of the workers involved in mining operations, environmental impact of the operations and socio-economic development of the region

through employment creation. Mining companies need to incorporate these issues (along with other issues identified for their specific operations based on the geography in which they operate) as part of their business strategy for long-term sustained growth of their business.

SOCIO-ECONOMIC CONCERNS Though mineral industry in India has been growing at moderate to high pace, the benefits of the same have not been passed to the local community. This has resulted in the growing perception that the industry is taking over the mineral resources and land from the locals leading to the loss of livelihood but not compensating appropriately. This growing discomfort between the locals and industry has resulted in strong opposition of land acquisition for major mining and mineral beneficiation projects, especially in the eastern regions of the country.

Mining operations have a huge impact on the ecosystem, and hence, sustainable environmental management throughout all the life stages of mining and mineral operations is a critical component of sustainable mining. While the minerals industry plays a significant role in the economic development of India, there are also tradeoffs to be made with respect to the impact of these activities on the environment and the local communities. This scenario calls for a sustainable development framework by the government to preserve & protect the natives & the nature.

PAVINGPAVINGThe The GREENGREEN PATHPATH

Budget Trend FY 05 FY 06 FY 07 FY 08 FY 09 FY 10 FY 11

Proposed outlay (INR Crores)

6244 4828 6412 10699 15403 19292 23806

Revised outlay (INR Crores)

5631 4255 6374 10988 12933 18002 NA

Planned Outlay (%)

63% 87% 90% 94% 95% 95% 96%

Budget trends witnessed in mining sector


SUSTAINABLE MINING

Another concern that needs to be addressed is the exploitation of the mineral resources in a manner, which fulfill the demand of present but at the same time conserve the resources for the future generation. Presently, the total proved coal resources are pegged at about 109 billion

tonne. With the present production rate, the proved resources will sustain for about 180 years but since production is expected to grow to more than 1 billion tonne per annum in the Twelfth Plan, the proved reserves will be exhausted in about 100 years. This is assuming complete recovery of the reserves, which is unlikely to be the case. With the present technologies, coal recovery in open cast mines is only about 80 per cent and less than 40 per cent in case of underground mines. Better technology is required to increase the recovery of coal.

On the regulatory front, the present regulations call for leaving a barrier pillar of 15 metre between two coal mines. Significant amount of coal resources are lost under these boundary pillars. Larger size mines should be promoted to increase the recovery rate. The other significant issue is the lack of R&D activities in the field of mining in India. More emphasis needs to be given to mining R&D to increase the recovery from the underground mines.

Most of the mineral bearing areas in

India are also those with high forest density. The mining activities have had an adverse impact on the surrounding forests and environment. Several mining projects have been deferred due to delay in getting environmental clearance. Besides, some of the mining projects have been closed due

to environmental concerns. Thus, extraction of minerals is required to maintain the pace of growth but at the same time, it is necessary to address the environmental concerns.

Given this context, it becomes necessary to develop a strategy for sustainable development of mining and mineral sector. At the same time, it is also important to communicate the strategies adopted and steps taken towards sustainable development to the stakeholders. The approach has to be both comprehensive – taking into account the whole minerals system – and forward-looking, setting out long-term as well as short-term objectives.

GLOBAL SUSTAINABLE DEVELOPMENT EFFORTSMajor work towards ‘sustainable mining’ has been happening in the recent years in the form of important collaborative processes, international conferences, extensive compilations and monographs, and the beginning of individual company plans. Among these, the Mines, Minerals

and Sustainable Development (MMSD) Project of International Institute of Environment Development (IIED) and World Business Council for Sustainable Development (WBCSD) is prominent. The project was initiated by nine major mining companies and conducted over a period of less than four years.

The final report provides a complete and balanced overview of what is required for mining to become sustainable.The MMSD report states that sustainable development of mineral industry will require a robust framework for sustainable development based on an agreed set of broad principles. It will have to be based on the local factors for each of the regions by understanding the key challenges and constraints facing the sector at different levels and in different regions. It also describes actions needed to meet or overcome these, along with the respective roles and responsibilities of each stakeholder.

Further, the framework is expected to suggest process for responding to these challenges addressing the concerns of each stakeholder and take care of everyone’s interest to the extent possible, besides setting priorities and tackling the problem areas. It should also have an integrated set of institutions and policy instruments to ensure minimum standards of compliance as well as responsible voluntary actions; and verifiable measures to evaluate progress and suggest improvements.

In addition, it aims to work on following ten principles towards achieving sustainable development: Implement and maintain ethical business

practices and sound systems of corporate governance

Integrate sustainable development considerations within the corporate decision-making process

Uphold fundamental human rights and respect cultures, customs and values in dealings with employees and others who are affected by mining activities

Implement risk management strategies based on valid data and sound science

Seek continual improvement of health and safety performance

Seek continual improvement of environmental performance

Contribute to conservation of biodiversity and integrated approaches to land use planning

Facilitate and encourage responsible

Viability of mining businessoperations

Control, use andmanagement of land

Contribution to socio-economic development

Contribution to localcommunities

Environmental impactof mines

Life cycle approach for use of mining products

• Good financial performance for access to capital• Social licence to operate• Safe, healthy and committed workforce

• Address competing land uses to avoid problems and disagreement around issues such as compensation, resettlement, land claims of indigenous people and protected areas

• Potential to contribute to poverty alleviation and broader economic development at the national level

• Requires development of framework for the creation and management of mineral wealth

• Impact on communities due to local employment generation, mine closure and distribution of benefits within the communities

• Management of large quantities of waste, cost of acid drainage, improving impact assessment & environmental management systems, and effective planning for mine closure

• Incorporating resource optimisation, efficiency and waste minimisation practices throughout the value chain of mining operations

• Enhancing the recovery of mineral resources.

Figure 1: Sustainable development challenges


SUSTAINABLE MINING

product design, use & reuse, recycling and disposal of products

Contribute to the social, economic and institutional development of the communities where they operate

Implement effective and transparent engagement, communication and independently verified reporting arrangements with stakeholders.These principles form the backbone of

global developments in the arena of sustainable mining.

SUSTAINABLE DEVELOPMENT JOURNEY In the year 2005, the high-level committee for the National Mineral Policy recommended introduction of best practices in implementation of environment management and also to track the global trends in sustainable development. This committee held that some of the challenges facing the Indian mining sector towards sustainable development would be to identify the appropriate use of land within a land planning framework through a democratic decision-making process on the basis of integrated assessment of ecological, environmental, economical and social impact. Further, it was spelt out that mining should contribute to economic, social and cultural well-being of indigenous host population and local communities by creating stakeholder interest in mining operations for the project-affected persons. The committee recommended development of a SDF-based International Council on Mining & Metals (ICMM)/ International Union for the Conservation of Nature and Natural Resources (IUCN) model, specially tailored to the Indian context. The said SDF, it was envisaged, would be composed of principles, reporting initiatives and good practice guidelines for the three sectors of Indian mining – SMEs, captive and large stand-alone sectors.

The recommendations of this committee were accepted by the Government of India, and the revised National Mineral Policy 2008 addressed the issues of recognising the impact of mining on other natural resources and also on the land use planning. The policy also recognised the significance of rehabilitation and resettlement of local host population and enunciates that apart from compensation as an important aspect of the SDF.

In December 2009, the Ministry of Mines, Government of India, commenced the work on the preparation of Sustainable Development Framework for the Indian Mining sector. The SDF is expected to facilitate the scientific development and exploration of mineral resources and ensure the protection of the environment and prevention & control of pollution from prospecting and mining-related operations. The draft SDF is expected to cover the following aspects among others, with regard to all non-coal, non-fuel minerals (both major and minor minerals): Factors influencing sustainable and

scientific mining (and indicators thereof) Broad criteria beyond which mining may

not be deemed sufficiently sustainable and scientifically manageable

Systemic measures needed to be taken or built to increase sustainability of mining operations considering its entire lifecycle inter-alia:a. Ensuring minimal adverse impact on

quality of life of the local communities

b. Protecting interests of affected persons including host population

c. Creating new opportunities for socio-economic development

d. Mineral conservation (both in terms of mining technologies/practices and mineral beneficiation)

e. Reducing waste generation and related waste management practices

f. Minimising and mitigating adverse environmental impacts particularly on surface as well as ground water (both in terms of its quality and availability as resource), air, ambient noise and land

g. Ensuring minimal ecological disturbance, in terms of bio-diversity, flora, fauna and habitat

h. Promoting restoration and reclamation activities, so as to make optimal use of mined out land for the benefit of the local communities.

Systems to devise measurable indicators of sustainable development and draft

contours of sustainable mining management system

Regulatory and other mechanisms to ensure that the systemic measures are in place and are implemented

Consultative mechanisms with stakeholder groups right from pre-mining stages (including exploration) through the lifecycle and up to post-closure stages to ensure their involvement and participation in identifying and addressing the sustainability issues; developing the broad contours of the approaches to the sustainable management of all the activities including formulation of the measureable indicators and monitoring mechanisms for the purpose

A system of public disclosure of mining-related activities and environmental parameters including indicators and mechanisms to facilitate formal and informal sustainability audits

Measures to ensure industry acceptance and adoption of the SDF including indicators for benchmarking the nature and extent of SDF adoption

Roll out mechanism for adoption of the SDF at the grassroots level including the training, publicity, conducting workshops, handholding, and time-frames for the roll-out.

PATH FORWARDSeveral complex decisions that need to be made on the path towards sustainable development will involve compromises or trade-offs: between different objectives and dimensions, between different groups of stakeholders, and between different generations. There may be conflicts

between global and local priorities. Long-term needs will have to be balanced against short-term imperatives. The various constituencies, acting in concert, will need to evaluate the acceptability of, for example, sustaining minor environmental damage in exchange for major

social and economic gains, or of sacrificing economic and social goals for a significant environmental benefit.

Deeksha Vats, Associate Director- Sustainability and Pukhraj Sethiya, Senior Consultant-Mining, PricewaterhouseCoopers with inputs from Krishna H Prasad, Manager and Shubhra Jain, Assistant Manager- PwC

Several complex decisions that need to be made on the path towards sustainable development will involve compromises or trade-offs: between different objectives and dimensions, between different groups of

stakeholders, and between different generations.


CENTRAL COALFIELDS

These days, the word mining is juxtaposed with land erosion and environment disaster. Hence, the efforts of mining companies towards creating a sustainable environment are considered as mere eyewash at the back of a strong business plan. Contrary to these notions,

Central Coalfields, a subsidiary of Coal India, is providing a new dimension to coal mining in India. The best in-class sustainable development practices along with advanced equipment and commitment to environment protection can be seen in every aspect of mining

and processing in its largest coal producing Piparwar mine.

otted with huge plantations on both sides, the road from Ranchi to Piparwar, a backward district in India’s mineral rich state (Jharkhand), is a beautiful

trek. After a few strides ahead, the forest cover thickens and one can witness huge trucks carrying coal. Pointing in the direction leading to the mine, the localites state, “This is a common sight, and going further ahead, the frequency of trucks on the road would only increase, as it is en-route to the India’s largest coal reserve.”

While the mesmerising surroundings kindled the growing anticipation of seeing these famous coal-mines, the mere thought of coal reserves brought to the fore the

alarming pollution rate juxtaposing harsh working conditions of the people. However, this perception proved to be just another illusion, even before reaching the Piparwar mine, one of the largest mines located in the region.The place has as much forest cover as what was seen on the way. Besides, it has a commendable dust-free environment, which is a rarity when it comes to coal mines.

Since its inception, Piparwar mine that is located in North Karanpura Coalfields in the Chatra district has witnessed two decades of mining. Despite such a long mining history, it is a shining example of the kind of sustainable mining that the government and corporates are aiming to achieve. Piparwar mine is a trendsetter in exemplifying how

planned quantity and quality of coal can be produced efficiently and economically, with due respect to safety, conservation and environment aspects.

THE GLORIOUS PAST Commissioned in 1989, Piparwar open cast mine, under Central Coalfields (CCL) – a public sector enterprise – was developed by White Industries, an Australian company.

Between the latitudes of 230 42’ 38” and 230 44’ 45”N to longitudes of 850 01’ 43” and 850 03’ 15”E, the mine is part of the integrated unit comprising Coal Handling Plant and Coal Preparatory Plant (CHP/CPP). It is connected by road from Ranchi, Hazaribagh and Chatra district. One of the

D SANDEEP PAI

CLIVING THELEGACY


CENTRAL COALFIELDS

significant features of this mine is that despite having a production capacity of 6.5 MT annually as per the project outlay, it is able to generate more than 9 MT annually. Another striking fact is that the mine has the highest output per man per shift, which amounts to around 36 tonne.

The CCL officials describe Piparwar mine as the company’s backbone. Charan Singh, Project Officer, Piparwar, says, “The mine is responsible for one-fifth of the total coal produced by the company. This has been possible because the mine is equipped with the latest mining technologies.”

With a mineable reserve of 197.49 MT( at the time of inception), all together, the mine has six coal seams (layers) starting from the deepest to the uppermost – Lower

Dakra, Upper Dakra, Bukbuka, Bukbuka Top, Bisrampur and Karkatta respectively.

By following the direction opposite to the flow of coal on the 4.3 km conveyer belt leading up to CHP/CPP unit, Lower Dakra seam can be reached, which is also the deepest face (80 metre below the sea level) of the mine.

INPIT CRUSHER AND CONVEYOR SYSTEM For mining the thick Lower Dakra seam, CCL has deployed Mobile Inpit Crusher and Conveying technology, the only unit of its kind engaged in coal production in India. With a crushing capacity of 2,800 tonne per hour, the technology is imperative for this seam primarily because of its thickness (22

metre), which is otherwise difficult to break.

On account of the crushing technology, the number of blasts required is less compared to those required otherwise. Baliram Singh, Tripartite Safety Committee Member, Piparwar Area, avers, “The layer is so thick that we cannot avoid blasting. However, the number of blasts is almost negligible and this plays a pivotal role in addressing environmental concerns. Moreover, it is the safest form of coal extraction for thick coal seam layers.” The significance of this seam is that it accounts for nearly 2/3rd of the total coal that is being extracted from this mine.

Inpit crusher operates very close to the face of the coal and extracts it in one bench

GO


CENTRAL COALFIELDS

making the process simple. It is mobile and moves in four directions – normal, transverse (900), angular (150), circular (3600). The coal is extracted using shovel and is placed in the first unit of Inpit crusher known as hoper having a capacity of 100 cubic metre. Water is sprinkled constantly into the hopper to avoid dust generation. “We use water here, which attaches itself with coal and does not allow dust particles to cause air pollution,” Baliram Singh adds. Thereafter, large size heavy coal blocks are transported through the steel-chain-conveyor-belt and put into the crushing unit known as double-role crusher. In this, two large size wheels run simultaneously and reduce the size of the coal to -300 mm, i.e. coal size=<300 mm. The crushed coal is placed into moveable wagon belts. Wagon belts are nothing but conveyer belt systems used for covering the distance between Inpit crusher and 4.3 km long conveyor, which goes to CHP/CPP.

Inpit crusher runs on a PLC controller, which monitors the entire process. The screen placed in the control room reveals problems, if any and the exact location where the problem has been encountered.

Because of the use of Inpit crusher, the manpower required is not more than 7 persons per shift. By deploying the conveyer system to carry coal, CCL has ensured that there is reduction in pollution because of the less movement of dumpers. In

addition, accidents caused due to the heavy movement of dumpers are avoided this way.

SURFACE MINER TECHNOLOGY While Lower Dakra is thick, the mine has seams having size of 1-3 metre as well. These upper seams are being mined using surface miner technology and pay loader-truck combination. Currently, in the Bukbuka and Bukbuka top seams where the coal size is less, mining is done through eco-friendly surface miner. The advantage of this

equipment is that it is blast-free and ensures total recovery of coal. It is generally used to crush coal whose thickness is less. Showing the front face of the one-metre highBukbuka seam, Baliram Singh explains, “As the coal layers are thin in these seams, blasting would result in wastage, as it might get burnt. To avoid this, we use surface miner to do selective mining.”

The equipment stands at the top of the coal seam and scratches the surface. About 76 pointed spokes at the lower end of the machine are responsible for breaking the coal into smaller sizes. Moreover, water is being sprinkled along with the scratching process to ensure that dust is not being generated. With an input of 160 litre of diesel, 800 tonne of crushed coal can be extracted per hour using this technology.

Nevertheless, crushed coal is being transported directly to the customers without processing because some customers want it that way. “Some customers demand unprocessed coal, so we send them directly,” says Baliram Singh.

ENVIRONMENT PROTECTION Apart from Inpit crusher and surface miner technologies, the company adopts best practices in every operation, ensuring environmental sustainability at its best. It is evident from the fact that the mine has 100

per cent back filling technique for overburden handling. Elaborating the process, Charan Singh explains, “As we are extracting new areas within the mine, we ensure that we conserve their top soil and the stones separately. Thereafter, when the mining in that area is done, we fill them back and start the plantation process.” Such has been the plantation drive that the recent satellite survey showed that the plantation cover has increased by more than 12.5 per cent as compared to when the mine was started.

SAFETY AND SECURITYApart from environment protection, the company follows stringent measures with regard to safety of its workforce. Elaborating on this, Charan Singh, explains, “As coal is sensitive to heat, sometimes excess heat lead to automatic fires. To ensure safety of our workers and bare minimum loss of coal,

Inpit crusher in operation in Piparwar OCP

Surface miner scuffi ng the top of Bukbuka coal seam


CENTRAL COALFIELDS

we have set up a department that deals with the fire-fighting operations.”

On normal days, the workforce is equipped with all the prescribed safety gears and equipment. “We provide all kinds of equipment to the workers, be it helmets or gloves. Also, we keep dividers between the roads in the mines, and have also framed several rules for the dumper’s movement to avoid accidents,” he adds.

Nevertheless, it is not just the exploration process alone, even in the beneficiation or recycling process, the company has adopted state-of-the-art technologies to drive operational excellence and attain sustainability.

CHP/CPP- COAL BENEFICIATION PLANT The beneficiation of coal is done in the CHP/CPP unit, which is the first ever non-coking coal beneficiation project in any public sector enterprise. The unit was started in 1997 and has a capacity of processing 6.5 MT annually. Last year, however, it challenged its own production capacities and processed a massive 7.2 MT of coal. The company provides best quality coal to its customers, which is evident from the fact that around 12-13 per cent of coal is rejected from the unit. A visit to the washery makes one feel that the sustainability mantra of the mine has been carried forward. Let us take a look at its processes and best practices followed to conserve water, air and soil:

Input from the conveyer is fed into the first crusher wherein 300 mm coal sizes are converted into 100 mm and is placed in stacker 1. It is then sent to the surge bin

where the crushed coal is stored before feeding into the washery. The washery has two modules, each with a processing capacity of 775 tonne per hour.

In the first stage, screening of –100 mm coal at 13 mm on both the modules produces two size fractions i.e. 100 to 13 mm and –13 mm. While the -13 mm fractions are sent directly to the stacker 2, the heavier coal is sent for preparation and washing. The preparation of 100 to 13 mm raw coal is done in batac jigs (capacity 646 tph each) to produce de-shaled coal and rejects. Here, de-watering of deshaled coal from each jig on both the double deck de-watering of 267 tph capacity each takes place.

The units are designed in such a way that it settles down the higher ash content carrying coal (34 per cent or more) and rest is emitted out. The ones that pass out from there are known as ‘pure coal’ and are carried to the stacker 2. MM Dongre, Section Engineer, CHP/CPP unit, states that the process is simple but highly productive. “We have seen that accepted coal has an ash content of 40-45 per cent at the time when it was inputted in the washery. However, after beneficiation, its ash content is reduced to much less than 34 per cent,” he reveals.

“The entire unit is controlled by a software known as Supervision Control and Data Acquisition Software (SCADA), which instantly determines any error in the entire system. Trained personnel operate master computer in the control room. Depending on the nature of the problem, they direct engineers from electrical and mechanical departments to rectify it,” he adds.

MAINTAINING ECOLOGICAL BALANCE The rejected coal is carried through a conveyor and dumped in the yard. To prevent any hazard, the rejects are either sold using e-auction or are used for the purpose of back-filling the mines.

Moreover, the water used in the washery is accessed from nearbyabandoned mines. The water is constantly recycled and reused in the washery.This is done by allowing the slurry (ofwater and waste particles) to settledown in the slurry pond. Various flocculants are used that facilitate faster settlingdown of the contaminated particles. When the particles settle down, water is sent for reuse in the washery. “In summer, when the water gets evaporated, the coaldust is collected and used for reclamationof land in the mines,” says Dongre. Thus,by deploying such a system, CCL has ensured bare minimum loss ofwater and effective utilisation of waste particles.

Apart from focussing on minimal water loss, the company gives paramount importance to air pollution control as well. Dust control on entire road transport from washery premises to ‘bachra siding’ by mobile water sprinklers can be seen. Moreover, just before the trucks leave for dispatch, water is sprinkled for air pollution control. It is not just the passage alone, even the transfer points are sprinkled to suppress dust generation.

COUNTERING THE HURDLES In the case of Piparwar mines, CCL has set standards for mining companies to follow.

Benefi ciation of coal is done in this CHP/CPP unit


CENTRAL COALFIELDS

However, the only hurdle that it faces is pertaining to logistics. Dongre admits, “Logistics is a problem as the coal is dispatched using trucks to the nearest railway consignment which is 8 km away. Though we take care of the pollution by using sprinklers, we have to bear the cost of the fuel.”

To overcome this problem, CCL is working in tandem with Indian Railways to

bring the railway tracks near the CHP/CPP unit. “Land acquisition has almost been done and soon you will see a highly reduced number of trucks in this region,” affirms Dongre. With the reduced cost of logistics, CCL will be able to provide coal at a cheaper rate to its customers. Currently, coal from the Piparwar mine feeds units of NTPC at Dadri, Badarpur, Bhatinda and Unchahar.

LEARNINGS TO IMBIBE Exhibiting operational excellence in one of its largest mines, CCL is certainly mining a sustainable future with a vision tobring forth the need of environment protection. Visiting the Piparwar mines reflects the same. It managed to do so just by deploying best-in-class practices and latest technologies, bearing in mind the importance of environment protection. Nevertheless, they have managed to produce more than expected quality of coal, which is extraordinary by all standards.

Moreover, the company has recognised hurdles coming its way and is determined to overcome them in the near future.With this, it has set a trend-setting expedition for other companiesto follow.

Processed coal stored as huge stacks before being dispatched

VIEW FROM THE TOP: CMD, HEC

‘Higher economic productivity can make mining products affordable’

on pg. 66


CMD, CENTRAL COALFIELDS

OLE OF COAL IN POWER GENERATION FOR FUTURE Coal is the prime source of power generation in India. Almost 2/3rd of generation in India constitutes thermal power with coal as the main fuel. The situation is not likely to change much in the

near future. Power plants are the main customers of coal suppliers. With the

growing power demand in the country, coal production needs to be increased to meet consumer needs. The demand for coal from the power sector is estimated approximately at 60 MT/year by the end of the Eleventh Five-year Plan. It is likely to reach 80 MT per annum (approximately) by the end of Twelfth Plan. During the same period, production will continue to increase, until it reaches almost a plateau level of around 125 MT by the end of Fourteenth Five-year Plan.

TECHNOLOGIES IMPLEMENTED Almost all opencast mines of CCL are fully mechanised. In large opencast mines, the entire mining operation including charring the drill holes is mechanised. Shovel-dumper combination is used for loading and transportation with Australian collaboration. In some of the

outsourcing patches, surface miner has been deployed, which completely eliminates drilling and blasting.

UG mines are labour-intensive. There are, however, some mines where coal loading has been mechanised using side discharge loaders (SDLs) and long haul dumpers (LHDs). Attempts are being made to systematically replace manual labour with mechanisation. Some mines have been selected for the introduction of mass-production technology for instance, continuous miners. It is expected that production using this technology would be commencing from Twelfth Plan.

ENVIRONMENT-FRIENDLY MEASURES ADOPTED CCL has accorded the highest priority to ecology development and environment management for sustainable mining. The company has made major breakthroughs by planned afforestation programmes

and reclamation of degraded land to improve the environment. The land being degraded by mining is being reclaimed concurrently or phase-wise through planned and sequential reclamation. The environment management plan is being prepared for the mines and scientific methods are being followed for reclamation and pollution control. Continuous monitoring with respect to ambient air quality, water and noise is carried out at units and clean water/treated effluents are discharged.

LAND RECLAMATION Large mines are being monitored for land reclamation by remote-sensing techniques through CMPDI on an annual basis. Mines like Piparwar and Ashoka are being monitored since the last four years and it can be seen from the analysis that the reclamation/afforestation has increased from 198 Ha to 225 Ha – an increase of about 14 per

R

CCL HAS ACCORDED THE HIGHEST PRIORITY TO ENVIRONMENT MANAGEMENT

FOR SUSTAINABLE MINING

“With the growing power demand in the country, coal production needs to be increased to meet consumer needs,” avers RK Saha, CMD, Central Coalfields, during an exclusive interaction with Sandeep Pai. Excerpts…


CMD, CENTRAL COALFIELDS

cent in two years. The success in land reclamation of these spoiled mines and

afforestation has been significant. The mined areas or the de-coaled areas are refilled with overburden at places where no mining is required in future. The OB fills and dumps are not conducive to growth of plants, since these sites do not contain adequate plant nutrients. The dumped soil is improved in stages through modern techniques to regain its fertility, and the horticultural operations are carried out by adding nutrients like organic, inorganic and bio-fertilisers. Bio-reclamation of degraded mined areas of more than 4,300 Ha (since 1991) of different types of land including OB dumps, subsided areas are carried out on a large scale.

ADDRESSING SAFETY CONCERNS The steps that the company has undertaken to ensure safety of its workers and enhance productivity include ensuring availability of safety materials, conducting scientific studies, organising safety awareness programmes, sectionalisation of underground workings, establishment of mine rescue stations/rooms in the coalfields, and enhancing preparedness for dealing with emergencies and eventualities. Other measures comprise observing safety drives periodically on different safety matters, imparting training to workers in group vocational training centres as well as external institutions.

CHALLENGES FACED The major challenges that engineers and workers face are related to law and order i.e. frequent bandhs by Naxal groups, threatening/extortion, etc. Given below are some of the problems faced by coal mines and measures taken by CCL to deal with it:

Interference by political parties/outside agencies/villagers: We have set up a grievance/dispute committee that addresses the problem areas amicably. Moreover, the management undertakes various courses of training/re-training to enhance skills of workers.

Government policies: Due to various policies, delays occur in land acquisition. To overcome this, continuous follow-up and meeting with government officials are being done.

Changing market condition: We constantly take steps to meet the expectations of customers by maintaining the quality of coal being supplied.

Adverse geomining conditions: We strictly follow the guidelines related to mining operation stipulated in various Rules/Regulations/Acts.

CCL’S CONTRIBUTION TO STATE’S OVERALL DEVELOPMENT CCL contributes in a number of ways for overall development of the state. Under corporate social responsibility (CSR), Rs 1 per tonne of coal produced has been earmarked for the purpose of improving the living conditions of the society around the periphery of CCL mines. A number of schools are run, bore wells drilled, mobile dispensaries operated, etc, by CCL around mining areas for the benefit of the society. During this financial year, 5 per cent of the retained earnings of pervious years subject to a minimum of Rs 5 tonne (whichever is higher) have been earmarked for CSR activities. At the time of emergency/unforeseen circumstances, CCL has always been eager to render support to the state, both in terms of cash as well as rendering services.

Our search for authentic and informative articles…

SEARCH solicits, original, well written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the general manufacturing arena.

You can send us Technical Articles, Case Studies and product Write-ups. The length of the articles should not exceed 3000 words, while that of product write-up should not exceed 200 words.

The article should preferably reach us in soft copy (either E-mail or CD). The text should be in MS Word Format and the images in 300 DPI resolution and JPG format.

The final decision regarding the selection and publication of the articles shall rest solely with SEARCH.

So, join our endeavor to provide relevant and useful content to our readers…rush your articles, write-ups to

[email protected]


MINING & CONSTRUCTION EQUIPMENT

The mining, irrigation and other infrastructural segments together account for around 45 per cent of the Indian mining and construction equipment (MCE) industry volumes. With mining activity being a key demand driver, and focus on infrastructure development by the government, MCE industry is all set to explore the untapped growth potential in the future.

T

EXCAVATING

he Indian mining and construction equipment (MCE) industry has been maintaining a healthy growth rate over the past few months. Indian MCE

volumes started picking up in November 2009, which had suffered a decline earlier due to the tight liquidity conditions on account of the economic slump, and weak sentiments across user-industries that resulted in a 15-30 per cent drop in demand across product segments.

While government-funded infrastructure projects largely remained on track even during the downturn, a number of privately- funded projects suffered due to insufficient credit and a sharp deterioration in the investment environment. Moreover, the progress in segments like mining and roads, which are relatively more mechanised, and thereby use more of MCE, supported growth of MCE industry during the past few quarters.

BUILDING DEMANDThe MCE industry is cyclical, with the long-term demand strongly correlated to the health of the underlying economy and infrastructure investments. It is particularly affected by macro-economic factors like

STRONGPOTENTIAL



investments in infrastructure, housing demand, real estate prices, employment rates and commodity prices. As the purchase of construction equipment industry is largely debt-funded (about 85 per cent of the MCE industry purchase is financed), timely availability of credit at favourable terms and interest rates also remains a strong industry driver. Given below are some of the key trends observed in the MCE industry:

FALLING COMMODITY PRICES CURTAIL DEMAND FOR MINING EQUIPMENTFor a period of over a year-and-a-half, starting 2007, commodity prices reigned high owing to strong global demand. With the fall in global liquidity and demand from Q3 2008-09, commodity prices corrected. While the fall in commodity prices, especially for steel, was beneficial for the cost structure of the industry, it also suppressed demand from the metal mining segment, which scaled down activity as prices fell.

The Indian mining industry comprises three key products: coal (around 50 per cent of the volumes mined in the country), iron ore (around 22 per cent) and limestone (20 per cent). The government and public sector undertakings (PSUs) account for more than 90 per cent of the coal mining activity, around 25 per cent of the iron ore mining and negligible limestone mining in India.

With ample coal reserves and the ongoing power deficit, coal mining by PSUs has continued to grow at a steady pace, thus providing regular demand for mining equipment. On the other hand, iron ore production in the country is influenced by global prices for ore (as over 50 per cent of India’s iron ore production is exported) and government policies. With falling commodity prices and liquidity crunch faced by private companies, there has been a decline in the demand for equipment from the Indian metal mining segment. In the longer term, commodity (metals) prices will continue to play a key role in demand for mining equipment like heavy tonnage dumpers, dozers and excavators.

NEW MNC ENTRANTS SETTING UP BASE IN INDIAWith MCE industry volumes of around 40,000-45,000 units per annum and an estimated turnover of $2.6-3.1 billion, the Indian market is relatively small as compared

to the global market that is estimated at over $75 billion. Nevertheless, many international original equipment manufacturers (OEMs) have indicated plans of setting up manufacturing facilities in India owing to its good growth prospects and slack demand in the traditional developed markets. With the incremental capacities and new entrants, the industry is expected to become more competitive and fragmented. However, growing mechanisation and large infrastructural projects proposed in the country indicate the potential to absorb these new capacities. The entry of global MCE manufacturers has also facilitated product upgrades in the growing Indian market.

THREAT OF IMPORTS FROM LOW-COST COUNTRIES LIKE CHINAChina has a huge domestic market for MCE. The Chinese loader market alone stands at over 1,25,000 as against 1,800-2,000 wheeled loaders sold in India per annum. With such economies of scale, the Chinese equipment has the competitive advantage of being significantly cheaper than the Indian equipment. A number of Chinese companies has established their presence in India through a combination of manufacturing facilities, sales offices or marketing tie-ups with Indian companies for selling their products in India. It is estimated that the Chinese MCE companies currently hold over 12 per cent in the wheeled loader segment, around 13 per cent of the dozer segment and enjoy a strong presence in concrete mixers, with the potential to expand their presence in the Indian markets.

The challenges for the Chinese products in India stem largely from warranty support

and availability of spares/after-sales support. Some Chinese manufacturers have started addressing these concerns through tie-ups with local established OEMs. While the current approach of domestic buyers towards Chinese equipment remains cautious on concerns related to quality and availability of long-term after-sales service, the future trends could be largely determined by the success of local tie-ups in addressing these concerns.

Further, the resale value of the Chinese equipment currently remains low, restricting availability of finance. However, the Indian OEMs will continue to face competitive pressures to lower costs, thus requiring higher localisation; improving value through

greater customisation to meet local needs besides strong service and spares support to beat competition.

Imports into India also originate from other countries too, either because of non-availability of such products in India (higher tonnage cranes and mining equipment for instance) or owing to a cost advantage (on used equipment). This trend is more pronounced in material handling equipment; where over 10-15 per cent of the equipment in the country is currently imported. Developing nations like India are key destinations for used cranes from countries like Australia.

LIMITED INVESTMENTS IN R&D BY MCE ANUFACTURERSMCE companies with MNC parentage typically have depended on parental support for product development and have made minimal investments on R&D - largely limited to homologation of the global products for Indian conditions. Further, the need for technology investments specific to

The IIP for April-February 2010 posted a growth of 10.1 per cent as against 3 per cent in the corresponding period during the previous year. Infrastructure spending by the government towards schemes like Pradhan Mantri Gram Sadak Yojna and preparation for the 2010 Common Wealth Games has served as a strong demand driver for the MCE industry, especially for the northern part of the country. The southern part of the country, which was hit by a fall in iron ore and granite mining activity, also showed some signs of revival. However, the demand from the real estate segment (which impacts concreting equipment) continues to be relatively weak, particularly in the commercial area. Nevertheless, the longer-term prospects for the industry remain healthy, with strong demand expected from the housing segment.



the Indian market is relatively low, as the requirements for emission/noise control in Indian off-highway vehicles continues to be basic as compared to the developed markets. The Indian MCE industry is currently BSII-compliant, with the next transition expected in April 2011. Developed nations like Japan and even emerging markets like China have already moved to cutting-edge technology of hybrids and electric vehicles (EV) to increase productivity and comply with stringent emission/noise control norms. With the increasing presence of international companies/products in India, Indian market participants have started to invest in R&D to match the international quality standards. Deeper understanding of the market and the requirement for application/topography specific products has further raised the need for increased R&D by participants in the Indian market.

Industry enjoyed high profitability during up-cycles. However, profitability and capital structure deteriorated in H2 2008-09. Most of the large established players in the Indian MCE industry enjoy healthy operating margins. A number of players operate as assembly facilities with high proportion of imported components procured as bought-outs/ completely knocked down (CKD). Managing raw material costs through effective sourcing, especially for imported content coupled with benefits from economies of scale had resulted in growing profitability for the industry during the five-year period from 2003-04 to 2007-08. However, the profitability declined in recent periods – especially during H2 2008-09 and H1 2009-10 – contributed by a sharp contraction in demand, thus resulting in under absorption of fixed costs.

Inventory pile-up was another cause of concern for the players during H2 2008-09, especially for those with significant import content. A number of companies anticipated robust off-take in H2 2008-09 and placed orders for components and CKDs from their global parents/suppliers. With a longer lead-time on imports, the sudden contraction in Q3 2008-09 resulted in stock pile-up.

Additionally, a number of OEMs were forced to extend support to their weaker channel partners (through interest subventions and longer credit periods), resulting in a significant increase in working

capital and deterioration in capital structure. However, with a relatively moderate level of leveraging, many industry participants had sufficient cushion to support these borrowings. With a sharp decline in volumes, most of the MCE players now have surplus capacities, and hence have cut back on fresh capacity-additions. However, some players with new product introduction plans may continue to invest, albeit at a slower pace.

The MCE industry has bounced back strongly during H2 2009-10, supported by easing of liquidity conditions; correction of pipeline inventory and revival in infrastructure investments led by government spending. However, the overall performance of the industry in 2009-10 is expected to be relatively modest owing to the weak first half.

DEMAND FOR SERVICE AND SPARES TO INCREASE IN IMPORTANCEGlobally, income from spares and services accounts for over 15 per cent of revenues for major MCE companies, supporting profitability and smoothening revenue volatility. This also enables the manufacturers to sell their goods initially at a competitive price while making up in the service contracts - a lifecycle approach to profitability. However, at current levels, the contribution to revenues in the domestic market from spares and services contracts remains low, largely due to a relatively small equipment population and availability of non-OEM spares.

The life of an equipment is around seven years although the actual on-road fleet in India is sometimes over 20 years old. Ground-engaging tools (GET) like undercarriages, buckets and teeth,

especially in the case of mining equipment, have to be replaced faster based on surface and usage while engines, transmissions and axles have to be overhauled after 4-5 years of use. Hence, there is a strong potential for annual maintenance contracts (AMCs) and spares business.

However, it needs to be noted that a

large geographically concentrated vehicle population helps generate economies from the service network. As the population of on-road equipment increases, service and spares income is likely to become a stable, high margin and counter cyclical source of revenue.

USED AND RENTAL EQUIPMENT MARKETS ARE STILL IN THEIR NASCENT STAGESWhile there is good potential for used equipment in India, the market size of which is estimated at about three times the primary market, India does not have an established common platform for trading in used equipment.

Again, the current rental penetration in India at around 7-8 per cent remains low as compared to the global standards of 50-80 per cent. An average of 30 per cent of the equipment sold in Europe and over 60 per cent in the UK is to rental operators. A robust rental market enables reduction in investments in projects by outsourcing the equipment requirement (including spares and services) and improving capacity utilisation of equipment. The key equipment in the rental fleet in India currently include backhoe loaders, pick-and-carry (PNC) cranes, excavators, motor graders and vibratory compactors.

While a number of organised equipment banks have entered the fray with large fleets (of over 100 equipment), the market continues to be serviced mainly by small fleet owners with less than 10 equipment each. However, there are various structural/operational concerns that need to be resolved for the Indian equipment rental markets to evolve. Concerns include lack of synchronisation of interstate tax

policies (on movement of equipment between states) and logistics of the equipment. Further, the dominance of unorganised market participants that operate on cash transactions (on rentals, thereby avoiding taxes and enjoying an

unfair advantage to the larger rental operators) prevents the evolution of a more organised system.

With the large infrastructure investment proposed over the next few years, demand for rental equipment is expected to see a large growth over the medium term. Globally, a number of OEMs are actively

Low-cost countries like India and China stand to gain from the potential for export of components, equipment and engineering/designing services - an area where

China has already made significant inroads.



involved in the equipment rental business, an area that has not caught on in India as yet.

LOW LEVELS OF INDIGENISATION EXPOSE MNC COMPANIES TO HIGH FOREX VOLATILITYThe Indian MCE industry has only few large local players. Most of the international majors in the industry are already present in India, either through subsidiaries or joint ventures. The level of indigenisation in the domestic MCE industry, however, continues to be low (at around 40-50 per cent depending on the company and the product) with the import of technology and component CKDs (especially for power train and hydraulics) by the Indian entity from its technology parent. The key import driver is a lack of domestic suppliers that assure good product quality. A lack of economies of scale has also been a contributing factor in the past, although this is likely to undergo a change in the future. High import content adds to the cost due to the longer lead-time and higher inventory levels for components, and exposes the industry to high forex volatility. In 2008-09 and the first half of the current fiscal (2009-10), rising cost pressures, especially on account of the hardening Yen, affected a number of players with Japanese parentage.

GLOBAL SCENARIOGlobally, the growth in the industry has been led by emerging economies; the economic crisis in the recent past, however, put a brake. The US is the largest mining and construction equipment market in the world followed by China (around 0.3 million units) and Europe (around 0.2 million units). The global MCE industry has been on an upswing since 2003-04 and has grown by over 15 per cent annually until Q3 2008-09. The growth was mainly driven by the fast-growing BRIC nations of China and India. The size of the MCE market in emerging economies has also expanded significantly and now accounts for 50 per cent of the global market as against just 35 per cent in 2004. The Indian market grew by over 30 per cent annually during this period but on a significantly lower base than in other major countries. The key growth drivers were strong economic

development, government and private investments in infrastructure, large government projects like road building, high commodity prices (supporting mining activity), the booming real estate industry and growing levels of mechanisation.

The global MCE industry experienced a contraction in Q3 2008-09 as a result of reduced construction activity, especially in the real estate segment; slowdown in

mining activity and a virtual standstill in equipment financing in the aftermath of the economic meltdown towards the end of Q2 2008-09. In 2008-09, the global MCE industry is estimated to have fallen by over 20 per cent, mainly on account of a 38 per cent fall in global demand for construction equipment while the demand for mining equipment improved in few geographies. The fall in demand was led by sharp declines in the key markets of Europe, Japan and North America.

Barring certain markets like China, the global CE industry continued to fall in the first nine months of 2009-10 as well, although the magnitude of global decline slowed down to around 4 per cent in Q3 2009-10. The mining industry, on the other hand, has shown stronger signs of recovery in Q3 2009-10, as commodity prices started inching upwards. In addition to China, where there has been a full-scale recovery of demand supported by fiscal stimulus and advancement in large-scale infrastructure development, markets like Australia, Brazil, India, Indonesia and Thailand have shown signs of a more gradual recovery. Among the developed countries, the Japanese market witnessed full usage of rental equipment in Q3 2009-10. However, a lack of consumer confidence in the prospects resulted in weak demand for new equipment. Normally, full usage of rental equipment is a precursor for fresh demand.

POSITIVE OUTLOOK Over the past few months, the industry has been on an upturn supported by increased financing availability; step-up in infrastructural investments and pick-up in demand for

commodities globally. Large proposed investments over the next several years in infrastructure (ports, airports, roads) have the potential to sustain the growing demand for CE. The Eleventh Plan Commission (2007-12) envisages the need for an infrastructure investment of over $155 billion for development of roads, bridges, railways, ports and airports and over $2 billion in mining. According to the Economic

Survey of 2009-10, the Ministry of Road Transport & Highways has set a target of completion of 20 km of National highways per day, translating to over 35,000 km during the period from 2008-09 to 2013-14. The NHAI has formulated closely

monitored work plans for awarding 12,000 km of projects each during 2009-10 and 2010-11. The Special Accelerated Road Development Programme in the North-eastern Region (SARDP-NE) envisages two/four-laning of about 5,184 km of National Highways and two-laning/improvement of about 4,756 km of state roads. Since inception in December 2005 and until December 2009, 515 projects across 31 states at a cost of Rs 580 billion have been sanctioned for urban infrastructure development under the Jawaharlal Nehru Urban Renewal Mission (JNNURM). These are, but a few of the large infrastructure initiatives that are currently under way in the country.

The long-term demand drivers for the construction equipment industry are relatively low levels of mechanisation and penetration of equipment in the construction industry; proposed heavy investment in infrastructure and increasing population and urbanisation. The demand for mining equipment is expected to grow in line with the demand for metals and energy.

Low-cost countries like India and China also stand to gain from the potential for export of components, equipment and engineering/designing services - an area where China has already made significant inroads. Some of the areas that need to be addressed during this growth phase include introduction of customised products for the Indian markets; setting up of a viable and efficient aftermarket network; an equipment rental & used-equipment market and training of manpower to operate the equipment.

Courtesy: ICRA Rating Services

While there is good potential for used equipment in India, the market size of which is estimated at about three times the primary market, India does not have an established

common platform for trading in used equipment.


aterial handling equipment (MHE) includes all the mechanical machinery that are deployed throughout the manufacturing, distribution, consumption

and disposal processes. MHE increase throughput, control costs and maximise productivity. With MHE playing such an important role in all industrial segments, it is vital to ensure that these are maintained well. Moreover, while using the equipment, the required safety precautions need to be kept in mind. All these efforts will enable a safe and smooth material handling process.

MHE MARKET IN INDIAToday, India has the capacity to manufacture almost all types of MHE. However, one of the major barriers impeding the growth of MHE market is the poor level of sophistication of the equipment. For

example, an automobile company, even today, may prefer to import a high-end system for their vehicle rather than using a locally manufactured one. One of the major reasons for this is that the segment is still dominated by the unorganised players, which account for almost 80 per cent of the products. However, with the fast-paced economic growth of the country, and with the constant inflow of foreign investments, the MHE industry is poised to scale new heights.

Elaborating on the current market scenario of MHE industry, Rajesh Sharma, VP & Head - Marketing, Escorts Construction Equipment (ECEL), explains “Investment on infrastructure projects such as urban utility, rural infrastructure, modernisation of airports, mass rapid transit system (MRTS), growing power sector, etc, have fuelled the demand for material handling equipment industry and we are looking at huge growth

potential. With Indian economy poised for a sustainable, nine per cent plus growth per annum and government’s five-year plan (11th Plan & proposed 12th Plan) documents envisaging various policy initiatives for sustainable growth, we can look at huge growth in this segment in the long term.” He further adds, “The short-term demand scenario also looks good, as the budgetary allocations for developing infrastructure in current fiscal of 2010-11 have seen a huge set-up. This would lead to a significant increase in demand for material handling equipment.”

According to Tushar Mehendale, MD, ElectroMech, the size of the Indian MHE industry is estimated to the tune of `5,000 crore and is likely to grow at 20 per cent year-on-year over the next five years, in keeping with overall economic growth. The two growth drivers for this segment include domestic production and foreign trade.

Though the Indian material handling industry is witnessing a growth spurt, even today, it lacks the desired sophistication, a prerequisite for new age equipment. With an aim to improve its manufacturing competitiveness, and keeping the required safety precautions in mind while designing

and developing equipment, the Indian material handling industry is poised to grow, not only in the domestic market, but also globally.

M SUDHIR MUDDANA

LIFTING UPLIFTING UPTHE COMPETITIVENESS QUOTIENTTHE COMPETITIVENESS QUOTIENT

MATERIAL HANDLING EQUIPMENT



Since MHE is closely associated with the country’s imports and exports, its importance to the logistics industry cannot be undermined. The report titled ‘World Material Handling Products’ states that the global demand for material handling products will grow 5 per cent annually through 2012. The demand for material handling equipment will continue to grow in the areas of manufacturing, logistics, warehousing, general engineering related to power plants, metro or irrigation projects, and government sectors like the railways, ordnance factories, armed forces, etc.

GROWTH DRIVERSApart from the improved level of sophistication, and the increasing foreign investments in the industry, there are other factors that will contribute to the growth of the MHE industry. When asked about the major factors that will take this industry to greater heights, Mehendale avers, “India has few advantages such as robust domestic growth rates, strong internal fundamentals and a healthy banking system that will ensure continuous growth of MHE. In addition, the resumption of a steady inflow of investments from foreign multinationals, increase in domestic spending on infrastructure construction and power projects will also make India an extremely attractive destination for companies that are facing shrinking sales in other economies. Consequently, India is emerging as one of the best global investment options. And as long as industrial investments continue to be made, the demand for capital goods such as material handling systems will grow.”

The widespread use of MHE has led to the shrinking of project timelines and scaling up of projects. This augurs well for the country’s economy, as timely completion of projects – airports, ports, highways, power, steel, etc, propel the economy to the next level of development, believes Sharma.

DEPENDENT INDUSTRIESThe importance of the MHE industry can be gauged by the number of industrial segments dependent on it. Any industry that involves repetitive handling of materials or bulk material handling is dependent on material handling equipment industry.

Mehendale states, “Any manufacturing unit, be it in any industrial vertical, requires equipment to handle materials in the factory. Different verticals need different solutions to cater to their MHE needs. Chemical industry, pharmaceutical, construction, electronics, energy, food & beverage, metalworking, metalcasting, plastics, aerospace manufacturing, automotive industries – all are dependent on MHE industry.”

Talking specifically about the cranes segment, Sharma observes, “The complete manufacturing set-up is highly dependent on the MHE industry. However, for us more pertinent would be to talk about cranes, which includes approximately 8,500 cranes and stands at `1,000 crore. In the mobile crane segment, where we have huge presence, we enjoy a marketshare of more than 60 per cent.”

GOING GLOBALThe global MHE market is projected to increase more than five per cent per year till 2012. In such a case, rapidly developing areas such as China and India will witness a rise in the global demand due to their healthy economic conditions. Talking about India, the Indian MHE industry is competitive as compared to developed countries like the US, Japan and Germany. Here, though there is lack of sophistication, a major reason for its competitiveness is that the industry offers value for money to customers by providing cheaper equipment, while being reliable.

Another factor that plays an important role in the growth of the Indian MHE industry globally is that, even today, economies such as the US, Europe and Japan, have not recovered fully from the slowdown, whereas India witnessed a GDP growth of 6.7 per cent in 2009-10 that is

expected to be 8 per cent in 2010-11. Therefore, with all these advantages, the Indian MHE industry may see a rise in sales of about 3 to 4 per cent globally.

SURMOUNTING CHALLENGESDespite the positive prospects, there are still several challenges that the equipment manufacturers face. Unless these are not overcome, it will be difficult to have a smooth and seamless MHE industry in India. Some of the problems faced are as

follows: There is low demand and low-scale of

operations. Due to this, MHE manufacturers find it difficult to sell critical components that are produced in smaller quantities at competitive prices.

There is a strong need for talented and highly skilled people in the MHE industry. Due to better offers from allied industries, all the valuable human resources make the shift. There is a need to enforce stringent

labour laws for those carrying loads manually.

While highlighting about the challenges faced by the material handling equipment manufacturers, Mehendale notes, “The major problems faced by the segment today are related to the low level of demand and volume as compared to major markets outside India. Due to this, Indian manufacturers face a cost disadvantage due to economies of scale as compared to foreign manufacturers from China and other countries. Further, the availability of components from ancillaries and other suppliers is at a much lower level in the Indian market as compared to other countries.” Elaborating further, he adds, “India also has a lot of administrative and infrastructural bottlenecks related to cost of power; delays in transportation and import and export clearances; administrative problems; high taxation limits; high interest rates, etc. Some initiatives from the

Impact of appropriate & efficient material handling equipment in India Reduces the production cycle Creates smoothness in all process like machining,

cutting, bending, welding, turning and painting Reduces the costing of final product Avoids accidents in the unit Reduces man power Improves the quality of the product.

Inputs by Vijay Devta, Sr Sales Executive, Safex Electromech

NEWS ANALYSIS: Business@Orissa

High on the investment radar

on pg. 50



government in these areas will certainly benefit industry. Moreover, the MHE manufacturers should ensure safety, quality & technical innovation in their solutions offered.”

According to Sharma, three major challenges currently faced by MHE manufacturers include:Unrestricted import of used equipmentThe unbridled imports of used equipment has not only impacted the local manufacturer in terms of the new equipment sales, but has also made India a dumping ground for used equipment, which many-a-times compromises on safety & other environmental regulations. The government needs to regulate such imports by imposing stringent rules pertaining to age and condition of equipment.Skill gaps and shortage of trained manpowerSkill gaps & shortage of trained manpower has become a major area of concern. For instance, in the mobile crane segment, there is no policy framework on specifying neither the skill requirement nor a mechanism to develop skilled operator. The need of the hour is to have a national policy framework, which specifies the skill & eligibility criteria for crane operations, and integrates this with a structure to conduct vocational training programmes at schools

and technical institutes. Recently, ECEL have tied up with the Government of Delhi and MITCON, an NGO in Delhi, to provide training to graduates from ITI and polytechnic institutes in operation and maintenance of cranes.Weaker implementation of patent lawsComing to the third challenge, weaker implementation of the patent laws, in India it is difficult to protect one’s design as laws are full of loopholes and the process of enforcing them is long-drawn and cumbersome. As a result, imitation and blatant duplication has become order of the day.

TECHNOLOGICALLY APPROPRIATE & EFFICIENT EQUIPMENTAccording to Sharma, the selection of appropriate & efficient material handling equipment is the most important factor determining the economies of operation. The correct selection would not only bring down the overall cost of operations, but also enhance the safety and comfort of the operators, resulting in less fatigue and consequently more productivity. “Over the years, we have seen the need for more robust equipment with high demand on uptime and capabilities. The equipment manufacturing industry has met these

expectations with technologically advanced products, marking a shift towards more versatile and capable equipment. We, for example, have launched TRX series of cranes, which are higher capacity cranes with higher reaches and are versatile with greater mobility,” he notes.

While Emphasising on how appropriate & efficient material handling equipment can help the Indian industries, Mehendale opines, “As the production processes get more evolved, and with increased exposure of the Indian industrialists to modern manufacturing techniques and global best practices, there is a definite shift towards adoption of newer technologies for industries as well. For example, the industrial cranes segment in India was traditionally dominated by the old 1960s type Russian crane design. However, companies are at the forefront in convincing people to dump the old technology and move towards more modern and contemporary crane technology that is prevalent in Western Europe.” He adds, “With the fast-changing business landscape, clients today demand a MHE model that yields a quicker ROI than ever. Even companies that are replacing or upgrading their existing range of material handling equipment are inclined towards technology that is efficient, faster, safer and cost-effective. This in turn adds to increased industrial productivity with minimum engagement of resources.”

On the shifting trends of the MHE markets towards automation, Mehendale points out, “The general trend in the MHE industry is towards increasing automation, enhancing productivity and maximising safety. Technologies have progressed rapidly in the past decade. We see superior control methodologies in terms of accuracy, repeatability and efficiency in the market today. Advanced mechanisms and use of electrical sensors, invertors help ensure safety while using such equipment.”

According to Vijay Devta, Sr Sales Executive, Safex Electromech, some of new edge technological innovations in India for material handling equipment are: Hydraulic conveyors Hydraulic working platforms and material

lift Passenger cum material lift in construction

industries In process industries roller conveyor.

SAFETY CONSIDERATIONSAlong with the advancements in

Parameters for efficient material handling equipment Safety: Safety is of paramount importance, as the value of human life can

never be underestimated.

Flexibility: An ideal material handling system should be as flexible as possible to allow for changes in the production flows that are so common with changes happening in the industry due to shorter product lifecycle.

Credibility: The vendor for the material handling equipment should have a solid credibility and name in the market. A renowned company cannot afford to take ‘short-cuts’ that will destroy its reputation, and hence, the products will always be up to the mark.

Technology: The choice of correct technology for the desired job is very important. Usage of exotic technology for a simple job does not serve any purpose just as usage of a simple technology for a difficult task. Hence, correct evaluation needs to be made on proper selection of product and its specifications.

Support: After-sales support is extremely critical to ensure that the equipment is in top notch running condition. The vendor must be in a position to support the equipment till its full lifespan.

Inputs by Tushar Mehendale, MD, ElectroMech

TIPS & TRICKS



technologies, another factor that will help improving the MHE industry is the adoption of adequate safety measures that need to be taken while manufacturing the equipment. This will not only avoid losses, but will also increase the overall productivity. “Optimum utilisation and good maintenance practices coupled with adequate knowledge on working of the equipment increase the life of the equipment and ensure safety of the operations,” said Sharma.

According to Mehendale, the adherence to safety norms while manufacturing products is a challenge that the Indian market has not been able to live up to. The absence of a regulatory body for standard safety norms is a concern. Strict discipline is required in designing and manufacturing of hoisting equipment to ensure that there is not even a remote possibility of accidents happening. The ability to safely and securely lift load against gravity without any casualties poses a challenge.

Devta believes that the process of using material handling equipment can be safe by using the following: Hand gloves Helmet Goggles Ear phones Safety belts.

Design aspectsDesign plays a vital role in equipment manufacturing. Considering the case of warehouse operations, material handling has a major effect on the efficiency and speed of the operation, which eventually results in the increase or decrease of time during order completion cycles. Therefore, investments made in MHE are important and always based on long-term requirements, considering product volumes and varieties. While designing an effective and efficient material handling system, a few guidelines to be followed include: The system has a continuous flow of material, i.e. zero idle time The use of standard equipment as it ensures low investment and

flexibility, especially in the case of future changes in material handling requirements

Incorporating gravity flow in material flow system Ensuring a minimum ratio of the dead weight to the payload of

material handling equipment.Selecting best fit equipmentAnother aspect to be kept in mind is the importance of selecting the right equipment that suits the needs. The selection of a particular system depends on the following factors. Speed in handling Product characteristics (weight, size, shape) Volumes to be handled Productivity Nature of the product (hazardous, perishable, crushable).

SURGING AHEADWith the advancements in technology, growing awareness on safety of equipment, large number of foreign investments, etc, the MHE industry is bound to grow. “Apart from advances in automation and controls, a lot of development is also being made in ensuring that the products are environment-friendly without sacrificing cost-competitiveness. An example is the distinct shift taking place in several industries in eliminating hydraulics and moving towards purely electrical drives. Thus, the MHE industry will soon be seeing a lot of exciting new developments in the near future and as always will help its customers maximise their ROIs,” concludes Mehendale.


As mining becomes intense, the role of mechanised and highly As mining becomes intense, the role of mechanised and highly productive, safe, efficient and cost-effective machinery and productive, safe, efficient and cost-effective machinery and equipment becomes paramount. However, it is also critical that equipment becomes paramount. However, it is also critical that India should be well-equipped to meet this surging demand for India should be well-equipped to meet this surging demand for mining equipment and technologies. mining equipment and technologies.

T

GROWING ON STRONGFUNDAMENTALS

he mining sector has been witnessing a growth rate of 3-4 per cent annually over the past several years. Moreover, the new mining policy of the Government

of India is expected to give a further boost to the sector and increase its share in the GDP. One of the factors that contributed to this growth is the use of technologically advanced equipment. Subsequently, the growth in the mining sector translated into an exponential growth for the Indian mining equipment industry. Currently, the market size of the industry in India is estimated approximately at Rs 3,700 crore. MM Shahane, EVP & COO – Engineering Products Business Group, Voltas, avers, “The size of the mining and construction equipment industry in India today is roughly to the tune of Rs 13,000 crore. However, if one considers only the mining equipment segment, which basically consists of large heavy earth moving machinery like rope shovels, huge excavators, mining loaders, dump trucks, draglines, underground equipment, then the size of the industry would be around Rs 3,700 crore. This would also include spare parts and service-related business.”

MINING SECTORIndia is a mineral rich country, with coal dominating the field. Majority of the country’s mines are located in Karnataka, Andhra Pradesh, Orissa, Bihar, Gujarat, Madhya Pradesh and Rajasthan. In the year 2008-09, the production from these mines was worth Rs 1,13,700 crore amounting to approximately 2.8 per cent of the country’s

PURNA PARMAR AND SHIVANI MODY

MINING EQUIPMENT


MINING EQUIPMENT

GDP. The mining sector is extremely labour-intensive, and therefore, generates large number of employment opportunities, with over two million people working in the sector.

Coal mining, which covers around 80 per cent of the mining activity, is slated to grow at a fast pace as power demand is expected to rise enormously. The government is planning to double power production that in turn will increase the demand for coal and give a boost to coal mining. Moreover, as surface coal mining is nearing saturation, mining companies are exploring the underground mining option for which sophisticated and highly technical equipment are required. Besides, with a growing economy, there is always a demand for all types of metals and minerals. Hence, as the mining sector becomes dynamic, the role of mining equipment also becomes decisive.

INDIAN MINING EQUIPMENT INDUSTRYThe overall performance of the mining equipment segment has been strong in the last three years. During 2009-10 and the current financial year, there have been substantial orders for mining equipment from various mining segments like coal, iron ore, zinc and other minerals. This has been primarily driven by the growth of the mining sector wherein many companies are undertaking large projects for mining of various minerals.

TECHNOLOGICAL TRENDSWith the Indian Government keen to

develop the country’s mining sector, mining equipment manufacturing companies offer products at par with international standards. “Several technological advancements have been happening in the area of mining equipment over the years. These include developments in hydraulic technology, use of environment-friendly technology like lower emission engines, electric-driven machines, etc. Further, there has been an increasing use of sophisticated electronics, control systems and computers for monitoring the mining equipment, which has extended up to even remote monitoring usage global positioning systems (GPS) and satellites,” says VS Satyan, Branch Manager, Dozco. The technology developments have made the maintenance of mining equipment much simpler. It is also possible to track the performance of various machines by logging onto the data through computer systems.

“The trends in the mining equipment industry revolve around developing many new types of machinery and technology that aim at reducing the mining cost. There have also been many upcoming trends in underground mining equipment where new techniques like long wall and high wall are being employed more often now,” observes Shahane.

The deployment of automation in the mining sector is relatively a recent trend. Implementing automation techniques in mining is far more complex considering the extreme applications.

AUTOMATION SOLUTIONSAdoption of fully integrated and automated

systems have made mining operations efficient and have addressed the issue of rising costs and safety of workers at remote sites. Moreover, it has helped minimise fatal incidents on mine sites.

The ‘smart’ mine of today include machines that navigate underground and collect as well as transmit complex sample analysis data. Technologies for automated aerial mapping as well as explosives are important developments for the industry, alongside sophisticated new processing technologies to access mineral sands, resources and uranium deposits. To carry out remote operations, many companies have set up centres in their facilities. The centres use remote-controlled ‘intelligent’ trains, drills and trucks to carry out the daily tasks. Teams are trained to manage mine operations remotely in sites, which are located thousands of kilometre away.

Annette Slyman, Commercial Manager, Caterpillar Global Mining Technology, states, “We have progressed in the mining machine automation, accelerating from the automation of specific functions of operator-controlled machines through semi-autonomous machine operation and ultimately to totally autonomous machines. For example, the largest Cat track-type tractor (bulldozer), the D11T, enables AutoCarry, which provides automatic blade control during the carry segment of the dozing cycle. AutoCarry is intended to enhance productivity in high production earthmoving situations with carry distances of more than 30 metre. By monitoring ground speed with the belly-mounted radar gun, AutoCarry controls blade load through

MINEGEM equipped LHD Courtesy: Caterpillar

D11T CD dozing at dusk Courtesy: Caterpillar


MINING EQUIPMENT

the electro-hydraulic controls to maintain optimal speed – without any input from the operator.”

A key area of automation in mining is robotics. Automation and robotics have an increasing impact on the safety, predictability, and precision of mining. It provides increased computing power; new algorithms for signal processing, perception and control; new sensing technology including GPS, radar and laser systems, which adds to the efficiency of the operations.

Professor Hugh Durrant-Whyte, Director, Rio Tinto Centre for Mine Automation, says, “The ability to accurately locate, control and co-ordinate robotic machines also delivers better predictability. When equipped with sensors, these systems are able to provide real-time estimates of material geometry and geology;

the operation of such machines can be controlled in a near optimal manner. Using this information to plan and schedule the actions of many robotic mining machines, working in tandem, will result in increased utilisation, precision and overall efficiency.”

Delving in depth on the benefits of automation, Slyman says, “Depending on the level of automation, the benefits include enhanced safety, increased productivity and sustainability, improved machine utilisation and many others. For example, removing the human operator from the underground mining environment improves safety immensely.” Slyman further adds, “Productivity increases when the machine is operated optimally, without human variability. Improved utilisation comes from fewer machine problems introduced

through operator errors, and in the case of remote operation of underground machines, the operator does not have to travel underground to rectify the problem. Shift changes are seamless. Sustainability mainly is enhanced through better fuel utilisation during automated functions.”

Some of the specific innovations in the field of automation for the mining sector include automated surface haul trucks, automated underground load-haul-dump (LHD) vehicles, and autonomous drills. In some cases, only components of automation have been developed, such as automatic swing control for drag-lines, heading control for coal shearers, or proximity warning and safety systems for trucks. Such developments reflect the relatively conservative nature of the industry in developing and adopting robotics. Experience shows that it is difficult to derive the full benefit when only part of a system is automated.

The mining sector has benefited greatly from improvements in computing and communications technology over the last few years, with mobile communications playing an increasingly important role in automation systems. A key focus for mining is tighter integration between increasingly clever equipment and back-end systems such as enterprise resource planning (ERP). For new mining companies, such as those in China and India this will provide a competitive edge. These countries have an advantage as the facilities are being built using the latest automation and control equipment.

Slyman says, “It appears that significant advances in perception, communications and distributed intelligent control systems, along with integration efforts with existing enterprise, fleet management, equipment maintenance and planning systems will bring advanced technologies, such as autonomous machine operation, into the realm of everyday operations over this decade and the next.”

New techniques are under trials in underground coal mining with elements of tracking the seam and keeping machines inside the seam. The mining sector is now moving into the third generation of automation, known as autonomous systems, as distinct from automated or automatic components of the mining process.

Solutions are now emerging that will allow companies to deploy intuitive, remote-controlled machines into remote

and/or dangerous areas and enable them to perform chemical analysis as well as independently assess and react to geological conditions in real-time. Automated aircraft are also increasingly being considered to perform aerial mapping of mine operations. Underground loaders are being fitted with technology to allow mapping of tunnels in real-time, while ore-digging equipment is increasingly being fitted with sensors as a means to quickly assess mineral concentrations.

WIRELESS SYSTEMS Nowadays, companies are using process-based production management system using electronic machine monitoring and PDA technology. Several firms have reported increase in productivity through the adoption of such technologies. The systems garner the desired inputs through accurate, meaningful and on-time process measurement enabled by electronic machine monitoring and real-time shift reporting by shift supervisors through the use of PDAs. In addition, deploying real-time monitoring systems can be useful for immediate resolution of mine site issues. Wireless technology has been effective in underground operations for sensing, control and visualisation systems for effective teleoperations.

TIME TO SPEED UP With the need to speed up high capacity mining and increasing automation, the requirement for large equipment is also expected to shoot up. The mining sector is now looking at highly sophisticated, efficient, customised and safe equipment, and therefore, it is imperative for the mining equipment companies to introduce technologically innovative machinery and increase R&D investments. Since there is a huge pressure on mining companies to speed up production and also maintain quality of the minerals, the demand for highly sophisticated equipment is sure to go up. The end-users opt for operationally efficient, safe and cost-effective machinery, and hence the industry needs to look at ways to fulfil the emerging demands.

The Indian mining companies largely cater to the domestic market. However, with the opening up of this market to the international players, the competition has intensified and the stakes have gone up tremendously. The local companies need to start benchmarking product efficiencies

Delay in project commencement, poor logistics support, lack of skilled machine operators and service mechanics are some of the challenges faced by the equipment manufacturing industry. However, the growth potential in the mining sector

overshadows these challenges.

S SRINIVASAN,Head - Business Planning & Development, Construction Equipment, Business Sector,

Larsen & Toubro


MINING EQUIPMENT

and quality with global norms. Shahane notes, “The Indian companies

that manufacture large mining equipment do not have the latest technologies related to electronics and control systems as seen in some of the imported mining equipment. The imported machines are integrated with automation and control systems. While Indian companies can upgrade their equipment, it takes time for development of the same. However, there are strong R&D opportunities for Indian companies, which would allow them to compete with the international manufacturers.”

Unlike agriculture and smaller construction equipment like tractors and backhoe loaders, the mining equipment volumes do not support multiple manufacturing locations. “There are few global players who support the global demand through competitively-scaled manufacturing locations. Indian companies are competent to source the best mining equipment through strategic partnerships with such world majors. L&T through its partnership with Komatsu has the capability to provide the whole range of mega-mining equipment. L&T has already supplied 240 tonne electric dump trucks to India,” says S Srinivasan, Head - Business Planning & Development, Construction Equipment, Business Sector, Larsen & Toubro.

While elaborating on the trends shaping up in the mining equipment industry, Srinivasan points out, “Today, larger size mining machines are being planned. Equipment is purchased with long-term maintenance contracts where the supplier is responsible for equipment maintenance including supply of spare parts. Moreover, high equipment uptime and higher asset utilisation is encouraged. With the advent of global mining companies, the demand for mining equipment has also increased, further growing the industry base of mining equipment manufacturers.”

According to Srinivasan, there is a significant increase in private participation in the Indian mining sector. The private sector is bringing in world-class mining technologies to India. Subsequently, large-size hydraulic excavators, ultra-class electric dump trucks and other mega-mining equipment are expected to be deployed in Indian mines. The machine utilisations are also expected to increase significantly. The use of modern technologies like geographic information system (GIS), GPS, Mine Planning Software, among others have helped the Indian

mining industry to a great extent.

ROADBLOCKS While the mining sector is slated to grow in the coming years, the mining equipment manufacturing industry is confronted with many challenges. For instance, environmental restrictions for open cast mining, stricter emission norms, higher competition from MNCs, and constraints in availability of financing are some of them. It is also possible that many mining projects may get detained due to delays in approval for forest and environmental clearances. “The manufacturers face challenges in terms of high input cost, high taxation rates, administrative delays in customs, bottlenecks in transportation due to administrative issues like road permits, etc. This increases the cost of operations in India,” opines Shahane.

Meanwhile, Srinivasan highlights, “Delay in project commencement, poor logistics support, lack of skilled machine operators and service mechanics are some of the challenges faced by the equipment manufacturing industry. However, the growth potential in the mining sector overshadows these challenges.”

FUTURE BEHOLDS The mining sector aims at achieving Rs 4,16,500 crore by 2015 and this augurs well for the mining equipment companies. On an average, 50 to 60 per cent of mining

equipment business in India comes from coal sector; approximately 20 per cent comes from cement (lime stone) sector, 10 per cent from iron ore and 10 per cent from other minerals like zinc, copper and bauxite. The coal and iron ore mining is expected to be intensified, as the government strives to meet the set target of ‘Power For All’ in the next couple of years. The mining equipment market is largely driven by the coal-mining sector, which is witnessing increased coal production for thermal power plants.

The current power generation in India is estimated at 1,63,669 Mega Watt (MW) as on July 31, 2010. Of this, 53 per cent is from coal-based thermal power plants. The government plans to add 78,000 MW during the Eleventh Plan period. Around 54,355 MW of energy is coal-based. Even if government realises 65 per cent of the planned output, an estimate considered by independent agencies, it is much better than 50 per cent achieved in the last three Five-year Plans. The planned addition to generation capacity during the Twelfth Plan is expected to be around 1,00,000 MW.

According to Srinivasan, India will continue to depend on coal-based thermal power plants to meet its energy demand. This growth in power generation will require large-scale deployment of mining equipment, and thus, we expect the market for mining equipment to grow by at least 20 per cent over the next five years.

The growth prospects for the industry are strong. These are due to large investments of over Rs 10,000 crore in various mining segments. In coal mining, Coal India and its subsidiaries are undertaking many new coal projects, while there are many coal blocks allotted to private sector companies, which are also expected to start operations in the next few years. These include Reliance (SASAN), ESSAR, Tata Steel, Hindalco, Tata Power, etc. In iron ore, there are many steel projects planned, which will require higher production of iron ore and many companies like SAIL, Tata Steel, Jindal, JSW Steel, Bhushan Steel and other smaller mining companies are expected to invest in developing new iron ore mines in the near future. In addition, the construction of infrastructure is expected to witness a boom since the government is trying to achieve an economic growth of 8 to 9 per cent in the next decade. All these indicate a bright future for mining and allied equipment industry.

The size of the mining and construction equipment industry in India today is roughly to the tune of Rs 13,000 crore. However, if one considers only the mining equipment segment, which basically consists of large heavy earth moving machinery like rope shovels, huge excavators, mining loaders, dump trucks, draglines, underground equipment, then the size of the industry would be around Rs 3,700 crore. This would also include spare

parts and service-related business.

MM SHAHANE,EVP & COO – Engineering Products

Business Group, Voltas


eyveli Lignite Corporation (NLC) is India’s largest lignite mining company and one of the country’s leading power-generation companies. NLC operates

three open-pit mines in Neyveli, Tamil Nadu, that produce around 24 MT of high-grade lignite per year. Mine I, the company’s original mine, is operated over an area of nearly 27 km2 and offers a reserve of about 365 MT. Mine II, first opened in 1984 and expanded in the early 1990s, features a reserve of nearly 400 MT. Most of this production is used in NLC’s thermal power-generation plants, which have a combined capacity of 2,490 MW.

Neyveli Lignite has been long searching

for a technology and automation partner to meet its future needs amid the fast changing dynamics of this industry. Amongst the successful for more than two decades, Siemens, which has been catering to the Indian mining sector by providing electrical turnkey solutions for various applications, proved to be the preferred partner for NLC. Siemens offerings include a range of electrical solutions and automation systems for the operation of conveyors and special mining machines such as spreaders, bucket-wheel excavators, stackers and reclaimers.

DATA TRANSFER VIA WLANSiemens, in September 2008, commissioned a complete electrical and automation system for a line of six conveyors and four special

mining machines, including two bucket-wheel excavators (BWE), one crawler-mounted tripper car and one spreader at Mine II. The system was designed for nine conveyors, which were subsequently put into operation step by step. It was the first time in India that conveyors were equipped with variable frequency drives.

These conveyors can be speed controlled from a centralised location depending on the load condition. The result is low operating costs, high availability and very low wear. Individual speed controls at the head guarantees optimised operating conditions of the conveyors, especially under heavy load conditions or when the drive drums are wet. The entire flow of material in the open-pit mine can be tracked

With surge in mining activities in the recent years and heightened focus on environment management, it is mandatory for miners today to deploy the best-in-class equipment and state-of-the-art technologies, which aim at reducing pollution to its minimum. One such promising development in this field is the deployment of electrical and automation systems, which have significantly helped Neyveli Lignite Corporation in lifting up its productivity and efficiency.

N

RELIABILITYRELIABILITY and EASE of MAINTENANCE by DESIGNDESIGN

INNOVATIVE SOLUTION FOR OPEN CAST MINES INNOVATIVE SOLUTION FOR OPEN CAST MINES


INNOVATIVE SOLUTION FOR OPEN CAST MINES

and controlled by Simatic S7-400 route controllers. A WincCC server provides relevant production data online. Since the conveyors need to be shifted from time to time, communication via cables was impractical. To overcome this problem, Siemens Scalance industrial WLAN equipment has been used to connect the conveyors and machines to the centrally located gateway PLC. Even when the conveyors are shifted, the WLAN equipment ensures instant and reliable communication. With the implementation of the system, the operator at a central location can select one of the 20 probable routes and issue the start-and-stop commands for each of them. All operation and machine-status data are available at a centralised control station, thereby reducing troubleshooting time and enabling the generation of sophisticated reports that allow immediate access to historical and live production data.

VARIABLE FREQUENCY DRIVESThe intricacies of the project can be best understood with the help of Figure 1, which graphically represents the layout of the conveyor line with four mining machines. The two bucket-wheel excavators (BWE 1 and BWE 2) carry out the excavation of overburden and dump the material on the first conveyor, which is then transported away by a series of further conveyors. The last conveyor is equipped with a crawler-mounted tripper car, which in turn dumps the overburden onto the spreader. The BWEs are equipped with industrial-grade laser scanners mounted on their discharge booms. These laser scanners detect the amount of overburden being excavated in real time and continuously transfer this data to the central control room over the wireless communication system. The centralised PLC in the control room analyses this information and determines the cumulative load on the conveyor line fed by both BWEs.

Each conveyor, length ranging from 800-1,800m, is capable of carrying 20,000 tonne of overburden per hour at a maximum speed of 5.4 m/s. To achieve the controlled power delivery to these high-capacity conveyors, each conveyor is

equipped with Simovert AC Masterdrives in 12-pulse configuration and controlled by a special software tool kit that has been developed for conveyor applications and runs on the FM458 technology module.

DYNAMIC CONVEYOR SPEEDThe speed variation of the conveyor ensures the safety of people and equipment, optimum usage of energy and avoidance of oscillations. The software features belt-slip supervision for safe operation of the conveyors. The current conveyor load is continuously recorded and stored during breaks. This feature permits a sophisticated load-based pre-control function that optimally adapts the torque to the conveyor load after a shutdown. This guarantees equal load sharing at start-and-stop operations as well as during normal operation and helps avoid any oscillations even at varying speeds and changing loads.

Due to the length of the conveyors, it takes more time to come to a complete stop from a full speed operation. In order to

use this massive inertia, the power is fed back into the system. Thanks to this innovation, mechanical brakes are only used when speeds reach near to zero, which significantly reduces wear.

The maximum speed of each conveyor is specified at 5.4 m/s and the maximum length of a conveyor is 1,800 m including potential conveyor length extensions. To avoid sudden changes in the speed of the conveyors, speeds remain fixed within a certain band of tonne-per-hour loading. When the loaded capacity is up to 60 per cent of the maximum, the conveyor speed is 65 per cent of the maximum possible; between 60-75 per cent of maximum loaded capacity, the conveyor speed is 75 per cent; and between 75-90 per cent of maximum loaded capacity, the conveyor

speed is 85 per cent. When empty, the conveyor line works at 55 per cent of the maximum speed possible to save energy.

After restarting the conveyor system with a simultaneous startup of both BWEs, the speed is immediately increased to 96 per cent and it remains at that level for five minutes. This prevents the transfer chutes from being blocked by existing material on the conveyor line or by the discharge boom of the BWEs. After running the line at 96 per cent speed for 5 minutes, the gateway PLC selects the optimal conveyor speed based on the loading pattern. Speed-increase commands are given to all the conveyors simultaneously to avoid chute blocking.

If only one of the BWEs is started up, then the command is issued to all conveyor PLCs to change the speed to 65 per cent of the maximum speed. In a situation in which both BWEs are running and one stops, the line speed is reduced to 65 per cent in a phased manner. This ensures that higher loads on the conveyor line are cleared before the speed reduction is initiated. In

the event that both BWEs are stopped, the conveyor line will become empty in due course. To minimise energy consumption in this phase, the conveyor line is operated at 55 per cent of the maximum speed. Similarly, the speed reduction is done in a phased manner.

Multiple technologies like these which have been adopted recently in mining have truely exemplified the need for automation in this space. Latest technologies for operation of conveyors and special mining machines have not only enhanced the process functioning and productivity but also strengthened safety conditions for equipment and the people working on it.

Atul Joshi, Chief Manager - Mining Group,Industry Solutions Division, Siemens

Figure 1: Confi guration of the BWEs, conveyors, CMT and the spreader


SMART ENGINEERING MATERIALS

SMART ENGINEERING MATERIALS: Unravelling A New World Of Opportunities .....................132

CERAMICS: Creating A New Wave In Energy Technology .............................................................138

NEW MATERIALS: Adding Substance To The ‘Material’ World ......................................................143


dvanced materials are amazingly versatile. They can have entirely new physical properties including the ability to memorise shape, or sense

changes in the environment and respond accordingly. The field of advanced materials research is broad in scope, with numerous potential applications. Today, research is need-based, driven by the market demands, and in tune with the Olympian motto – altius, fortius, celtius that mean higher, stronger and faster. This

is evident from the fact that a product, which is used to make windscreen wipers run smoothly and quietly, is also the main component for stain-resistant carpet, upholstery as well as the non-stick surface on frying pans, for instance, teflon also known as polytetrafluoroethylene (PTFE). It has found myriad uses, the most conspicuous being kitchen gadgets that need to endure a

severe working environment and last long. Materials are divided into groups based

on what they are made of. These groups include polymers, metal alloys, ceramics, semiconductors, composites and biomaterials. In addition, the search for lighter, stronger or cheaper materials led to the development of glass fibre reiforced plastics (GFRP) for fibreglass, half a century

ago. This paved the way to the exotic world of composites made from metals or polymers or ceramics – with added strength coming from powdered particles or fibres embedded in them.

A

The last five decades have witnessed an unprecedented spurt in ‘designer’ materials that address specific problems in industries, research or military applications. Today, advanced materials outperform conventional ones with superior properties such as toughness, hardness,

durability and elasticity. The development of advanced materials enables the design of new products, including medical implants and computers, and thereby opens up a new world of possibilities.

UNRAVELLING A NEW WORLD OF OPPORTUNITIES

Nickel-based superalloys not only have high temperature oxidation resistance, but also the incredible property of not melting, not even softening at 14000. That is only

2000 below their melting points.




Different types of composites are available now such as metal matrix composites (MMCs), polymer matrix composites (PMCs) and ceramic matrix composites (CMCs).

Rigid foams are plastics that have been ‘blown’ with gas during solidification, and act like wood when machined or shaped. These are commonly used in lightweight but strong furniture or for construction of houses. Expanded metals or honeycomb structure type metals and alloys are often used in aerospace engineering to reduce weight drastically without sacrificing strength.

While some advanced materials are already well-known, it will take a few more years for others to find applications in products. Given below are insights on some advanced materials and future technologies:

AN ARRAY OF ‘SMART’ MATERIALS ‘Smart materials’ respond to the minutest changes in their surroundings such as temperature, light, magnetic fields or electrical currents. Future research may result in the development of materials for building self-repairing houses; making antennae that bend towards a weak signal, liquids that solidify when heated, and cans that can be crushed and could regain their original shape under heat – the ‘shape memory alloys’ (SMAs). Originally invented in early 1960s, SMAs did not find too many applications. It just remained a laboratory curiosity.

The first alloy with memory effect was ‘Nitinol’ –half nickel and half titanium, which was difficult to cast or form or weld. Today, the Japanese have patented more than 160 stainless steel grades that exhibit the SMA effect, so virtually every designer can now afford to use them. Medical instruments and implants received high level of acceptance in the market. German companies are offering a tubular maze of SMA, small in diameter, as a ‘stent’ to widen the arteries of heart patients. These small diameter mazes blow up by ten times to their original size when

they come into contact with human blood, which is warmer than outside temperature.

At present, smart materials are made by embedding sensors into existing materials. For example, a pressure- or wear-

sensor can be embedded into a car tyre. This will alert the driver when the tyre needs to be changed and how to drive to reduce tyre wear. New ceramics can sense strain in a building structure and provide early warnings on mechanical failure, while others react to changes in temperature or electric current.

Ideally, devices made from smart materials would not only provide the information to assess a situation, but also react to it. These devices could then lay down extra adhesive to reinforce a weakened structure or apply an anti-corrosion agent in response to rust, without any human effort.

SENSORS IN CLOTHES Smart materials in clothes will have the ability

to monitor health, stress levels or other physical needs and respond accordingly. The fibres may become more insulating, if one is cold, emit an alarm if one is about to get an heart attack or provide a read-out of vital health risks. Scientists are working on ways to incorporate ‘responsive polymers into fibres and to make them tough enough to cope with daily wear and tear.

TRANSPORT BUSINESS - CARS, BIKES AND TRAINS No car, bike or train or plane today can be designed nor made without the use of advanced materials, and most importantly, the use of advanced surface engineering when metallic alloys look like they have exhausted their strength properties. For example, thermal barrier coatings of alumina or zirconia, which are advanced ceramics, are applied to the nickel-based superalloys that form the blades of gas turbines at the heart of a jet engine. Automotive vehiclesThe passenger car consists of several types of advanced materials, including plastics and advanced alloys. Ceramics are used in engines to reduce wear; oils with additives maintain lubrication; polymers are used in interiors; pipes are made of neoprene and other specialised materials, etc. If one examines the designs and the bill of materials for making Formula 1 cars, one would see hundreds of new advanced materials used judiciously, so that those cars work consistently and reliably.

Materials scientists have developed new high-strength steels for use in car bodies that are 24 per cent lighter and 34 per cent stronger than conventional materials. The magnetorheological fluids can be used in the suspension system of cars to cope with vibration. These liquids are free-flowing

A shape memory alloy polymer sheet for aircraft

The Maltese researchers have developed a new route for the manufacturing of high value-added auxetic foams from ordinary, cheaply available, conventional foam. These auxetic foams exhibit the unusual property of getting thicker when stretched rather than thinner.

Materials scientists have developed new high-strength steels for use in car bodies that are 24 per cent lighter and 34 per cent stronger than conventional materials. The magnetorheological fluids can be used in the suspension system of cars to cope with vibration. These liquids are free-flowing until they are placed near a magnetic field, and then instantly and reversibly become semi-solid.

FACT

FACT

FACT



until they are placed near a magnetic field, and then instantly and reversibly become semi-solid. In the future, bumper bars may be made of an auxetic material, which grows thicker when stretched and thinner when compressed. Titanium alloys are increasingly replacing the advanced grades of steels, as they are much lighter and stronger – the main deterrent in the use of titanium alloys is the difficulty in extraction of titanium and welding/cutting or fabrication, as it tends to get oxidised at temperatures as low as 1500 – applying protective coatings on large surfaces would be costly and impractical.Bicycles and motorbikes Every part of a bicycle takes advantage of advanced materials including the spokes, tyres, seat and frame. Kevlar tyre tubes are becoming popular because they prevent punctures from thorns, glass, and other sharp objects and can prevent ‘pinch’ flats when a bicycle tyre thumps into a rock.

The frame of a standard bike is made of chromium steel, which is inexpensive and generally rust-resistant. Aluminium alloy is becoming more common but, for the bicycle connoisseur, the ultimate frame material is titanium. It is highly corrosion-resistant and light, but is more flexible and resilient than steel.

BIO-MIMETICS/BIO-MIMICRY: NATURE-INSPIRED NEW MATERIALS Materials scientists have always watched the wonders of nature to get inspired by the simplicity as well as complexity of nature, when it comes to magical effects. The strongest substance in the universe is the spider’s web, which can stretch up to 300 times before it breaks; a flea can jump up to 50 times its own height; an ant can carry up to 200 times its own weight, etc. A million wonders exist around us in nature. Bio-mimicry covers a new generation of materials that aims at mimicking materials and structures in the natural world.

The fibrous structure of bamboo, which is one of the strongest wooden materials, has inspired many composites. ‘Velcro’ is believed to be one of the best inventions since it has limitless use, with a clean & robust appearance and an impressive lifespan. It was inspired by the almost invisible ‘burr’ on wool fibres, which seemed to have interlocking properties.

Hydrophobicity or water-repellent properties commonly used in thin man-made fibre fabrics for windcheaters, light jackets etc, was inspired by the lotus leaf on

which water drops cannot stay. They just roll off. Today there are ‘atmospheric plasma treatments’ that can turn a surface into hydrophobic or hydrophilic (water absorbent). When plastic materials are printed, the inks do not get absorbed causing smudges and blotches. A hydrophilic or hygroscopic surface absorbs the ink fast. Once printed, another plasma treatment makes it hydrophobic, so that in future no fluids or substances could erase what is printed. It is indeed a neat solution from bio-mimetics.

The idea for nanosprings – minute ‘springs’ for use in tiny nano-machines – came from an elastic protein called resilin, which helps power insects’ flight and fleas’ jumping ability. Resilin has a rubber-like elasticity, changing shape under stress without breaking and recovering to its original form when the stress is removed. Scientists plan to use resilin for spinal disc implants, as a substitute for heart and blood valves or even to add extra bounce to running shoes.

Other discoveries inspired by nature include pollution-free water-based paints, and Velcro fasteners that came from observing burrs attached to woollen

materials such as socks.

MEDICAL APPLICATIONS OF ADVANCED MATERIALS Producing a material that can function effectively inside the human body is quite a challenge. They need to be resistant to corrosion; compatible with the biological system; and have the

right kind of strength or flexiblity. Medical applications of advanced materials may be relatively simple, such as uses in dentistry or for making better contact lenses, or they

may be as complicated as producing a functional and lasting hip.

Materials scientists are working towards implanting man-made devices and materials into the human body to overcome rejection of biological implants by the immune system. Implants include:

Artificial joints including hips, knees, spine, shoulder, finger and toe joints

Artificial heart valves Implanted lenses Cardiac stents to hold arteries and veins

around the heart open Urinary catheters Dialysis tubing for kidney problems.

However, how well an implanted material can do its job depends on how its surface interacts with the cells of the body – its biocompatibility. Fouling is caused by the accumulation of proteins and cells on surfaces, which can lead to bacterial infections and other life threatening complications.

Scientists are developing new coating materials to resist fouling of implants. One coating that shows great promise is a two-part polymer that has a sticky side, based on an adhesive made by mussels to hold onto rocks – and another side that repels cells and proteins.

THE MATERIALS AGE Human beings created the stone, bronze and iron ages. Many believe that we are now in the materials age, and it is not hard to understand why. Advanced materials impact every aspect of human life, right from the clothes to furniture or any products used in day to-day lives. The future for new materials seems most exciting.

MAK Babi, Metallurgist & Plasma TechnologistE-mail: [email protected]

Kevlar tyres for bikes

The idea for nanosprings – minute ‘springs’ for use in tiny nano-machines – came from an elastic protein called resilin, which helps power insects’ flight and fleas’ jumping ability. Resilin has a rubber-like elasticity, changing shape under stress without breaking and recovering to

its original form when the stress is removed.

EQUIPMENT BUYING GUIDE: Overhead Cranes

Sourcing TheBest Fit Solution

on pg. 156


CERAMICS

he growing need for production of huge amount of energy and mitigating the human impact on the environment go hand-in-hand. Currently, the primary

reservoirs of energy include fossil fuels like petroleum and coal. However, the use of fossil fuels adversely impacts the environment through the emission of green house gases such as carbon dioxide and nitrous oxide. This poses as a big challenge, which can be resolved by promoting all forms of clean energy technologies. Hence, it is clear that major advances in alternative energy technologies are required at the earliest.

ALTERNATIVE ENERGY SOURCESAlternatives to fossil fuels constitute solar and nuclear energy. The problem with effective use of solar energy revolves around its appropriate distribution among the users.

Many believe that hydrogen will serve as the means of distributing solar energy, especially for transportation and distributed power generation. The idea is to use solar power to dissociate water into hydrogen and oxygen gases. The hydrogen can then be distributed, much like fossil fuels are distributed at present. Other ways of distributing solar energy are through rechargeable batteries and solar thermal power. Another option lies in finding a clean, environment-friendly and responsible way for using the fossil fuels, which will be possible by enhancing the efficiency of fossil fuel energy harvesting. This implies that thermal power stations must consume less coal per megawatt hour of electricity produced.

Widespread use of clean energy is hindered mainly by technological challenges. More often than not, the success of clean energy technology hinges on the materials used, more so on the development of better

materials. While talking of materials, these fall into the categories of metallic, polymeric and ceramic. Of course, there are composite materials, which combine two or more of these basic material types. All these types play their roles in energy technology. Here the focus is on ceramic materials.

CERAMIC MATERIALSThe fossil fuel deposits continue to be the major source of energy. Steam turbines are coated with wear-resistant materials, often ceramics. Ceramic coatings play an important role in enhancing the efficiency of power generation using coal, natural gas or petroleum-derived fuels. The purpose of ceramic coatings is to provide protection to metallic components against corrosion, oxidation, wear, erosion and excessive heat. As an example, stabilised zirconia coatings are deposited on the high-pressure turbines and combustor liners of gas turbines used for power generation as well as aircraft

TAs the alarm bell on energy constraints ring out for action, the whole world is shifting its focus towards sources of clean and environment-friendly energy. Moreover, researchers are exploring various material options, especially ceramics, that can enhance the efficiency of power generation, be it from fossil fuels or alternative sources such as solar or nuclear. In this regard, there are several untapped opportunities

in the area of ceramic materials for energy technology creating a new ray of hope for achieving energy efficiency.

CREATING A NEW CREATING A NEW WAVEWAVE IN INENERGY TECHNOLOGY


CERAMICS

engines. These ‘thermal barrier coatings’ (TBC) represent one of the most critical applications of ceramic coatings. They allow the gas turbine to be maintained at high temperatures, which enhances efficiency. Moreover, the lifespan of metallic components is increased as TBCs keep them below their maximum permitted temperature.

Air plasma spray or electron beam physical vapour deposition is used for depositing TBCs with thickness in the range of about 150 to 250 micrometre. Usually, a temperature difference of ~100°C is maintained across the TBC. Another application of ceramics in gas turbines is in the form of abradable coatings, which maintain a tight seal between the rotating turbine and its casing. This is not all. The efficiency of internal combustion engines, especially diesel engines can be augmented by using ceramics. For instance, a thick coating of a zirconia ceramic on the piston head can increase performance or lifespan. Similarly, ceramic turbochargers can operate at high temperatures and increase the power delivered by the diesel engine for the same amount of fuel consumed. Many automobile components are coated with wear-resistant ceramics such as nitrides to enhance wear resistance.

ROLE OF CERAMICS IN ALTERNATIVE ENERGYCeramic materials hold huge potential in alternative energy technologies, be it solar or nuclear.Solar energy Focussing on solar energy harvesting, the main photovoltaic (PV) material continues to be silicon. Ceramic materials, particularly silicate glasses, are used as substrates on which the various layers of a photovoltaic cell or a solar cell are deposited. Also, transparent but electrically conducting ceramics such as oxides of indium, tin, zinc and their combinations act as contacts in the PV cell. As mentioned earlier, the electrical energy generated in a solar cell can be stored in rechargeable batteries, or it can be used for dissociating water into hydrogen

and oxygen gases. Splitting of water can also be achieved by directly using sunlight in the presence of a catalyst. Right now, titanium dioxide-based ceramic photocatalysts are being developed for this purpose.

The idea of hydrogen as the medium of distributing energy for transportation and power generation has fascinated many researchers for several decades. The product of oxidation of hydrogen is water, which is environment-friendly. The most important energy conversion device for power generation from hydrogen is the solid oxide fuel cell (SOFC). This device is almost entirely made from ceramics. Stabilised zirconia ceramics can conduct electricity through the diffusion of oxygen ions at temperatures above ~600°C. This property is exploited for building SOFCs. The chemical energy of the fuel-oxygen reaction is released directly as electricity. While hydrogen is the most common fuel, hydrocarbon fuels like methane and combustion by-product gases like producer gas can also be used as fuels in an SOFC. This is not possible in other types of fuel cells based on polymers and expensive platinum. Such fuel flexibility of SOFCs is perhaps its strongest advantage. Apart from stabilised zirconia, SOFCs make use of ceramics such as strontium doped lanthanum manganite (LSM) in cathodes, lanthanum chromite in interconnects and glass-ceramic sealants. The only metallic material required is nickel catalyst in the anode. Research efforts are in progress to develop better materials for SOFCs.Nuclear energyNuclear energy is a major alternative to solar energy. Current nuclear power plants are of fission types, i.e. large atoms emit radiation and become smaller atoms. These power plants also have steam turbines and heat exchangers that are coated with ceramics. However, the biggest contribution of ceramics is in the form of radioactive waste immobilisers. Glass ceramics and crystalline ceramics with the ability to hold radioactive atoms within their structural cages are being developed, so that the waste can be prevented from entering the ecosystems for centuries to come. Only ceramic materials offer this possibility of managing radioactive waste.

Another type of nuclear power plant uses a fusion reactor. Such reactors are still

in the experimental stage. In a fusion reactor, small atoms like deuterium and tritium, which are isotopes of hydrogen, are made to collide with each other to produce larger atoms like helium. The primary challenge in fusion reactors is to develop the materials that can face plasma and withstand bombardment of neutrons. Ceramic materials like SiC/SiC composites are candidate materials for confining plasma. In magnetically confined fusion reactors like Tokamaks, superconducting ceramics are used for generating strong magnetic fields.

BECOMING GLOBAL LEADERS IN ENERGY TECHNOLOGYIn the Indian context, and in terms of manufacturing technologies, there are ample opportunities in energy conversion technologies. Surface engineering of power plant components is well-established in India. Various coating deposition techniques like plasma spraying, high velocity oxyfuel (HVOF), detonation gun, cold spray, and chemical vapour deposition can be carried out for depositing ceramic coatings for wear resistance, corrosion and oxidation resistance, and thermal insulation (TBCs). However, the raw materials for these deposition techniques are almost always imported. Indian manufacturing enterprises have the opportunity to not only carry out the deposition jobs, but also develop the raw materials and further improve the coating techniques.

Alternative energy technologies have tremendous opportunities for getting ahead of the competition. In the area of solar cells, cost reduction is the greatest challenge in the Indian context, and indeed for the whole world. Innovative manufacturing techniques can achieve this goal. Ceramics processing technologies are put to the test when developing solid oxide fuel cells. Any advancement in this area will prove crucial for the profitability of this technology. There are several exciting opportunities in the area of ceramic materials for energy technology for Indian entrepreneurs. Academic institutions and government research laboratories are putting in a large amount of research efforts in this domain. Now the time has come for the entrepreneurs to grab these opportunities for becoming global leaders in energy technology.

Dr Ashutosh S Gandhi, Department of Metallurgical & Materials Engineering, IIT, MadrasEmail: [email protected]

A well-established application of ceramic coatings is that of porcelain enamels on steel components of heat exchangers. Specially developed compositions are coated using frits in the form of slurries. Enamelling is completed in furnaces at temperatures of ~425°C and above.

FACT

FACT


NEW MATERIALS

he ever-increasing demand for eco-friendly products has resulted in enormous consumption of natural resources, which are therefore soon depleting.

Novel material systems play a key role in tackling these challenges and increasing the eco-efficiency in process chains and material life cycles. Besides, most of the innovations are based on the utilisation of new material developments. These advanced engineering materials pave the path for new systems solutions with high added values in various fields of applications.

MATERIALS THAT MATTERThe areas of application of engineering materials are many and varied: from automotive and aircraft engineering via resource-saving chemical process engineering to medical engineering and technology. Completely new system solutions, for instance, for energy-saving lightweight engineering designs in vehicle body, motor and turbine engineering; or emission-free drive trains in transport engineering; resource-saving separation processes for materials mixtures, or also for medical implants, can become a reality through materials developments like these.

Many companies and research institutes are constantly striving to develop new materials for the industries to upgrade their product lines, and at the same time, help them enhance productivity with the use of these materials. Some of the new materials developed include DiaCer, PureEdge, Duratron D7000 PI, Spectra fiber, silicon carbide, DuPont PV5300 Series and DuPont PV5200 Series, buckypapers, etc.

DIACER Scientists from four Fraunhofer institutes, together with partners from industry, produced a new composite material called

TWith continuous evolution of new materials, the manufacturing and allied sectors are all set to make quantum leap forward. The polymer composites hold promising prospects in the world of science and can add substance to a variety of sectors from fuel-efficient aircraft to

major pharmaceutical breakthroughs in cancer therapies.

ADDING SUBSTANCE

TO TH E ‘M ATERIAL’ WOR

LD


NEW MATERIALS

DiaCer. The composite material, diamond-coated ceramics – DiaCer – combines the best of both materials. Any area where components and tools are subjected to heavy strain such as in pumps or forming and shaping dies, DiaCer offers maximum wear-resistance coupled with low values of friction. The basis is a silicon-nitride or carbide ceramic, which researchers of the Fraunhofer Institute for Ceramic Technologies and Systems IKTS in Dresden modified for the diamond coating. Dr Lothar Schäfer, Project Co-ordinator, Fraunhofer Institute for Surface Engineering and Thin Films IST in Braunschweig, says, “Components and tools are initially placed in a vacuum reactor for the hot wire chemical vapour deposition (CVD) technology applied for the coating process. Next, the researchers add methane and hydrogen. Further, for enabling the diamond coating to grow, wires are spread at intervals of just a few centimetre across the objects that need to be coated. The wires are heated until they reach incandescence.” He also added, “This activates the gases; carbon is deposited on the surface in crystalline diamond form. By employing the process we follow, we can apply a diamond layer of up to a half square metre in size. There is nothing else like it in the world.”

DURATRON D7000 PIQuadrant is expanding design and performance possibilities for machined parts in high temperature applications with the launch of Duratron D7000 PI polyimides and modified PEEK Semitron MP370. The new materials provide cost-effective solutions to the performance gaps currently facing machine designers and engineers. Duratron D7000 PI and new bearing grade Duratron D7015G PI are high performance polyimide materials that bring the benefits of polymer materials to applications operating in the region of 315°C (600°F). While polyimide has been widely used in semiconductor and

electronics manufacturing equipment for years, Quadrant’s new Duratron D7000 PI materials are available in a wider range of sheet sizes and tube configurations than other PIs. Sameer Bhogate, GM, Quadrant says, “As a result, new opportunities in parts design are made possible. It also provides access to these shapes via the strongest worldwide distribution network in the materials industry. This new material marks an important addition to Quadrant’s portfolio of ultra high temperature, polyimide materials. The new Duratron PI grades, available in a range of sizes, will help engineers to select the most suitable and highest performing products for specific applications and environments more precisely and economically.” Quadrant has also introduced a new addition to the Duratron line of advanced machinable plastics. Duratron PI machinable shapes are ideal starting points for designs that reduce weight, extend length of service before maintenance or replacement and reduce overall costs by increasing process uptime.

SPECTRA FIBERSpectra fiber, a polyethylene fibre, is produced using a patented gel-spinning process. A bright white polyethylene, it is pound-for-pound, fifteen times stronger than steel and more durable than polyester. It has a specific strength that is 40 per cent greater than aramid fibre. Polyethylene is a remarkably durable plastic, and scientists at Honeywell have captured the tremendous natural strength in the molecular backbone of this everyday plastic to create one of the

world’s strongest and lightest fibres. The gel-spinning process and subsequent drawing steps allow Spectra fiber to have a much higher melting temperature (150°C or 300°F) than standard polyethylene. With outstanding toughness and extraordinary visco-elastic properties, Spectra fiber can withstand high-load strain-rate velocities. Light enough to float, it also exhibits high resistance to chemicals, water and ultraviolet light. It has excellent vibration damping, flex fatigue and internal fiber-friction characteristics, and Spectra fiber’s low di-electric constant makes it virtually transparent to radar. Spectra fiber is used in numerous high-performance applications, including police and military ballistic-resistant vests, helmets and armored vehicles, as well as sailcloth, fishing lines, marine cordage, lifting slings, and cut-resistant gloves & apparels.

SILICON CARBIDESebastian Polster, a student from Fraunhofer Institute for Integrated Systems and Device Technology IISB, has developed a new upcoming semiconductor material silicon carbide. Silicon carbide (4H-SiC) is the ideal semiconductor material for power electronics. For instance, efficient power converters for electric vehicles or photovoltaic systems can be produced as well as electronics that work at high temperatures. Until now, however, very few electron devices made of silicon carbide are available in the market. The reason for this is that the quality of the crystals and epitaxial layers is not yet sufficient for the demanding applications because even the slightest material defects, in the form of dislocations, can lead to a malfunction of the component. Dislocations are deviations from the ideal crystal lattice structure, which may occur in different types.

DUPONT PV5300 SERIES AND DUPONT PV5200 SERIESDuPont PV5300 Series and DuPont PV5200 Series deliver long-term protection for the

most sensitive part of photovoltaic modules – the solar cells. They contribute to ensure longer life and reduced cost per watt, helping system manufacturers deliver more reliable and cost-effective solar power. On a global basis, DuPont expects to nearly triple annual sales from its portfolio of photovoltaic materials to more than $1 billion by 2012. “With these new introductions, DuPont science is

Many companies and research institutes are constantly striving to develop new materials for the industries to upgrade their product lines, and at the same time, help them enhance productivity with the use of these materials.

The new materials provide cost-effective solutions to the performance gaps currently facing machine designers and engineers.

QUICK TAKE

Duratron D7000 PI’s Key Benefits: Good performance at elevated temperature – over 600˚FGood chemical resistanceEasily machined from a broad range of shapes – rod, sheet, tubular formsHigh strength, tough and dimensionally stable.


NEW MATERIALS

enabling the faster spread of solar power,” said William F Weber, VP & GM – DuPont Packaging & Industrial Polymers. “These new encapsulant materials contribute towards keeping the cost per watt low and reducing the total cost of ownership for solar power. We expect growth of more than 25 per cent per year for encapsulant materials such as these in the next five years, due to the anticipated strong growth in solar module installations globally.”

DuPont PV5300 Series sheets are five times tougher and 100 times stiffer than materials typically used as encapsulants. Their structural properties make possible new module designs such as building-integrated photovoltaic (BIPV) tiles that can be installed on building roofs. Companies like SYSTEM Photonics S.p.A of Italy are adopting DuPont PV5300 for architecturally appealing built-in rooftop photovoltaic power generation. The company’s DuPont PV5200 Series sheet is designed to meet the needs of thin-film solar power generation, a fast-growing segment of the industry. They are based on polyvinyl butyral polymer technology and offer high performance in physical processing. They enable faster, more efficient module production and longer service life.

DICARBOXYLIC ACIDS USING POLYKETIDE SYNTHASESJay Keasling and Leonard Katz of the Joint BioEnergy Institute (JBEI) have invented polyketide synthases (PKSs) that can be introduced into a host organism for the production of a variety of dicarboxylic acids often used as polymer intermediates. The invention promises to enable the manufacture of a wide range of polymers from sugars derived from renewable, cellulosic or other biomass instead of from petroleum intermediates. While PKSs have been widely used to produce pharmaceuticals and agricultural products, Keasling and Katz are the first to use this specific PKS system to produce a range of dicarboxylic acids. Because of the chemical and biological flexibility of the enzymes they are using, a large number of diverse diacids can be produced. The technology is compatible with multiple feedstocks and hosts, enabling the optimisation of yields for a particular diacid.

Lawrence Berkeley National Laboratory (LBNL) is seeking collaborative research partners interested in funding development of this technology over a three-year period. The major application of this technology is

to produce a wide variety of dicarboxylic acids for the manufacture of commercial polymers, e.g. polyesters, polyamides, polyurethanes. The major advantage is that it uses materials that are renewable, cellulosic or other biomass instead of petroleum. Polyketide synthases can be modified to produce a wide variety of diacid polymer precursors. It is compatible with a variety of host organisms and feedstocks, enabling yield/tolerance optimisation.

LOOKING INTO THE FUTURE With the constant emphasis on development of new engineering materials, one can only expect these new technologies to redefine humans lives – through advancements in medicine, computer science, energy, consumer products, architecture, etc. These materials and their uses are evolving faster on account of the efforts taken by researchers and thinkers. The innovation drive and the need for meeting the ever-growing demands of customers ultimately result in better products made with new and improved materials. Thus, sky is the limit for the future of engineering materials.

Compiled by Geetha Jayaraman


CUTTING EDGE SOLUTIONS

n many countries, fogged or frozen windows can be a bane for drivers’ lives in winter. While heaters may be a solution in

many cases, a better option – especially concering energy costs – would be to ensure the problem does not arise in the first place. This means preventing condensation on windows which would save a great deal of hassle – and car owners can save the time they once spent scraping off the ice.

Researchers at the Fraunhofer Institute for Surface Engineering and Thin Films (IST), in Braunschweig, have finally solved the problem. They will be developing a process that can be used to manufacture transparent, conductive and heatable films. Moreover, their surface films also provide another decisive advantage: the low emitting properties of the outer film ensure the window cools down much more slowly, preventing condensation. The window therefore remains dry and ice-free. Films that up to now have been produced with tin oxide are both mechanically and optically still far from ideal. Cracks may form as a result of excessive temperature loads – a problem encountered during the

glass bending process. As a result, tin-oxide films only have limited industrial applications. “Our new film is extremely resilient” says

Dr Bernd Szyszka, Fraunhofer IST. “Temperatures up to 9000C are no problem, and even if you bend it aggressively – the film remains intact.” The coating can therefore also be used in large industrial plants where transparent protective heaters are often required to monitor the process chain safely.

What can the new film do, that tin oxide cannot? “Our coating system is based on

nanocrystalline indium tin oxide (ITO)”, says Szyszka. “This material doesn’t just have outstanding optical and electrical properties; it is also mechanically and chemically much more stable than tin oxide.” The researchers are utilising high power impulse magnetron sputtering technology (HIPIMS). With magnetron sputtering, accelerated noble-gas ions shoot atoms from an ITO plate, much like what happens with billiard balls. These atoms are deposited on the required substrate in vacuum. “Yet instead of 10 ampere, we use 1000 ampere with HIPIMS”, explains Szyszka. “We ionise the sputtered material; therefore the film is built up by higher energetic particles and shows superior properties.” This provides a major advantage for the engineers as depending on the pulse and power conditions during sputtering, the engineers can adjust the texture and

morphology of the film so that it subsequently takes on the desired properties during a subsequent tempering process. “We can then bend the film and even coat three-dimensional materials with the technology”, says the researcher. The HIPIMS process can also be conducted at room temperature,

so that even temperature-sensitive plastics can be coated.

A transparent heatable fi lm made out of indium tin oxide surrounds the glass tube

IHEATABLE FILMS: AN INNOVATIVE OPTION TO AVOID FOG ON GLASS

ow can domestic electricity customers be motivated to use energy more efficiently, let alone make more efficient use of

renewable sources? One possibility is to install electronic meters to measure the electricity consumed. In the RESIDENS project, scientists are examining how to get the best out of smart meters by simplifying their use.

In the project RESIDENS - research project for more efficient energy usage by system orientated integration of end consumers - researchers are examining how electricity customers can be motivated to use energy from renewable sources more efficiently. The work is being conducted as a collaborative effort by researchers at Ilmenau University of Technology, the Fraunhofer Application Center for System Technology AST and the Fraunhofer Institute for Digital Media Technology IDMT in Ilmenau. But

electricity customers can only use energy more efficiently if they know exactly how much power they are consuming at any time, and under what conditions they can save money by using green electricity.

This is why the researchers are using electronic power meters, which measure how much electricity is consumed and transmit the recorded data at almost any predefined interval to the meter-reading company. Smart meters make it possible to analyse the data in numerous different ways, explains AST engineer Peter Bretschneider. For instance, you can display a reading of the instantaneous power consumption or the cost of a kilowatt-hour of electricity. And you can trace how much energy you have used over a certain period. The smart meter enables actual consumption to be determined on a monthly basis. The meter also displays the currently applicable tariff, enabling customers to select the appropriate

time to do their laundry, by waiting until off-peak rates apply before starting the washing machine.

To simplify the use of the new digital meters for electricity customers, the researchers are also working on applications for a Web portal, where consumers will be able to see at a glance how much they paid for electricity last year, how much energy they have consumed today, and how the cost compares with the previous day’s electricity consumption. An annual overview highlights the months in which the most electricity was consumed, and a daily overview pinpoints the hours of peak consumption. The portal will also inform consumers of the most cost-effective times to use green electricity and calculate their carbon footprint on the basis of their present pattern of consumption. This might prompt electricity customers to switch more often to energy from renewable sources.

HSMART METERS HELP TO SAVE MONEY

To avoid fogging or frozen windows, researchers have developed a process that allows them to manufacture not just transparent, but heatable films. These films also prevent condensation, ensuring ice cannot build

up on the windscreen overnight.


CUTTING EDGE SOLUTIONS

hough hydrogen can be considered as the fuel of the future, this lightest of the chemical elements poses as a

danger to industrial machinery, especially the vehicle engineering as it can embrittle the metals used. This can cause components to suddenly malfunction and break. To overcome the issues faced due to the element, a new special laboratory is created to aid researchers’ search for hydrogen-compatible metals. The use of hydrogen to power vehicles was seen in the US television series ’Knight Rider’. Here, KITT – the legendary talking supercar had a hydrogen

turbo motor that helped it chase the bad guys, while running at over 300 miles an

hour. In the future, cars may be equipped with hydrogen propulsion not just in the movies, but in real life as well.

In the transportation and energy sectors, hydrogen is seen as an eventual alternative to the raw materials of fossil-fuel power, such as coal, petroleum and natural gas. However, for metals like steel, aluminum and magnesium - which are commonly used in automotive and energy technology – hydrogen is not quite ideal. It can make these metals brittle, while decreasing their ductility. Therefore, the durability of the metals decrease and can lead to sudden failure of parts and components. Beside the fuel tank itself, even ordinary components like ball bearings could be affected. Costly repairs are the consequence. To prevent cracks and breakage in the future, the researchers at the Fraunhofer Institute for Mechanics of Materials IWM, in Freiburg, are studying hydrogen-induced embrittlement. Their objective is to find materials and manufacturing processes that are compatible with hydrogen. “With our new special laboratory, we are investigating how and at which speed hydrogen migrates through a metal. We are able to detect the points at which the element accumulates in the material, and where it doesn’t,” says Nicholas Winzer, Researcher, IWM.

Researchers will be able to release and simultaneously measure the movable part of

the hydrogen by heat treatment, where samples are continuously heated up. In addition, the experts can measure the rate that hydrogen is transported through the metal while simultaneously applying stress to the material samples mechanically. They can determine how the hydrogen in the metal behaves when tension is increased. For this purpose, the scientists use special tensile test equipment that permit simultaneous mechanical loading and infiltration with hydrogen. Then they determine how resistant the material is. Explaining the special feature of the simultaneous tests, Winzer says, “In industry, components have to withstand the combined forces of temperature, mechanical stress and hydrogen. With the new special laboratory, we can provide the necessary analytical procedures.” Researchers use the results from the laboratory tests for computer simulation, with which they calculate the hydrogen embrittlement in the metals. Doing this, they enlist atomic and FEM simulation to investigate the interaction between hydrogen and metal both on an atomic and a macroscopic scale. “Through the combination of special laboratory and simulation tools, we have found out which materials are suitable for hydrogen, and how manufacturing processes can be improved,” says Dr Wulf Pfeiffer, Head – Process & Materials Analysis Business Unit, IWM.

TRESEARCH EFFORTS ON TO DISCOVER HYDROGEN-COMPATIBLE METALS

Through the combination of special laboratory and simulation tools, we have found out which materials are suitable for hydrogen, and how manufacturing

processes can be improved.

DR WULF PFEIFFER,Head – Process & Materials Analysis

Business Unit, IWM

ests and calculations show that fibre-reinforced plastics are highly damage-tolerant and distinctly superior to aluminum

in car wheels. A car breakdown, due to its wheels, can be expensive. Also, there are safety risks involved to the occupants. To create the fundamentals for the production of lightweight and yet safe & reliable components, Fraunhofer Institute for Structural Durability and System Reliability LBF, in Darmstadt launched the high-strength plastic structures project in cooperation with five other Fraunhofer institutes. “The aim was to provide the conditions and the tools for the operationally reliable design of extremely light safety parts made of sheet molding compound (SMC) material, which could be produced on an ongoing basis in medium to large volumes.

SMC is a fibre-reinforced composite material which mainly consists of inorganic constituents,” explains Prof Dr-Ing Andreas Büter, Fraunhofer Institute for Structural Durability and System Reliability LBF, in Darmstadt. “Up to now, SMC has only been used for secondary parts of the bodywork such as the bonnet or doors,” states Büter. “The purpose of our project was to clarify whether SMC is also suitable for safety-relevant primary parts.” SMC is superior to metal in several ways. It is not only lighter but also exhibits an excellent mass-to-strength ratio. In addition, it is cheap to produce in medium

to large quantities.Describing the tests

conducted at the LBF, Büter said “On our test stands, we have simulated, for example, how the wheels and suspension of a car behave on a rough road, in forward motion and reversing, and how long the components can endure these conditions,” After three years of research work, scientists

can now present the results. On conclusion of the project Büter highlighted an important finding “If correctly processed, fibre-reinforced plastics are highly damage-tolerant and distinctly superior to aluminum wheels.”

TFIBRE-REINFORCED PLASTICS FOR CAR WHEELS

This wheel made of fi bre-reinforced plastic is particularly light and exhibits high structural durability.


he level of automation in the manufacturing industry in India is varied, with some industries having a high level of automation compared to others that

still rely on manual processes. Deterrents to the penetration of automation include

the low-technology awareness, lack of regulation, and abundance of low cost labour. The entry of multinational companies into India, especially original equipment manufacturers (OEMs) that set up manufacturing facilities in the country, created a market for automation equipment. It is the MNCs that were the early adopters

of automation and proponents of quality inspection in manufacturing units.

However, the machine vision systems or automated inspection systems market in India is relatively in its nascent stage and adoption of these systems is still to reach appreciable volumes. Some of the challenges that continue to constrict the

T

ON THE CROSSROADSON THE CROSSROADSThe lack of awareness about the importance of machine vision systems coupled with limited automation in core manufacturing industries has resulted in a restricted demand for these systems in India. The fact that the machine vision systems market is on the crossroads and

has not registered exuberant growth in the past half a decade evokes questions on its future and what lies ahead for it in India. It remains to be seen whether the market has met its Armageddon or is it the Genesis.

MACHINE VISION SYSTEMS MARKETMACHINE VISION SYSTEMS MARKET


MACHINE VISION SYSTEMS MARKET

industry include: Relatively low quality awareness in

manufacturing set-ups Misconception of machine vision systems

being higher priced Lack of qualified system integrators Cheap labour costs acting against

automation, and therefore, inspection systems

Low awareness about machine vision systems.Despite these bottlenecks, there is a ray

of hope for machine vision systems industry, which is witnessing a higher level of demand and acceptability, albeit slowly.

OPPORTUNITY CLUSTERSOver the past decade, machine vision systems have started witnessing adoption in industries such as food processing, automotive and pharmaceuticals. The advent of global automotive OEMs has strengthened the demand for suchsystems in the country. Even indigenous automotive component manufacturers are realising the advantages of deploying automated inspection, and hence, are adopting these systems. The pharmaceutical industry in India, which caters to a large generics market globally, has evolved to be a preferred destination for Contract Research and Manufacturing Services (CRAMS). With most of the Indian pharma companies having to adhere to the prescribed US FDA norms, the regulatory restrictionsencourage them to adopt highly efficient processes, which include automated inspection systems, as well. The food processing industry, too, relies heavily on exports and has various regulations that it has to adhere to when exporting to countries like the US and Europe. These regulations have driven the adoption of machine vision systems.

FUTURE GROWTH ZONESGlobally, some of the largest adopters of machine vision systems constitute the electronics and semiconductors industries, though they have not been significant demand creators in the Indian market. Electronics industry is yet to adopt automated vision equipment on a large scale, and this primarily stems from thefact that mostly assembly activity happens in

the country. Further, as most of the equipment used in electronics manufacturing are imported, it comes embedded with machine vision equipment, thereby lowering prospects of local sales.

India’s electronics consumption that currently stands at $40 billion is expected to grow in excess of 20 per cent year on year. However, local production, on the other hand, meets just about 50 per cent of this consumption. Even if local production grows on par with consumption, it will not be sufficient to meet the demand. This has resulted in the government directing its focus on encouraging more of indigenous electronics manufacturing under the aegis of a dedicated task force. Efforts taken in this direction are expected to usher more of local manufacturing, which is expected to drive the demand for machine vision systems as well.

The semiconductor industry has remained on the backburner despite the growing electronics market. India has attained its dominance in the design field, but fabrication continues to be a distant

dream. The absence of indigenous fabs or even many assembly, test, mark and package (ATMP) units has not only enervated the semiconductor industry locally, but it has also been the dampener for markets like machine vision systems. The proposed government plan to set up a fab coupled with the increasing interest shown by private companies to set up ATMP facilities in the country are expected to be energy boosters for the automated inspection market.

Besides these, other markets such as food sorting, cotton contamination detection, medical applications and process industries such as steel are expected to be demand drivers for inspection systems.

India’s foothold on the global photo voltaic (PV) industry is expanding exponentially. Investments for setting up of PV cell and module manufacturing units are on the rise. The PV industry is expected to

be the next big application area for machine vision systems when these investments translate into production centres in the ensuing years.

EVOLVING TRENDS AND THE WAY AHEADThough in its nascent stage, the machine vision market in India has been constantly evolving. From technology evolution such as a shift from analog to digital to smart cameras to application evolution such as the shift from end-of-line inspection to component/assembly level inspection, there have been continuous developments in the machine vision industry. Cost that was hitherto considered a challenge has also been overcome by these trends. Prices of cameras are on the decline and costs of component level systems are about $5,000, which is five times lower than an end-of-line inspection system.

The potential in India for machine vision systems is reflected by the abundant opportunities for automation in various industries. This huge potential has attracted

the attention of global suppliers.

While the market is expected to foresee demand for high levels of customisation that are specific to different industries, a significant increase in the demand is also likely from OEM applications that procure locally-made machines. The need for system integrators

who have the specific application expertise is going to be on the rise as demand for customised systems increases.

Given the growth in demand in the future, the success of the machine vision industry depends on how well suppliers can educate users on the right systems for their process and how well system integrators absorb the requirements of customers and implement the correct solutions. The machine vision systems market in India, is thus, at the crossroads of growth and its success depends heavily on the value chain stakeholders, who need to enhance awareness and evolve business models for machine vision systems in India. The burden lies on the suppliers to educate users on the need and benefits of automated inspection to grow the market.

Deepa Doraiswamy, Industry Manager – A&E,Frost & Sullivan – South Asia & Middle East

India’s foothold on the global photo voltaic (PV) industry is expanding exponentially. Investments for setting up of PV cell and module manufacturing units are on the rise. The PV industry is expected to be the next big application area for machine vision systems when these investments translate into production centres in the ensuing years.

OVERHEAD CRANES


n overhead crane is a simple equipment, which reduces human effort in lifting and carrying load from one place to another. It typically consists of a

hoist to lift the load, the girder or the beam, and a trolley to move along the girder.

Often, manufacturing floors have limited workspace and overhead crane systems act as a perfect solution in these places. Support columns generally take up valuable floor space, which can be avoided by using overhead cranes. Instead of requiring support columns, these systems are supported by the existing building structure. The first step to decide whether an overhead crane is the right solution for a company is to consult a qualified architect or engineer. This is because a building structure should be able to support the crane system, and professionals are the

right people to determine that.Selecting the right type of overhead

crane is critical to streamlining workflow and maximising productivity. In order to make a profitable investment, it is imperative that all buyers should freely interact with the crane manufacturers and provide them relevant information, so that the crane can be engineered optimally and a well-engineered turnkey solution can be sought. Outlined below are twelve parameters that can help buyers choose a well-designed and cost-effective lifting solution.

11 TYPE OF CRANEDifferent types of cranes are deployed to lift various categories

of loads. Some of them include: Single girder electrically operated/semi-

electric/hand-operated cranes Double girder electrically operated/semi

electric/hand operated cranes

Single or double girder cranes designed as gantry cranes or semi-gantry cranes

Special cranes.The first two crane types are normally

used for indoor applications, while the third type is normally used for outdoor applications. It must be understood that the lifting capacity and span do not play any role in selection of type, though it is believed that a single girder crane cannot be selected for capacities in excess of 10t.

22LOCATIONA crane could be located either outdoor or indoor or at times

both. It is important for the buyer to specify this need appropriately. An outdoor duty crane has to be engineered considering wind forces, and therefore, specifying this aspect is important. It would help to optimally design the crane, if the buyer also specifies the geographical location (besides

AThe marketplace, today, is flooded with multiple options. Therefore, a buying decision for an individual in the purchase department of any organisation can be cumbersome, especially if one has to deal with overhead cranes. Since the overhead crane segment is highly unorganised in India, customers are unable to make an informed decision. Here we attempt to assist prospective buyers of electric overhead travelling cranes in selecting the appropriate equipment most suitable for their applications.

SOURCING THEBEST FIT SOLUTION

OVERHEAD CRANES


simply specifying outdoor), so that the correct wind speeds are assumed while designing. Moreover, if the crane is operating in a coastal area, it might need epoxy painting instead of normal synthetic enamel paint. Specification might also be applicable for indoor duty cranes, especially those operating in acidic or alkaline atmosphere.

33SAFE WORKING LOADSafe working load is defined as the load that could be lifted under

the crane hook. If the crane is intended to be used along with a magnet, ‘C’ hook, grab, ladle or any other appliance; the dead weight of such appliance should be specified, so that the safe working load of the crane would be determined appropriately. Never build-in factors of safety over and above what has been specified earlier, since this would result in over engineering of the crane leading to added costs.

44CLASS OF DUTYCranes are classified from M1 to M8 depending upon their usage

pattern. Higher the class of duty, higher would be the cost. Crane mechanisms also differ based on the utilisation. It should be remembered that while the crane is available 24/7, no crane operates 24/7 at its rated load and speed. The class of duty essentially depends upon the application of the crane, usage frequency and pattern. Ideally, the buyer should provide a load spectrum. This would be too difficult, and hence, the class of duty should be arrived at, after explaining to the manufacturer of the crane its application in detail. Since the selection of the class of duty would not only determine the cost of the crane, but also affect all other points listed above, maximum attention should be paid to this aspect.

55SPEEDSSelection of speeds is directly dependent on the crane’s usage

and application. Increased speeds (where not required) would increase power rating of motors, increasing the cost of the crane as well as the owning and operating cost.

66CONTROL SYSTEMA variety of control systems are possible such as pendant control

from floor, fixed cabin control, movable cabin control, control through radio remote control, etc. Appropriate selection depends upon the application.

77HOOK AND END APPROACHESOne cannot expect the hook to

be in line with the column or reach up to the end of the shop in any crane. In other words, some loss of built-up area cannot be avoided. The appropriate approach would be to minimise this loss, so as to enable maximum utilisation of the built-up area. To ensure this, the mechanisms have to be designed optimally, and this would depend upon the class of duty selected. Since the class of duty is totally dependent upon the application, the buyer and the manufacturer should understand the application and usage pattern to the fullest.

88CRANE HEADROOMThis is defined as the highest obstruction of the crane above

the long travel rail top. Lower the dimension, lower could be the building height. A reduced building height would certainly reduce the building cost.

99HOOK HEADROOMThis is defined as the distance of the hook at its highest elevation,

below the long travel rail top. This should be minimum to optimise the column height, so as to reduce the building cost. The sum of dimension six and seven would be constant for a given crane. Hence, if the

crane is to be installed in an existing shop, one could distribute this sum so as to optimise the usage of the shed.

1010WHEEL LOADSFor a given crane, heavier the crane and the trolley, higher

would be the wheel load. This has a direct impact on the gantry girder selection, column design and foundation. It is a misconception that a heavier crane is a stronger and safer crane. So long as the crane is engineered to satisfy all the clauses of the relevant IS specifications, the weight of the crane and trolley should not be the method of establishing the strength and safety of the crane. In fact, the buyer should opt for the lightest crane with the least wheel loads.

1111DOWN SHOP LEADS AND LT RAILSDown shop leads is the power

supply system adopted to feed the crane with electrical power. There are several systems possible. The safest system is through shrouded busbars, since this provides maximum safety and does not affect end approaches at all. Bus bars have to be selected based on the connected load. If multiple cranes are proposed to be operated, the connected loads of all such cranes have to be considered while selecting the busbar rating. The buyer, therefore, has

Selection parameters in a nutshell The type of crane required should be correctly determined The location must be specified, whether indoor or outdoor or both The safe working load selected should be appropriate The class of duty needs to be in conformity with the application The speeds must be apt for the application intended The control system should be in conformity with the application The hook and end approaches needs to be minimum to enable maximum

utilisation of shop area The crane headroom has to be minimum, so as to reduce the shop

height The hook headroom must be minimum, so as to increase the height of

lift The wheel loads should be minimum, so that the gantry girder and

column sizes are reduced to the minimum, saving building and foundation costs

The down shop leads and LT rails have to be determined The owning and operating costs should be minimum.

OVERHEAD CRANES


to provide this data. The same applies to LT rail selection too.

1212OWNING AND OPERATING COSTSA crane is invariably installed at

an elevation of six or more metre above floor level. Hence, a crane involving minimum maintenance should be preferred. By providing leak proof gearboxes, lifelong lubricated bearings, appropriately selected wire rope and optimally selected electrics one can achieve this objective.

Other factors that influence the cost of the crane are: Provision of full length platform on both

girders Provision of hydraulic or spring buffers Provision of under bridge lighting Provision of closed, glazed and air-

conditioned cabin.It is important that the need for all the

above-mentioned additional features is

carefully evaluated. Once the specifications are finalised and frozen, vendor/s will have to be selected to obtain quotes. Here are a few important points to be considered when choosing the crane vendor: Experience including client list, number

of years in business, number of cranes currently manufactured per year, technical tie-ups and collaboration, if any

Existing design team and their experience

Manufacturing facilities including handling capacity trained & experienced craftsmen and supervisors

Sub-contractors and their technical capability

In-house load testing facility, which should include test pit and calibrated test loads

Surface treatment and painting facility, which should include shot blasting and dedicated paint booth

Empowered and independent quality

assurance team and their experience Welder’s testing and systematic periodic

approval procedure and maintenance of records

Stocks of critical items always maintained

Dedicated erection and commissioning teams located at various locations

Provision of annual maintenance contract (AMC)

Dedicated after-sales and service team Availability of spares on a timely basis Adherence to safety and environment-

friendly manufacturing norms.Having selected the vendor/s with the

above guidelines, the buyer can obtain technical and commercial quotes, evaluate and then place the order for the crane.

Any company that requires a cost-effective solution for material handling while saving precious workspace, should definitely consider overhead cranes. However, proper consultation and consideration should be done before making a purchase, as there are many options available. The chosen crane solution should truly be the best fit for one’s business needs.

S Raman, Head-Design, ElectroMech

Any company that requires a cost-effective solution for material handling while saving precious workspace, should definitely consider overhead cranes. However, proper consultation and consideration should be done

before making a purchase, as there are many options available.


INNOVATORS’ OUTLOOK

VOLUTION OF INDUSTRIAL DESIGN IN INDIAIt must be the goal of every manufacturer to make the dream of ‘Designed in

India’ on each and every product come true and work towards it. But this is not an easy task to achieve. The first priority should be to transfer the outstanding abilities in the field of software design to all other products. The best products are the ones that are able to conquer the world, and one instance of successful product in India is Tata Nano.

BARRIERS TO INNOVATION & WAYS TO OVERCOME THEMThe companies aspiring to achieve design success are faced with a multitude of barriers. These include: Regional and cultural distance from

world markets/Western customers, i.e. knowledge of customer requirements

Technology gap/lack of access to high-tech technology in a number of areas

Lack of presence in Western markets (small marketshares, etc), e.g. with sales & service network/partners

R&D infrastructure/universities, research institutions, etc, not yet on par with

Western universities/research institutions in a number of technology areas.However, there are ways to resolve the

problem areas. The measures that need to be taken include: Increasing the number of foreign

investors, JVs, etc to gain good knowledge of international markets

Improving the ease of doing business in India and removing all the bottlenecks encountered to attract foreign investors, JVs, etc.

Investing in companies that have access to Western markets, knowing the customer expectations and requirements, besides acquiring relevant technologies

Increasing trend scouting in Western countries

Thinking out-of-the-box and defining stretch targets

Aiming at market segments where customer demand is not sufficiently satisfied

Combining Indian creativity with Western technologies

Leveraging knowledge of well-educated, young Indian engineers, MBAs, etc and combining the knowledge pertaining to Western technologies/management practices/markets with that of Indian technologies

and cultural strengths/ customer requirements/market specifics and so on.

INNOVATIVE CAPABILITIES OF INDIAN SMEsSMEs in India have huge potential to create innovative products and move towards global markets. The latest trends in design that can drive the growth of Indian SMEs are simple products for meeting growing demands of Indian and other emerging markets, for instance goods catering to the rapidly growing middle income population. Regionally adapted or best-suited products

E“The perfect mix of superior technical properties and design newness will help create a winning design,” affirms Axel Schmidt, Partner

& Head, Roland Berger’s Global Operations Strategy Competence Centre, during an interaction with Prerna Sharma. Excerpts…

DESIGN SUCCESS CAN BE ACHIEVED BY IDENTIFYING FEATURES THAT THE CUSTOMER VALUES


INNOVATORS’ OUTLOOK

for market segments, which are currently offered by international competitors without adaptation to specific market requirements, should be among the areas of focus. Design that is based on specific customer usage and different from world market standards in terms of performance, convenience, economic value, environmental, health and safety standards in India and other emerging markets needs to be developed. The product concepts must be based on adapted product characteristics, simple product architecture, modularisation with low number of variants and use of ‘industry kits’, high level of functional integration, installed cost-driven approach (manufacturing, assembly, logistics, etc.). In addition, product development should be based on low degree of vertical integration, use of low-cost engineering resources, strong front loading, lean engineering approach and there should be no duplication of work between OEMs and suppliers.

INGREDIENTS TO CREATE A SUCCESSFUL DESIGNTalking about industrial design, the perfect mix of superior technical properties (e.g. performance attributes) and design newness

will help create a winning design. Other factors include differentiating product offerings from that of competitors, creating a new market niche and matching products with customer expectations, i.e. fulfilling the functional objectives of the customer in a better manner. Design success can be achieved by identifying features that the customer values and is willing to pay for. All these factors can provide a distinct advantage to companies.

INDUSTRIAL DESIGN IN INDIADesign in India is gaining pace slowly and steadily. The factor that would make India design hub of the world is globalisation of R&D. According to a recent study, depending on the nature or the industry, companies globalise based on key parameters such as technology access (e.g. pharmaceuticals industry) or market access (e.g. consumer goods, automotive suppliers, engineered products). Thus, for industries where technology is crucial, India needs to adopt state-of-the-art machineries. For industries where market access is crucial, India needs to convince global companies of the attractiveness of the Indian market

and the need to design or customise its products locally at a competitive cost. This will be possible by creating awareness about the competitive advantage in India compared to other emerging/potential global R&D locations such as China, Eastern Europe, Brazil among others.

ADVENT OF MATERIALS IN DESIGNNew materials enable the development of different forms and designs as well as functionalities. One example, I would like to refer, is the lightweight aspect pursued in the vehicle construction industry through the use of aluminium and plastic materials. Flexible designs would not have been possible with traditional materials.

DESIGN PHILOSOPHY TO SUCCESSOur design philosophy to success revolves around differentiating our products from that of competitors by way of superior technical properties (e.g. performance attributes) and design newness. Of course, this has to match with customers’ expectations and offer them what they need.


SIMULATING ASIMULATING A

Worldwide, simulation technology plays a key role in making industrial equipment more productive in terms of machine capacity as well as operational speed.

FACT

FACT

FACT

DESIGNDESIGNNEW WORLD OFNEW WORLD OF

FACTORY AND PLANT EQUIPMENT

imulation-driven design plays a major role in developing industrial machines for manufacturing and process facilities around the world. To keep up with

the increasing demand for manufactured products, companies rely on factory equipment that include machine tools, injection-moulding equipment, robots, material handling equipment, stamping machines and other industrial machines.

In the competitive drive to produce more with less, the increased speed and efficiency of today’s technology-based equipment is credited as a major element in industrial productivity gains. According to the National Association of Manufacturers, the US productivity grew 4.8 per cent last year amounting to a 24 per cent increase during the past four years. So, in order to remain competitive, companies around the world invest heavily in the latest state-of-the-art production equipment.

On the flip side, industrial equipment buyers have a long list of demanding requirements. Machines must operate for decades under harsh conditions and often for multiple shifts, seven days a week. Downtime is unacceptable, since daily revenue losses can run into millions of dollars

when production is halted. Energy efficiency is mandatory in lowering operating costs in the face of rising electricity utility prices. Noise emissions must be low to meet strict regulatory standards. Vibrations must be minimised to avoid fatigue failures and unwanted resonances in precision machines. In addition, equipment must be cost-sensitive; new models must be launched quickly to meet fierce global competition.

Companies in the factory and plant equipment market regard engineering simulation as an indispensable tool in meeting these challenges. The simulation technology, in particular, is used by many of these firms in their product development cycle. A range of leading-edge solutions provides a breadth and depth of analysis capabilities including meshing of complex parts and assemblies, computational fluid dynamics (CFD), optimisation, structural and thermal tools, and a wide range of multiphysics solutions.

BOOSTING MACHINE SPEED AND CAPACITYWorldwide, simulation technology plays a key role in making industrial equipment more productive in terms of machine capacity as well as operational speed. A technological research centre, for example, performed a coupled thermo-structural analysis with simulation mechanical software in developing a new design for a steel-making ladle — resulting in a 15 per cent more capacity for handling liquid metal.

Likewise, metalworking equipment manufacturers use mechanical simulation in static, dynamic and thermal simulations of the metalworking equipment it develops, which includes transfer lines, machining centres, flexible manufacturing systems, and milling & broaching machines. Typical simulations include deformation of parts, modal analysis and frequency response of the machines together with tools and workpieces, structural temperature distribution and topology optimisation.

Simulation also helps in the development of robots that are widely used in different industries.

ROBOT DEPLOYMENTAccording to the Robotic Industries

SFrom small job shops to giant super factories & processing plants to facilities throughout the supply chain use production equipment to turn raw materials into products. However, to survive in the global economy of the third millennium, manufacturers need to be inventive in terms of factory equipment and raw materials, as well as processes they develop. Using simulation-driven design tools can bring value and innovation to a wide range of product development applications.


FACTORY AND PLANT EQUIPMENT

Association, nearly one million robots populate global manufacturing, with almost half of it working in Japan. Robots perform a wide range of production tasks including material handling, workpiece and tool positioning, arc & spot welding, packaging, and process applications such as inspection, testing, spraying and dispensing. Simulation is critical in developing these versatile machines for optimal speed, precision, lifting capacity and cost.

A German-based company recently used simulation workbench tools to develop a six-axis robotic system for ultrasonic testing of helicopter parts up to six metres in length. The company reports that the ability to analyse the design throughout the development process enabled them to verify that

the rigidity and vibration behaviour of the system met customer demands of rapid testing movements, high dynamic precision and accurate synchronisation among multiple robots working together.

Simulation is a powerful tool for better understanding the behaviour of complex industrial

machines. With this insight, engineers can then more effectively optimise designs and develop innovative concepts.

COMPLEX EQUIPMENT BEHAVIOURSome of leaders in engineering consulting firms use advanced analysis tools such as CFD for design evaluation, optimisation and problem-solving in which heat transfer, fluid

flow, combustion and mass transfer are critical issues.

Researchers use simulation CFX software in analysing a multiphase grinding mill that vigorously stirs incoming material together with solid grinding media using a series of high-speed rotating disks. The CFD analysis showed the complex multiphase

swirling flow through the mill’s intricate geometry and the nature of media distribution, secondary flows and wear characteristics of parts. In this way, simulation has improved the understanding of mill behaviour for scaling up the design and enhancing mill operation.

Adoption of simulation methods offer several benefits in terms of increasing efficiency, enhancing quality and enabling breakthrough innovations.

BETTER QUALITY AND GREATER INNOVATIONThe structural analysis software is a core tool for the state-of-the-art development facilities of moulding industries that are into designing and manufacturing the most comprehensive range of injection-moulding equipment – machines, moulds, hot runners and robots – for the plastics industry. In developing these large injection-moulding machines, engineers face demanding design challenges. Machine weight must be minimised to keep manufacturing and transportation costs low. Operating speeds should be fast enough for required throughput of manufactured plastic parts. Reliability and precision needs to be maintained to provide satisfactory service with minimal downtime. Efficiency is a requirement to keep energy consumption low, and thus, minimise operating costs.

Engineers met these challenges with simulation workbench and other relevant tools. The integrated solutions provided efficient contact representation for complex non-linear assembly analysis, additional pre-analysis in construction and the benefit of common simulation methods in various types of analyses. Engineers report that analysis that formerly took a week can now be completed in just half a day. This level of increased analysis efficiency enables development teams to achieve better machine quality and greater innovation in products.

Pierre Thieffry, Lead Product Manager,ANSYS Inc

According to the World Machine Tool Output and Consumption Survey, Japan ranks number one in terms of world output of machine tools and second in usage of equipment. Meanwhile, figures from financial services firm JP Morgan specify that the rate of manufacturing expansion in the European sector is reaching a six-year high.

FACT

FACT

FACT

Adding Revenue By Shortening The Development Cycle Computer simulation enabled a leading engineering firm in the US to reduce the time needed to develop a new aggregate drying burner designed for use in asphalt plants from the normal 6 to 12 months to only 32 days. The burner is intended to remove moisture from rock, so that it will bind properly to cement in forming asphalt. Getting dryers to market as quickly as possible necessitated development of the burner in an extraordinarily short time. The design team used CFD technology, recently added to the simulation software solutions, to readily evaluate numerous virtual prototypes and quickly iterate to an optimised design. The primary concern was related to determining the best way of injecting fuel to obtain an optimal gas mixture. CFD saved considerable time by determining the flow and chemical concentrations early in design, providing far more information than would have been ever possible with physical experiments. In only two weeks, a working prototype was built; within a month, the design was optimised to meet stringent emission regulations. In this way, simulation drastically reduced time-to-market, thus providing up to a year of additional revenues while substantially bringing down engineering costs.

CASE IN POINT

Grinding mill

SPOTLIGHT: NALCO Damanjodi Refinery

RefiningWith Excellence

on pg. 90


orldwide, the aim of all businesses is centered on growth and profitability. As with any initiative, growth is a comprehensive goal that requires several

components to be implemented. In order to map out an appropriate

strategy, it is critical to identify and understand the purpose for which a company was founded and whether it is structured to attain continuous profitable growth. In

addition, it is pivotal to assess whether a company was established to offer a specific product/service or to meet an identified need in a niche market. The answers to these questions will enable to identify and understand an organisation’s targeted objectives.

It can be observed that some companies that were established in the 1800s are still thriving today on the merit of efficient & solid planning. In addition, some of them, which were created to launch a new

technology or service, were successfully acquired by another company and continued to build the brand. These success stories were achieved because of strong leaders, who were able to craft and implement a blueprint for success.

First and foremost, what a company needs is a vision – an idea (or concept) of where it would stand at maturity. The vision needs to be such that it can be communicated easily and understandably, makes a difference to marketplace and will

WProfitable growth is everyone’s business. However, being caught up in the rat race to be the best, companies, globally, miss out on a few important, but simple things that could propel growth. Some of these crucial factors include vision, mission statement, core values, among others. By adopting such strategies, companies can chart out the roadmap to success.

PROFIT MANTRA


PROFIT MANTRA

guide an organisation through the good and bad times.

VISION & MISSIONThe purpose of a vision is to provide a roadmap for the company’s growth. No one would like to venture on a trip without having an idea of the destination. It is the same concept with regard to businesses too, if one doesn’t have a completion target (or goal) it would be difficult to gauge how, when and where to grow one’s business, chalk out the best expansion plan, etc. Without the answers to these vital questions, one could get lucky and realise the company’s targeted growth, but it would be achieved at a high cost, with several detours or derailments.

The key to keep the growth on track is to have a visionary vision. A vision is something that will project a company’s future 100 to 150 years from the time of its establishment. If it is designed to project growth during the next five years, it cannot be termed as a visionary vision. If the vision revolves around being number one, the most recognised and the fastest growing or the most profitable company – it doesn’t qualify as a visionary vision.

A vision should describe what product/service a company offers that would have a measurable impact on the world. One might think that his/her company’s product/service offerings are best managed locally or regionally, but in this day of globalisation and technology, even localised products/services have (or will have) an impact on everyone. Hence, it is important to make sure that the vision is a guiding light for the organisation to move ahead successfully, enabling it to measure the value of the products/services it provides to make the world a better place. After vision comes the need for mission.

MISSION STATEMENTA company’s mission might best be drafted into one succinct mission statement and should highlight ‘what a company does’. The mission statement simply tells everyone involved with the organisation what the company does and why it exists. The purpose is to keep everyone focussed on the goals. Along with a vision and a succinct mission statement, it is imperative that every organisation has a set of core values.

CORE VALUESThese values usually comprise 4-6 statements

that describe how a firm operates. These should represent a comprehensive list, covering all aspects of business including product/service offerings, customer relationships, commitment to employees and company’s philosophy. Core values are

like the reflectors along the highway. Those reflectors are there to warn people regarding where the ditch or embankment begins, ideally giving them time to move away from danger and get back on the road. Core values have the same function in that they are there to guide an organisation’s growth profitably and ethically.

TWO-TIERED STRATEGIC PLANIf a company aims at becoming ‘the biggest, the best, number one in marketplace, the most recognised, and/or the most profitable’, then its leaders should identify four or five yearly corporate goals. Once these goals are identified, then the strategy can be created that will help achieve the objectives.

The corporate strategy should be a two-tiered plan, focussed on both the short-term (1-3 years) and the long-term (3-5 or 10 years) plan. The plan needs to identify the market segments the firm is involved in and provide options (flexibility) for adjustments to the ever-changing economy. It acts as a roadmap to achieve the company’s vision, but there can be delays and/or changes in plans, so one should be prepared to deal with them.

QUALITY FOCUSIn this age of technology, anyone can find

and share information on virtually anything at anytime. It is critical that a company is focussed on building and maintaining a strong reputation. The cornerstone of a strong reputation is an unwavering commitment to delivering quality products

and services every time. There can be a fine line between investing too much in building a quality product or service that will be obsolete in a few years and keeping costs under

control, so that the organisation can make profit. The key is to find that balance between building a quality product and delivering a quality service that everyone in the organisation is proud of and willing to support.

INNOVATIONOne of the key factors impacting a company’s growth is the ability to innovate quickly. However, care needs to be taken that innovations are not done just for the sake of being perceived as an innovative company.

True innovation delivers value and a measurable improvement in product/service offerings and upgrades. To be an innovative organisation, it is essential to reach out and communicate with one’s customers, vendors and suppliers. It is vital to find out if any new benefit or feature is desired in the marketplace, and strive to bring that product/service to reality. There have been a myriad of companies that ‘thought too far out-of-the-box’ with their innovation and were unable to establish a competitive presence for their products/services. Continuous two-way communication with customers is critical for a successful innovation strategy.

ATTAINING CONSISTENT GROWTHA strong, committed and focussed leadership willing to build a company that provides products/services offering the right value and meeting customer expectations will drive the profits of a company. The inclusion of vision, mission, core values, attention to quality, innovation among others into the priority list of an organisation will ascertain that it will stay on the growth track.

Janet Boulter, Business Advisor, Center Consulting GroupE-mail: [email protected]

Steps to ensure profitable growth Visionary vision Descriptive mission statement Set of achievable core values Two-tiered strategic plan Commitment to quality Ability to innovate

successfully.

The cornerstone of a strong reputation is an unwavering commitment to delivering quality products and services

every time.


he keys to becoming a world-class manufacturer are not a secret. They are simply a distillation of the experiences of leading companies and how they

have managed to excel in their chosen markets. Any company can take advantage of the wisdom and the practices developed in more than 100 years of manufacturing since the industrial revolution. But many simply do not have the insight or the will to recognise what must be done to accomplish it.

It is a poor workman who blames his tools for shoddy work, but it is also true that professionals understand the value of good tools and insist on having and using the best whenever possible. When selecting a production machine, be it a machining centre, insertion machine, automated

assembly line or robot, one would certainly look for something that can handle the given tasks and is flexible enough to adapt to additional products and uses that may arise in the future. This practice is even more important with a business solution because of the change in the way information is being handled and used for various purposes. And, it is essential to remember that information management is a fundamental support for each and every key to world-class performance. Some of the strategies to achieve manufacturing excellence are presented below.

REDUCE LEAD-TIMESShorter lead-times are always beneficial. In many markets, the ability to deliver sooner will give a company an edge from its competitors. Quick delivery can justify a

premium price and will certainly enhance customer satisfaction. In all cases, shorter lead-times increase flexibility and agility, reduce the need for inventory buffers and diminish obsolescence risk. Lead-times are cumulative and bi-directional – that is, order handling, planning, procurement, inspection, manufacturing, picking, packing, and delivery all contribute to the lead-time. In addition, the time taken to get signals down the supply chain to initiate each activity adds to the overall time taken to get the job done.

Inflexible business rules and policies can result in undesired effects. Purchasing rules focussed on unit cost lead to large quantity buys that result in high inventory and long lead-times. Ironically, this type of buying can also lead to shortages, since longer lead- times mean that a manufacturer will be making and buying to a less accurate forecast.

T

The ultimate goal of companies, be it large or small, is to become a world-class organisation and be able to compete in today’s global markets. This is possible by adopting a few strategies such as reducing lead times, meeting customer expectations, cutting operation costs, to name a few. Being world-class is all about being as good as any competitor in the world, and just a little better, quicker, smarter, or more responsive than the rest.

WORLD-CLASS MANUFACTURING

UNL CKINGTHE POTENTIAL TO BE THE BEST



The best combination of price and lead-time often comes from a stable buyer-supplier collaborative relationship based on long-term contracts with deliveries according to a forecast that is shared with the supplier and updated frequently. The same is true on the customer side. Instead of focussing on securing large, one-time, single orders that clog up the supply chain, companies must focus on creating long-term contracts with customers and sharing forecast information with them to reduce lead-times.

The same issues concerning large lot sizes also apply to internally produced parts and products. Large lots, driven by a focus on lowest unit cost, raise inventory and lengthen lead-times while reducing flexibility and responsiveness, as well as increasing eventual cost through premium expediting. Instead of using large fixed lots, companies must dynamically adjust the lot size based on market demand, product mix and capacity. Ongoing continuous improvement efforts focussed on reducing set-up times can help companies reduce lot sizes, which provides flexibility in responding to market demand.

Appropriate measurements contribute to high performance on the plant floor. On-time shipment and inventory turns are good examples of high-level measures that tie to company objectives. Focussing on isolated measurements like equipment utilisation on non-constraining resources encourages ‘busy work’ that creates excess inventory and longer lead-times.

Shop floor measurements must encourage overall performance – shipping orders on time at minimal total cost and minimal total cycle times. Performing manual transactions often slows down the supply chain and adds to lead-time. Reporting transactions at each operation or creating a paper purchase order before suppliers work on a component are just two examples. In addition, manual transaction reporting often introduces errors and impacts work productivity. Companies must eliminate non-value added transactions and automate transactions to speed up the supply chain. For example, supplier purchase orders can be electronically sent or completely eliminated using supplier relationship management (SRM) solutions.

CUT OPERATION COSTSAlthough recent developments in planning

and customer relationship management (CRM) have focussed more on top-line benefits – growing revenue – the bottom line is still greatly dependent on controlling costs. Companies with a lower operational cost structure enjoy an obvious advantage in profitability, and the ability to adjust pricing to meet competitive pressures, if necessary, to maintain or gain marketshare.

Costs are really just a part of the scoreboard. When a company implements world-class operational processes, it improves multiple measurements simultaneously, including cost, lead-times, inventory and customer service. This approach is superior to a pure cost reduction focus without associated business process change, which can negatively impact other

operational measurements. Localised cost reduction efforts can often increase costs in other areas. Moving production overseas to an area with lower labour rates, for example, will increase costs for procurement, transportation, inventory and reduced flexibility, among others.

The relative cost of source/make/deliver, and therefore, the opportunities for cost reduction, will vary with the specific industry and the kind of products the manufacturer makes. Most manufactured products today have relatively little direct labour content, generally less than 20 per cent and often less than 10 per cent, whereas the material content of most products is more than one-half the cost-of-goods sold (COGS). The rest is ‘overhead.’ Since most direct labour costs tend to be fixed, effective deployment of these resources can reduce unplanned manufacturing overtime, premium expediting and outsourcing, as well as dramatically reduce cycle times. Since material cost is the dominant cost, significant opportunities for reduction lie in analysing current spending and devising effective sourcing strategies for materials. Overhead reduction is always a fertile area for bringing down costs by using automation to streamline the procurement, manufacturing and customer management processes.

Additionally, fulfillment costs have not

received as much attention as it deserves; inventory cost, transportation, management costs, electronic communications, and storage account for a significant part of the cost of doing business. Fortunately, improving customer service can also generate cost benefits at the same time.

IMPROVE BUSINESS PERFORMANCE VISIBILITY Today’s fast-moving, ever-changing manufacturing environment demands faster responsiveness to changes in the market, product innovation and supply chain events. In this environment, ignorance is one of the greatest threats to a manufacturing company’s health and success. Executives and senior managers must understand how

the enterprise is meeting strategic objectives. Middle-level managers need visibility into how they are performing against tactical objectives. Responsible individuals must be notified immediately when supply chain issues threaten the completion of objectives, so actions can be

taken to ensure customer delivery and quality requirements.

A well-implemented and effective business solution delivers overall visibility into the health of the company and its operations, besides providing detailed information for performance measurement, process management, and problem identification and remediation.

An enterprise business solution will literally capture thousands of pieces of information each day, as activities are reported throughout the enterprise. All of this detailed data is of little use without placing it in context and seeing each activity in relationship to all the other activities and the overall plan. To turn data into meaningful information is an up-and-down process. Bits of data, taken together and summarised, form higher-level contextual information and from such summaries, the observer must be able to drill down to details to understand exactly what is happening and how to drive those activities towards the goals and objectives.

Management information and analysis is only as good as the data it is based on. Therefore, data must be collected as quickly as possible and with the least amount of human intervention, which tends to introduce delays and errors. It is equally important to collect data from supply chain

The ultimate goal of any business is pleasing the customers. The most successful companies don’t just meet customer expectations, they exceed them and beat the competition by setting the bar at a level that makes

it difficult, if not impossible, for others to surpass.



partners through automation as much as possible. Electronic data interchange (EDI) is the most commonly used method today, but it is rapidly being replaced by XML-based e-commerce communications and Web-based portal technologies.

All systems should be integrated, so that information can pass freely between them without manual re-entry. Many manufacturers are left with ‘islands of automation’ after implementation of specialised information systems in isolated portions of the business over the years. While each contains valuable information, absence of integration prevents the effective use of that information for overall management and co-ordination of effort towards company objectives.

SPEED TIME-TO-MARKETDeveloping and introducing new products and services is vital to most manufacturing companies. Good ideas are not enough; well-managed processes for bringing new products to market can lead to significant competitive advantages. Those activities, however, represent a significant risk that can either lead to missed opportunities or huge financial losses. In addition to new product development, the same processes and resources are applied to product improvements, corrections and variations throughout the product lifecycle. Based on market research, products are often subject to frequent engineering changes due to customer requests, technological advancements, regulatory concerns or competitive pressures.

Changes and improvements are easiest to make – which are least costly and disruptive – earlier in the process. It is a good business practice to collaborate with all operational areas of the business while the products and processes are still being designed. Co-operation should be focussed on the following areas: making sure that the new product meets market needs (marketing and sales), it is priced to sell and generate a profit (marketing and accounting), it can be manufactured efficiently (production, production engineering, quality, purchasing and key suppliers), and that the product can be maintained and serviced (service) with ease.

With increasing customer expectations and competition from new players around the world, bringing better and less expensive

products quickly to market has become more crucial than ever. Customers are quick to compare and switch vendors. The Internet empowers buyers by providing fingertip access to many more suppliers around the globe; they can even customise products over the Internet without having to ask an engineer to quote their specific requirements. These capabilities impact behaviours and expectations, and success in today’s markets can only be achieved through innovation, agility and aggressive marketing.

EXCEED CUSTOMER EXPECTATIONSThe ultimate goal of any business is pleasing the customers. The most successful companies don’t just meet customer expectations, they exceed them and beat the competition by setting the bar at a level that makes it difficult, if not impossible, for others to surpass. Successful manufacturers manage the entire customer relationship –from prospect to post-sales service and support – involving the entire organisation

in a customer focus. Whether or not they have direct contact with customers, contributors must keep the customers’ needs in mind as they plan and carry out day-to-day operations.

Manufacturers must truly understand the customers’ goals and objectives. Products and services must strive to support the customers’ vision. Communication is important; neglect is the number one reason that customers terminate a relationship. The key is to give customers access to all appropriate information required to manage customer relationship – the Web is an ally in achieving this objective.

As most companies have painfully learnt in recent years, customers often change their mind. To be fair, market conditions are such that product cycles and demand patterns are constantly changing. Agility is extremely important. A solid, collaborative partnership with customers will provide the most reliable advanced information, and therefore, the earliest warning on upcoming changes. A company should strive to be the preferred supplier by offering competitive

products, high quality, the right price and superior customer service.

STREAMLINE OUTSOURCING PROCESSESOutsourcing of manufacturing operations is a common practice today because it offers flexibility – the ability to change products or processes rapidly – and can often save money by exploiting economies of scale or other favourable cost factors offered by the contractor. There are two approaches to outsourcing: a single process step or group of steps may be performed by an outside resource (heat treating, for example, or electroplating) or the entire manufacturing process might be contracted to a third party. In either case, the manufacturer relieves demand on its own plants and can concentrate on its core competencies – which might not include volume manufacturing – while its partner(s) provide the resources for producing products.

Depending on the current resources and circumstances, outsourcing a part of the manufacturing process could save a company

from having to expand its manufacturing space (perhaps even adding a new plant), searching for and hiring experienced resources, training the new recruits and paying various expenses involved in

ramping up a new production line or process. Capital assets can become a liability in a fast-changing marketplace. As customer demands and technologies change the nature and make-up of products, it can be an advantage to not get tied to a relatively inflexible physical plant. The fastest and easiest way to achieve manufacturing excellence is through partnerships with companies that have attained superior capabilities in particular phases of the process – like production. By partnering with world-class contract manufacturers, one can reap the benefits almost immediately – well-managed processes, high quality, on-time deliveries – and increase performance and expectations. At the same time, a firm can focus on its own resources and capabilities – product innovation, design, marketing, distribution, sales or manufacturing.

MANAGE THE GLOBAL ENTERPRISEThe world in which we do business is shrinking, and virtually every enterprise is now involved in some form of international

Today’s fast-moving, ever-changing manufacturing environment demands faster responsiveness to changes in the market, product innovation and supply

chain events.



trade, whether marketing and selling to customers in other countries, or simply using parts or materials that are produced elsewhere. The Internet is, to a large extent, responsible for opening markets to products and services almost without limitations of time and distance. The ‘glass-is-half-full’ crowd will view these developments as the onset of unlimited opportunity, while the half-empty-glass crowd will see significant threats in virtually unlimited competition from literally any place on earth.

Like it or not, every executive must recognise this new reality and factor in global business into plans, processes and strategies. He/she must design products to appeal to international markets; search for suppliers in other geographies; understand local regulations and expectations, import/export processes and requirements. Moreover, it is necessary to address language challenges in labelling, documentation and marketing, besides establishing new sales channels or co-ordinate manufacturing operations across geographies and time zones. The Internet is a key tool for joining the global business community and conducting business around the globe.

Globalisation and Web commerce have changed traditional business behaviours and practices. If manufacturers don’t expand into new geographic markets, their marketshare is likely to shrink as new competitors will enter their territory and target their loyal customers. Companies must adapt their products and services to new potential customers. They must leverage the Internet to quickly establish a virtual presence. They must use collaborative technology in order to respond to customer’s requirements better and faster.

Manufacturers often grow and enter new markets by acquiring or merging with other companies. This usually means, however, that different facilities within the newly merged enterprise are using several applications on different hardware platforms, applying different part numbers for the same items and using different operating procedures. The challenge is to bring as much uniformity to the varied facilities as practical without destroying the uniqueness and competitive edge that the individual units had before the merger. The new divisions need to communicate, exchange many kinds of data (product information, customers, suppliers, employees, etc), co-ordinate and synchronise logistics operations, provide visibility to materials and components requirements, optimise fixed assets utilisation across multiple facilities, consolidate financials and much more. A natural consequence of having operations scattered through multiple locations, whether around the world or in a specific region, is the need to gain visibility across all sites. Visibility can lead to more negotiating power for purchased parts, more efficient centralised credit and collections and accounts payable, and opportunities for improved customer service by gaining access to worldwide inventories and production capabilities.

MARKET WINNING PERFORMANCEThe keys to world-class manufacturing dictate a requirement to deploy technological capabilities to improve manufacturing operations and processes. World-class manufacturers can choose their battles and compete on their own terms. They are in control of their own destiny and are seldom, if ever, blindsided by something they haven’t anticipated or cannot handle.

Courtesy: Infor Global Solutions Technology GmbH


HITECH MANUFACTURING SHOW

ENVISIONING THE FUTUREFUTUREOF MANUFACTURINGMANUFACTURING

veryone wants a glimpse of the future, to know what it withholds, to witness growth, prosperity and ultimately accomplishing the goals. Same theory

holds true for the manufacturing sector. The blooming manufacturing environment in India today desires as well as deserves a promising future.

INDIAN MANUFACTURING COMING OF AGE India is fast emerging as a global manufacturing hub with huge amount of investments spanning across industry verticals. India is no longer merely ‘a sweat shop’ or ‘cheap labour market’ but is fast positioning itself as innovation and technology driven manufacturing hub. Indian companies are fast developing increasingly sophisticated manufacturing technology to match global standards.

But, in order to achieve a world-class stature, the industry needs to inculcate self-sustainable habits with minimal pollution levels, maximum recycling, optimised energy supplies and efficient infrastructure along with being responsible towards society. There is a need for a collaborative effort in this direction from various industry verticals in order to accomplish a common goal.

For the first time in India, there is an event that promises to deliver future solutions for the complete manufacturing & engineering industry. With HiTech Manufacturing Show (HMS) as a backdrop for the entire value chain, the show also has HiTech Material Handling and HiTech Automation as concurrent shows to

compliment the growth process and future of the industry. It intends to bring the entire manufacturing and engineering industry under one roof to provide a conducive environment for sharing ideas, smart strategies and pooling strengths for a better manufacturing future.

HiTech Manufacturing Show, a Network 18 event, is a dedicated platform for initiatives like sustainability, design innovation, green manufacturing and automation that will be driver growth in the years to come.

SUSTAINABLE MANUFACTURING Sustainable manufacturing is a practice that spreads out across a company’s processes into the social and natural environments that it operates in and affects, with an overt objective of reducing or eliminating any negative impact, while pursuing the desired level of technological and economic performance. Inculcating sustainable practices in the manufacturing process will not just help the individual company but also the industry as a whole. At HMS, the industry will converge to embark on sustainability in day-to-day manufacturing.

AUTOMATION DRIVEN PRODUCTIVITYNeed for automation in manufacturing process is increasing by the day. “Automation will play a crucial role in helping manufacturing companies achieve economies of scale, global competitiveness, and meet stringent quality/safety standards,” says R Narayanan, Head - Discrete Automation and Motion Division, ABB India. Today, industrial automation is considered to be a step

beyond mechanisation. A concurrent show on automation at HiTech will do justice to this aspect of manufacturing that will have a lion’s share in manufacturing in the future.

DESIGNING A GROWTH MAPA cutting edge design can effortlessly give companies an edge over their competitors. It is a strategic activity in many organisations as innovative products contribute significantly to the sales revenue. Keeping this in mind, the event will have a specialised ‘Design Zone’ where a visitor can design his product with the help of design software on display.

GREEN MANUFACTURING: LEADING THE WAY FORWARDThe most important goal of green manufacturing remains the same – designing, manufacturing and delivering products that minimise negative effects on the environment through their production, use, and disposal. At the show, a committed platform ‘Green Zone’ will help the industry come together and discuss their green initiatives by way of seminar and interactive sessions.

These factors will not only aid individual organisations but the entire manufacturing industry and help pave way for a luminous manufacturing outlook. “Integrating futuristic processes across the manufacturing value chain will give Indian manufacturers an edge over their global competitors,” says Frank Khoshnoud, Sr VP & Head - Manufacturing, Retail & Distribution (MRD), Patni.

With HiTech Manufacturing Show, India is finally set to give shape to its futuristic aspirations of smart manufacturing with an intention of achieving a leadership position globally.

E

Indian manufacturing sector has shown its calibre in toughest of times and performed consistently. But, merely depending on these achievements won’t suffice and if India has to live the dream of becoming a future factory for the global marketplace, then its manufacturing growth ought to be innovation-led and technology-driven. HiTech Manufacturing Show to be held in Mumbai on 17-19 February, 2011 at NSE, Goregaon, Mumbai is one such platform that will be the flag bearer for the futuristic manufacturing processes & practices. Here’s presenting you a window to gaze through the future of manufacturing technology…

Mumbai | 17-19 Feb, 2011

SHIBANI GHARAT


STATOIL

orway has a top ranking in the list of countries with the highest gross national income per capita, a key indicator of a nation’s standard of living. Underpinning Norway’s high standard of living are vast oil & gas reserves lying under its continental

shelf, beneath the frigid waters of the North Sea. Norway’s oil resources are so abundant that the country ranks behind only Saudi Arabia in oil exports.

With 25 per cent of its economic activity associated with the oil & gas industry, the fortunes of Norway’s economy have become closely entwined with the health of this industry. However, the oil & gas producers are faced with many challenges in their efforts to increase recovery rates and extract more out of the remaining 50 per cent that is left in the oil & gas bearing reservoirs of the North Sea.

N

Modest recovery rates have been seen as a fact of life in mature oil and gas fields. But, Statoil – a leading player in the oil & gas segment in Norway – saw Norway’s economic reliance on petroleum production as an incentive to ‘rewrite the rules’ on production efficiency. It teamed with an industry consortium to combine advanced sensing technology with integrated operations to optimise the management of its oil & gas fields that will eventually yield huge revenues for the Norwegian economy.

PROBLEMStatoil sought to offset the natural trend towards declining production levels and aimed at streamlining as well as improving operations. Compared with a worldwide average recovery rate of 35 per cent, it aimed at increasing its rate to 55 per cent for sub-sea platforms and 65 per cent for fixed platforms by incorporating new technologies into production processes. SOLUTIONStatoil teamed with key industry players to create a new process framework that links advanced real-time sensing capabilities in the field to powerful, collaborative and analytical resources accessible across the enterprise. Together with other initiatives, the solution will contribute to Statoil’s efforts to increase the recovery rate of its existing oil & gas fields, thereby adding to its oil revenues.

PUMPING UPPUMPING UPPRODUCTION LEVELS PRODUCTION LEVELS ThroughThrough‘SMART’ TECHNOLOGIES‘SMART’ TECHNOLOGIES


STATOIL

In April 2006, the Norwegian Oil Industry Association (OLF) published a report stating that if the oil & gas companies on the Norwegian continental shelf were to quickly integrate their operations by advanced use of information and communication technology, they could increase their revenues by $41.5 billion. If they fail to do so, they would risk losing $10 billion in potential revenue within the next three years, the report said. These rather dramatic figures have caused the entire industry to consider new measures to integrate operations and reverse the decline in North Sea production rates and extend the lifespan of its existing oil & gas fields. As one of the largest producers accounting for 60 per cent of Norwegian oil & gas production, Statoil has been a key catalyst for this change.

TAKING CONTROLTo address the challenges stated in the report, Statoil initiated the TAIL-Integrated Operations (TAIL IO) project with key industry partners IBM, ABB, SKF and Aker Kværner to identify methods, technologies and work processes for integrating its operations.

As the name implies, TAIL IO aimed at improving operations in fields approaching the end of their lifetime. The widespread use of advanced information and communication technology was only part of the equation to reach the estimated potential. The implementation of new work processes based on real-time access to data, in addition to organisational changes of moving functions and personnel from costly offshore oil rigs to onshore locations, was equally important.

Statoil and the consortium members have been contributing equally to the project in terms of resources and inputs. The company approached ABB, Aker Kværner and SKF for leveraging their extensive engineering and energy expertise, and IBM for its ability to apply innovative insights and open standard technology to drive efficiency improvements. A key part of IBM’s mission in this consortium was to bridge the gaps between different parts of Statoil’s operation, so that data and employee knowledge can be leveraged across all processes.

For Statoil, having to operate with independent ‘islands’ of corporate knowledge has been more than just a metaphor, since its offshore platforms have

long operated independently of one another. This means that even though a group of platforms may be gathering subsurface data on the same underlying oil or gas field, they nonetheless have been unable to combine their information into a more comprehensive view of the field.

To bridge this gap, IBM offered its WebSphere integration software with manufacturing domain adapters and an integration industrial-semantic model based on a linkage of key oil & gas standards to create a flexible information integration and interoperability framework. When implemented, this will allow Statoil to aggregate its collective knowledge across rigs and fields, thus creating a foundation for more informed decisions, optimised processes, and ultimately, higher production efficiency. Within this framework, IBM WebSphere Enterprise Service Bus is a standards-based integration broker within a service-oriented architecture environment – a crucial factor to enable the flow of information through the company’s IT

systems, regardless of its format, and make it accessible wherever it is needed the most.

DECISION-MAKING IN FOUR DIMENSIONSIBM provided Statoil with the key elements required to implement ‘smart’ field management practices. Using data from wireless sensors, which monitor subsurface conditions (such as pressure and temperature at different points in the field, as well as the movement of gas or oil deposits within the field), the solution can provide Statoil’s engineers with the information they need to know when,

where and how much to pump. By combining information from all its production facilities, the company can gain a much more comprehensive view of the state of its oil fields, vastly improving its ability to optimise extraction activities.

When the ability to visualise subsurface conditions in three dimensions was first introduced, it represented a major innovation in oil production. As embodied in the IBM solution, Statoil’s vision of smart field management pushes that notion even further by adding a fourth dimension – time. Getting data feeds from its sensors in real-time will provide the company with the means to make decisions for production optimisation on the spot, without having to wait for weeks or months to gather and synthesise information. This can make a crucial difference in maximising a field’s production yield.

The solution’s framework for integrating information and business processes is also the key enabler of Statoil’s preventative maintenance strategy, which is designed to

identify potential maintenance issues before they become critical and cause shutdowns. Wireless sensing and telemetry technology combined with IBM Information Server software helps the company derive more value from the complex, heterogeneous information spread across its systems.

The solution enables to gather information on asset conditions, such as the thickness of a pipe, from all its platforms and facilities. Algorithms developed by IBM Research will process this data to determine when proactive or ‘condition-based’ maintenance should be performed. For Statoil’s production engineers, IBM Research developed similar well-algorithms

Business Benefits Of TAIL IO Project Expected 5 per cent increase in oil & gas production through planned

and improved maintenance processes Expected 30 per cent reduction in costs through the use of predictive

maintenance practices Extension of oil field life and increase in production yield through

‘smart’ field management, enabled by real-time wireless sensing of subsurface oil field installations

Lower costs and improved production efficiency through the consolidation of well monitoring and management into onshore facilities

Increased interdisciplinary collaboration through improved information sharing.


STATOIL

that analyse the subsurface data gathered by sensors to provide the decision support needed to optimise field production.

COLLABORATING OFFSHORE AND ONSHOREWhile the IO initiative is in many ways all about bringing information and processes together, it is also about bringing them onshore. The combination of the harsh platform life, the steady aging of its workforce and the increasing challenge of keeping up the work continuity, threatened Statoil with a staffing crunch and, perhaps more importantly, the loss of valuable human capital as experienced workers retired. By leveraging the process integration enabled by IO as well as advanced wireless sensing and communications technology like RFID, the consortium is helping Statoil in migrating key processes from its platforms to its onshore facilities.

By making its processes less location-dependent, Statoil will gain a whole new level of efficiency and flexibility in the way it deploys its personnel. In addition, by stemming the outflow of experienced workers, this new service paradigm will enable the company to preserve its valuable assets – its employees’ knowledge.

Statoil expects the TAIL IO project to identify ways to increase its overall production by 5 per cent – an enormous margin in the realm of offshore oil & gas drilling. What is more, by enabling the proactive maintenance of its facilities, the company expects to reduce its operating and maintenance costs by 30 per cent. By moving from a scheduled maintenance process campaign to a proactive and preventative maintenance model, it aims at achieving a drastic reduction in shutdowns and their consequences such as expediting costs and long delays. This model will also help Statoil to optimise turnarounds and shutdowns across all assets.

Adolfo Henriquez, Head, Statoil’s Integrated Operations, believes that IBM’s insights will play a critical role in the success of the IO project. “Few companies have the combination of technological expertise, leading-edge research and industry knowledge that IBM has displayed in its engagement,” says Henriquez. “Our efforts to bring more integration and collaboration to our production processes are critical to the future of the offshore industry. IBM has shown a strong commitment towards helping us achieve this goal,” he adds.

Courtesy: IBM Corporation

Furnishing with the key elements IBM provided Statoil with the key elements required to implement ‘smart’ field management practices. Using data from wireless sensors, which monitor subsurface conditions (such as the pressure and temperature at different points in the field, as well as the movement of gas or oil deposits within the field), the solution can provide Statoil’s engineers with the information they need to know when, where and how much to pump. By combining information from all its production facilities, the company can gain a much more comprehensive view of the state of its oil fields, vastly improving its ability to optimise extraction activities.


PROACTIVE MAINTENANCE

SURPASSINGSURPASSINGCONVENTIONAL TECHNIQUES

aintenance-related issues typically contribute to more than 25 per cent of the total cost of finished goods in the manufacturing sector. Industry experts

believe that just a two per cent reduction in this cost can equate to a 7.5 per cent gain in sales.

Recent studies have shown that the majority of unplanned downtime is caused by mechanical assembly failure. Further, equipment analysis shows that fastener loosening, polytetrafluoroethylene (PTFE) tape fouling control valves, fitting leakage and spun bearings are some of the problem areas resulting in the need for equipment repair. In order to highlight these challenges and promote a shift from reactive maintenance methods, techniques and procedures to proactive methods, Loctite Maintenance Reliability Workshops were recently conducted. The workshops aimed at a series of practices that provide maintenance personnel with ways to increase the reliability of mechanical assemblies, minimise maintenance costs, and offer proactive solutions to prevent unplanned downtime. Moreover, various

case studies were presented on the occasion to enlighten the participants about the significance of proactive maintenance in their shopfloor.

REDUCING DOWNTIME: A CASE-IN POINTA leading lumber and plywood manufacturer managed to save on manufacturing cost by adopting the proactive maintenance technique. Like in many cases, one of the major causes of unscheduled downtime was on account of mechanical failures such as fastener loosening. This manufacturer was experiencing ‘tap root’ (mechanical assemblies) that cause failures with their limit switch arms. Limit switches translate motion into switch actuation. The maintenance department found that the screws were loosening in the arms, which made them fall out or become misaligned. A maintenance person was assigned the task of tightening all the screws. This job took about 5-10 minutes per occurrence with two occurrences per shift. Each time the task was completed, the equipment was ‘tagged out’, tightened and brought back on line. In one year, it was found that over 91 hours had been spent on labour

and downtime.The company implemented a proactive

maintenance process as a response to the labour and downtime problem. In just two months, the maintenance personnel identified 29 ‘tap root’ (mechanical assemblies) that caused failures. If left uncorrected, these failures would have cost the company over $53,000.

The maintenance personnel chose the appropriate thread-locker to rectify the limit switch situation. The thread-locker unitised the screws within the assembly and prevented them from getting loose. Since implementing this technique, the manufacturer could prevent 91 hours of downtime and labour costs in one year, which translated into a saving of over $57,000 on maintenance costs.

SOLVING AIR LEAKSAir leaks are among the biggest contributors to needless costs in any facility. A leak is more than a minor inconvenience and a costly drain on overall operating costs. A single leak in a plant’s air-line can siphon off as much as $8,286 every year. For instance, say a leak point resulted in a loss of 35.73 cubic metre per minute (cmm) of air at a

M

Over a quarter of the total cost of finished goods

can be attributed to maintenance problems, such

as mechanical assembly failures. The key to prevent

such failures and reduce the maintenance cost is through

implementing proactive maintenance practices.

Proactive maintenance is now recognised as the most

important means of achieving savings unsurpassed by

conventional maintenance techniques or reactive

processes. Proactive maintenance training programs are key to minimising downtime.


PROACTIVE MAINTENANCE

line pressure of 100 psi. Figures similar to this compelled an automotive component manufacturer consider proactive maintenance for ways to decrease costs associated with air leakage.

Through proactive maintenance process, state-of-the-art ultrasonic equipment was used to identify air leaks, includingfittings, valves, flanges and hoses were tagged with a number, their location, severity and cost. The maintenance team was trained to remedy the fittings andavoid problem reoccurrence, which saved the company over $37,000 in air

leaks per year.Apart from air leaks, oil leaks also pose

several challenges to manufacturers. A one-drop oil leak every 10 seconds results in 153 litre of fluid per year that must be recycled or disposed of. And if this number is multiplied by several leaks in the facility, it does not take long to realise that hundreds of thousands of litre of oil is lost every year. Disposal costs can range from $500 to $1,000 per 208-litre drum. In addition, safety hazards exist when oil leaks onto the shop floor. Here is an instance wherein a paper mill resolved the problem of oil leak through proactive maintenance.

DEALING WITH CHALLENGES PROACTIVELYProactive maintenance has many advantages over the traditional reactive processes. It

enables to take corrective actions aimed at the sources of failure. It is designed to extend the life of mechanical machinery instead of making repairs when often nothing is broken; accommodating failure as routine and normal; and pre-empting crisis failure maintenance.

Rupesh Navthale, Senior Executive - Marketing, Henkel Adhesives Technologies India E-mail: [email protected]

Proactive maintenance deploys various techniques to extend operating lives of machines. Root cause failure analysis, which determines the mechanisms and causes of machine failures, constitutes the major part of a proactive. The fundamental causes of such faults can thus be rectified, and the failure mechanisms can be gradually engineered out of each machinery installation.

QUICK TAKE

Oil leak prevention with threadlocker

Projecting ‘A Promising

Pune is emerging as a preferred manufacturing hub owing to massive investments and lucrative projects that the region has attracted during the past one year. These projects have had a major impact on the local industry and have also played a pivotal role in changing the dynamics of the region. Assisting the trade & industry and keeping the growth spiral alive in Pune are trade shows like Engineering Expo that help the entire industry to converge effectively under one roof.

SHIBANI GHARAT

hat does General Motors, Mercedes Benz, Bajaj Auto, Volkswagen, Tata Motors, Apollo Tyres, Alpha Laval, Force Motors, Piaggio Vehicles, Bharat

Forge, Mahindra & Mahindra, Kirloskar Oil Engines, ThyssenKrupp, TCS, Wipro, Patni, Honeywell, Whirlpool, Matsushita, LG have in common? Besides being colossal in their respective industry verticals, they all have a manufacturing facility in Pune.

Pune, once known as the ‘Oxford of the East,’ is growing strength by strength to become the ‘Detroit of the East.’ From educational institutions to foreign institutional as well as direct investments, the city has a new face and identity today. Presently, almost every foreign company wants to be a part of Pune’s flourishing manufacturing belt.

PUNE, AN INVESTMENT HUBThe city has been a favourite destination for several MNCs since time immemorial. It has a vast pool of engineering and management talent. Its propinquity to Mumbai, favourable climate and a cosmopolitan culture have contributed to the growth of this city. Moreover, the opportunities that Pune offers in infrastructure and its allied sectors are tremendous. Besides, the distribution of SME clusters in Pune follows a logical pattern of proximity to industries.

During the last few years, this region has

seen a plethora of gigantic investments. In the last year alone, three massive new plants owned by General Motors, Volkswagen and Mahindra & Mahindra were inaugurated here. The new projects include Fiat-Tata joint venture at Ranjangaon with a proposed investment of `4,000 crore, GM’s `1,400 crore investment with a further `900 crore expansion, Volkswagen’s project of `3,800 crore, Mercedes’ `250 crore investment and Mahindra & Mahindra planning a huge `5,00,00 crore investment by 2012. Bajaj Auto proposes `300 crore investment in two- & three-wheelers and a further `1,000 crore investment in a car plant. In January, automotive component manufacturer ZF India inaugurated a manufacturing facility in Pune. In April 2010, China-based SANY Group, a leading global major in construction machinery industry, inaugurated its first manufacturing facility at Chakan, near Pune.

These companies usually zero in on Pune component manufacturers for localisation of their products to suit the Indian conditions. From engines to raw materials, hydraulic parts, auto components, material handling and storage equipment, everything is local. This has helped the industry at Pune massively with generation of significant employment opportunities for

the local populace. They set up their manufacturing units in various industry clusters like automobile, auto components, engineering and machining, electronics,

plastic and rubber components, etc, located in satellite towns of Ranjangaon, Pimpri-Chinchwad and Talegaon.

SMEs GAINING MOMENTUMPune SME clusters are the ones that have benefited the maximum from these investments. Apart from economic gains, these big manufacturers have helped the industry by bringing in latest technologies, technical knowledge and efficient management system to the region.

“There is a dramatic impact on technology upgradation in the region over the past few years. Companies like Volkswagen apply the latest manufacturing technology in their units. They demand products that are compatible with their technology. This has resulted in an increasing demand among the local companies to

WVibrant competition has helped in increasing competitiveness, spur

innovation and boost efficiency.

Mangesh Agarwal, GM, CFFI India

match the quality and technology standards of these big organisations. They have started accepting automation in a big way,” says Milan Supanekar, Director, Welding Technologies India. SMEs have some inherent advantages as compared to large enterprises in terms of greater flexibility in operations for responding efficiently to changing customer needs.

Vibrant competition among the local companies to attract the attention of big companies is now being seen in this region. “This competition has helped in increasing competitiveness, spur innovation and boost efficiency,” says Mangesh Agarwal, GM CFFI India, Durr Ecoclean. He believes that there is a notable change in the quality of the products, especially after the big manufacturers have turned their attention to Pune.

SURVIVING IN A COMPETITIVE SET-UP The SMEs in Pune operate in a dynamic

business environment where growth has become a necessary objective for the survival and viability of the enterprises. The challenge for any company in a competitive set-up is to remain competitive and consistently deliver value to customers. “It is also necessary for a manufacturer to deliver proper post-sales services and back-up support,” opines Supanekar.

One of the strategies these companies can implement to remain competitive and deliver customer value despite their small-scale of operations is by way of promoting their products and services. Jagdish Gajjar, Manager – Operations, J K Automation, explains, “Spreading awareness about your products and services will surely help your organisation in getting that extra edge over your competitors. Word of mouth publicity is not enough.”

There are several channels for promoting one’s organisation and products. Creating product presentations and catalogues, advertising in B2B publications are some of the tried and tested methods to spread product awareness. “We offer in-house seminars with references and case studies; we also get our prospective clients to come and visit our plants,” says Agarwal.

But there is a common point of agreement that the most efficient way of spreading awareness about products and services is by participating in exhibitions. Exhibitions and trade shows have been used as an effective marketing medium to find new customers, improve business relationships with existing customers, introduce new products and services, and deliver many other meaningful and tangible business outcomes.

AN IDEAL PLATFORM TO SHOWCASE BUSINESS Engineering Expo is a complete manufacturing & engineering trade fair to

display one’s products and services. It is one of the most preferred platforms to grow business, as selected by 1000+ companies that participated in the previous editions of the Expo. More than 55,000 industrial buyers benefit from Engineering Expo, every year. Over the years, it has become one of the most lucrative platform for business growth.

“Engineering Expo has helped us in spreading awareness about the products that we offer,” points out Anand Rajadhayaksha, Manager-Advertising, Nilkamal.

“Every year, we introduce new designs and sizes of material handling crates & bins to suit diverse applications in various industries like automobiles, pharmaceuticals, engineering, electricals & electronics, hospitality & catering, logistics, textiles, supermarkets, retail, food & beverages, agriculture & seafood, etc. Expo brings all the industry verticals together under one roof, making it easy for us to market our products effectively to various organisations,” he added.

Seconding Rajadhayaksha’s point, Supanekar states, “Participating in the Expo has helped to create awareness about our five-year old company. Moreover, we were able to acquire bulk purchase orders in the past,” says Supanekar, whose company supplies almost 90 per cent of their materials to JCB.

With the flourishing industrial environment, the opportunities for businesses are budding in Pune. Efforts in the right direction will help the domestic industry in Pune to amalgamate with the global market and be a driving force for the industrial growth of Maharashtra, and hence, India. Initiatives like Engineering Expo will prove to be principal platforms for this thriving industry to grow to limits beyond measure.

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 Rs 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, tie up, and exchange ideas for the growth of the industry. 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.

There is a dramatic impact on technology upgradation in the region over the past few years. Companies like

Volkswagen apply the latest manufacturing technology in their units. They demand products that are compatible with their technology. This has resulted in an increasing demand among the local companies to match the quality and technology standards of these big organisations.

Milan Supanekar, Director, Welding Technologies India

Pune | 19-22 Nov, 2010


DATA ANALYSIS

hen Albert Einstein said, ‘Information is not knowledge’, he could have been referring directly to the challenge that small and medium enterprises

(SMEs) face while transforming data into insights that can drive improvements in strategy and operations. SMEs are better positioned than ever to collect and analyse data. The real imperative, however, is to develop visibility into how their businesses operate, enabling employees and executives to react quickly to market changes and shift strategies as new opportunities emerge.

Certainly, any discussion of business analytics may at first seem irrelevant to SMEs, many of which operate without large databases or high-end information technology (IT) resources. Moreover, data management and analysis can be daunting even for firms that deploy the most sophisticated technology and management practices. Practically, though, SMEs are just as able as larger companies in deriving the

benefits of business analytics. But it will probably require them to re-evaluate their approach – or design a new one – to create knowledge that can drive business performance.

Indeed, SMEs require such visibility and insights to achieve sustainable growth and profitability. Strategically, they must beable to break down their business and identify relevant areas (e.g., customer segments, supply chain activities, revenue streams, partnerships) to find out atwhat stage of evolution they are in. Operationally, by looking at individual revenue sources, customers, products or services, delivery channels and supplychain links, they need to ascertain the activities that are most profitable andhave the greatest potential. Moreover, they can combine these insights and spotwarning signals from daily operations that have long-term strategic implications – for instance, a near-term concentration of receivables that would suggestwhen longer-term business diversificationis advisable.

TOOLS FOR ATTAINING VISIBILITY According to a recent survey by the Economist Intelligence Unit, SMEs recognise that unstructured data can be counter-productive. Fifty-one per cent of the survey respondents said that they have to spend valuable time searching for key information among unstructured sources. However, one-third of respondents said that they have ready access to the information they need to complete their tasks.

SMEs need to formalise their approach to assemble, store and analyse data in a systematic and relevant manner so as to gain visibility into specific aspects of their business that are most relevant to meeting business goals and strategy (even though visibility may drive a shift in that strategy).

For SMEs, technology is increasingly becoming affordable, thanks to the rising number of off-the-shelf and customisable business intelligence applications available to fit a variety of scales, budgets and capabilities. Pre-configured servers and software are available, with ‘plug-and-play’

W

The advantages of business analytics are many for both big and small firms. However, to derive the maximum benefit, small and medium enterprises need to re-evaluate their approach or even design a new one to create knowledge that can drive business performance by enhancing visibility. SMEs can optimise operations on a daily basis, and make strategic decisions for pursuing business profitably by gaining visibility through proper use of data.

DRIVING BUSINESS PERFORMANCE THROUGHVISIBILITY


DATA ANALYSIS

options that enable SMEs to adopt solutions that incorporate available data from a variety of sources, if necessary. SMEs lacking historical data can opt to set up their systems and populate them with data as it arrives. Subsequently, these data can be warehoused, integrated and analysed.

VISIBILITY CAN DRIVE PROFITABILITY The key, of course, is to utilise the analytics in a manner that can drive business results – by reaffirming or changing the way in which operations function on a daily basis and by driving longer-term strategic decisions. The tangible benefits of visibility depend on the SME, but the applications are considerable, irrespective of the type, scale, business focus or profile of the SME. Following are a number of potential benefits to be taken into account:Greater customer-centricity: By gathering information about products that sell best in specific locations, SMEs can make more customer-centric decisions about everything from marketing campaigns to staffing and inventory. When such data is linked with information-sharing systems, it can also help employees to add qualitative insights – for

instance, sharing tips on the type of selling behaviours that have been shown to drive a customer to complete a given transaction. SMEs can also acquire quantitative insights into factors that drive customers to be loyal, or to any defect that prevent a customer from buying a product. Moreover, they can also find out which customer segments are profitable and those that destroy value. All this information provides the right ammunition for any SME trying to optimise its business focus and resources. A more responsive supply chain: Information gathering and sharing systems can also be established to provide visibility directly to supply chain partners. Such systems [part of a segment often known as collaborative planning, forecasting and replenishment (CPFR) tools] provide suppliers, for example, with real-time point-of-sale data, so they can track customer demand and immediately re-stock depleting inventories. Business-driven financial accounting: All SMEs produce basic ‘books’ or year-end accounts. However, they need to maintain accounts that provide thorough and timely visibility into profit-and-loss streams, cash flows, debtor and creditor positions among other statistics. This visibility can help them

control cash flow more effectively, and optimise working capital and other resources, as well as help in containing costs. In fact, visibility may enable an SME to avoid or reduce external fund-raising. Although, if fund-raising is necessary, data-driven management accounts will also provide a clear picture of whether the SME is a good risk for financers (whether the SME is approaching a traditional bank, a micro-lender, peer-to-peer lender, or a vendor) or for potential strategic partners.

A STRATEGIC APPROACH SMEs are less likely than larger companies to have in-house systems that automatically gather, house and analyse data. But SMEs can still ‘mine’ their data to obtain visibility into their business. Admittedly, SMEs will need a strategic approach, and a workable IT solution, to produce the type of business intelligence that will actually drive enhanced performance. But once established, the resulting visibility can help SMEs optimise operations on a day-to-day basis, and make longer-term strategic decisions about the way to pursue their business profitably.

Courtesy: Economist Intelligence Unit


INDIA ENERGY 2010 & INDIA NUCLEAR ENERGY 2010

wing to factors such as population growth and rapid economic development, India’s energy consumption has been increasing at one of

the fastest rates in the world. This can be gauged from the fact that commercial primary energy consumption in India has grown by about 700 per cent in the last four decades. Also, the per capita consumption in India is around 400 KWH per annum. Therefore, due to the rising population, expanding economy and a quest for improved quality of life, energy usage in India is bound to grow at an exponential rate.

Despite the overall increase in energy demand, per capita energy consumption in India is still very low compared to other developing countries. Today, India has one of the strongest potentials for the effective use of renewable energy. It is the world’s fifth-largest producer of wind power after countries like Denmark, Germany, Spain and the US. There is a significant potential in India for generation of power from renewable energy sources, be it any renewable source of energy, viz, hydro, biomass or solar energy.

Looking at the immense potential for growth in the renewable energy market, UBM India is organising its 2nd edition of India Energy 2010 & India Nuclear Energy 2010, a three-day international exhibition on energy & power and nuclear energy. This event will be held from October 7-9 at the Bombay Exhibition Centre, Mumbai. India Nuclear Energy Summit, a one day Conference will take place on October 8, 2010. This annual exhibition aims at

providing a global platform for showcasing cutting-edge technologies, raw material & component supplying companies. The format of the event has been designed to offer networking and business opportunities and provide an interactive platform for equipment, technology suppliers and end-users.

The exhibition and the concurrent summit will serve as an excellent networking platform for the exhibitors, visitors and delegates. The technical summit will be conducted by experts from India and overseas in select areas of the nuclear industry and they will also present case studies, which would be topical and relevant to nuclear professionals and the end-user industries.

EVENT HIGHLIGHTSHon’ble Union Minister of Power, Government of India, Sushil Kumar Shinde, will visit the exhibition and conference on October 8. Dr Srikumar Banerjee, Chairman, Atomic Energy Commission, is the keynote speaker for the concurrent India Nuclear Energy Summit 2010. The event has been able to attract participation from leading companies like Alstom, Areva, Power Grid Corporation of India, BHEL, NHPC, REC, Schneider Electric, Wartsila, Ingersoll Rand, GMR Group, JSW Energy, Rolls Royce, and many more. The event has also received excellent response from overseas with country pavilions from

France, Russia, the US, Finland, and individual companies from other countries.

A UNIQUE PROPOSITIONIndia Energy 2010 supported by the Ministry of Power, Government of India, and Ministry of New and Renewable Energy, Government of India, will be a holistic event covering the entire gamut of the energy sector. The event has participation from leading corporates and PSUs from the energy & power sector, making this a premium networking event for the energy sector in India.

India Nuclear Energy 2010 is co- partnered and endorsed by the Department of Atomic Energy, Government of India. In the backdrop of recent agreements between India and various other countries and international bodies like IAEA and the NSG, this is the right event at the right time for India. It provides an opportunity for domestic & international companies to avail of the huge untapped potential that the nuclear industry has in India.

India Nuclear Energy is the only event of its kind in India on nuclear sector. It offers advantages to the companies visiting and exhibiting their latest offerings. It provides a comprehensive platform for qualified buyers and sellers from the global nuclear fraternity to find new customers and suppliers and evaluate the Indian nuclear market.

India Nuclear Energy Summit 2010 will provide a global platform, which addresses

key issues, identifies opportunities and challenges, captures learning and best practices from global success stories and focusses on strategies for the sector, as it prepares to meet new challenges and moves towards competitive efficiency in the sector.

O

With environment conservation taking the centre stage these days, Indian companies are now turning towards alternative and abundant sources of clean energy. As a mandate, energy conservation and efficient new technologies are the need of the hour for the power sector to grow. To tap this potential market, UBM India with SEARCH as its media partner, is organising its 2nd edition of India Energy 2010 & India Nuclear Energy 2010 from October 7-9, 2010, at the Bombay Exhibition Centre, Mumbai. A preview…

AIMING FOR‘POWER’FUL FUTURE

India Energy 2010 Highlights It brings together the world’s diverse energy fraternity It offers the best networking and business opportunities Designed to attract top-level management, production,

utility, R&D and sourcing professionals Great place to meet potential manufacturers and suppliers.

7-9 October, 2010Bombay Exhibition Centre, Mumbai


MINING

MINING PRODUCTS

Radhika Industries (Diamond) manufactures and offers mining products, such as inner sleeve of beads & shanks, crimp locks,

diamond wire springs, joint accessories, crimping machines, etc. Inner sleeves are widely used in various industries. These are available in different shapes and dimensions that suit industry’s requirements. Usually positioned every three diamond bead crimps are made in special annealed steel in order to squash without b r e a k p r o t e c t e d by an electrolytical galvanization treatment. The springs for diamond wire assembly are made in special carbon steel grade-B smoothed and drying oiled. Joint accessories are available in various sizes and dimensions. These are made from quality materials that ensure strength and durability. Various quality control checks are performed to offer a range of superlative products. Manual heavy-duty crimping machines are offered for use in marble quarries to join inner wire rope.

Radhika Industries (Diamond), Delhi 110 085.Tel: 011-6515 8610, Fax: 011-2518 1453, Mob: 09212327050Email: [email protected]: www.radhikaindustries.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 262 to find it quickly

CLUSTER HAMMERS

KLR Industries offers Hippo cluster hammer that are manufactured to international specifications, from only the

best quality alloy steel, machined to high-precision and supreme standards. These products are heat-treated in the most modern, fully process controlled,in-house facility. The tungsten carbide buttons, which are used, are obtained from leading and reputed indigenous and foreign manufactures. These cluster hammers are quality products that conform to international standards and strict quality control methods. KLR products are constantly improved with adaptation of the most recent manufacturing technologies. The product features ensure: longer product life; higher & consistent penetration rate; capacity & capability to perform hitch-free at higher pressure range; reduced number of parts, compact structure for lower rate of wear & tear; avoidance of back hammering, hammer blocking; and minimum maintenance costs.

KLR Industries Ltd, Hyderabad 500 062.Tel: 040-2712 1828, Fax: 040-2712 0558Email: [email protected], Website: www.klrindustries.com

MINING DTH HAMMERS

Hi-Tech Pneumatics & Heat Treaters manufactures and offers mining DTH hammers that are designed to be aggressive so

that maximum drilling penetration can be achieved. Wear sleeves have heavy wall thickness and are specially heat-treated to last

internal and external wear. Pistons have been carefully designed to avoid stress contours and carry optimum weight to give more strokes. The use of superior materials and precision heat treatment allows the pistons to last long with minimum wear & tear. Inner cylinders are precision ground and honed to ensure consistent stroke alignment, which reduce internal hammer component wear and allows for unrestricted high volume air flow & enhanced hole cleaning

capacity. Air distributors have been carefully studied and designed by the design department by using latest Pneumsoft Software. Front chucks are usually subjected to severe wear & tear as the pulverized cuttings cause extensive wear.

Hi-Tech Pneumatics & Heat Treaters Pvt Ltd, Bengaluru 560 058.Tel: 080-2836 1397, Fax: 080-2836 3597, Mob: 09845193287Email: [email protected], Website: www.hi-techcluster.com

MINING DRILLING RIGS

PRD Rigs India offers mining drilling rigs (model PRD-125 wagon drill) that are designed innovatively and manufactured under

strict quality control. These are perfect lightweight and heavy-duty equipment ideal for carrying out all types of drilling operations by DTH method in mines, quarries and construction projects. They

have capacity of 4” to 4½” dia hole up to 40-meter (130 feet) depth by DTH method. Salient features include: lightweight, yet rigid, value engineered construction ensuring easy portability & high drilling performance; design for rotation winch & self-propellant pneumatic piston-type air motors to provide maintenance-free efficient performance; effectively brake wheels with adjustable front two stabilisers; centralised control panel with auto

feed arrangement; provision for anchoring of mast/locking arrangement between mast & boom that ensure perfect rigidity during drilling; and swivel of mast 25 degree either side & capable of drilling holes from 15-degrees in word from vertical up to horizontal position.

PRD Rigs India, Tiruchengode 637 209.Tel: 04288-256435, Fax: 04288-251645, Mob: 09786665888Email: [email protected] , Website: www.prdrigs.com

MINING & DRILLING EQUIPMENT

Guru Precision Tools offers an array of mining and drilling equipment that are

offered with a capacity in steel. These drilling equipment are also offered with the option of automatic feed and manual feed spindle. The range of radial drilling machines is widely used in the automotive and heavy engineering industry.

Guru Precision Tools Pvt Ltd, Bengaluru 560 021.Tel: 080-2312 4227, Fax: 080-2312 3402, Mob: 09845049816Email: [email protected], Website: www.guruproindia.com


MINING

CORE CUTTING MACHINES

Motorised core cutting machines offered by Associated Scientif ic & Engineering Works

have spring-loaded slide handle for easy coring. These machines have convenient carrying handle on carriage. Standard features include: 6-inch bit capacity, weigh only 45 pounds, 15 A, 3.5 HP core bore motor, single-speed 800 RPM, very durable & reliable, and water hose connection.

Associated Scientific & Engineering Works, New Delhi 110 055.Tel: 011-2352 1188, Fax: 011-2353 4863Email: [email protected], Website: www.asewindia.com

DRILL HAMMERS

Goodwill Enterprises offers a series of drill hammers that are specially manufactured for all

types of formation, which gives higher penetration at lower air consumption. These are heavy-duty valveless hammers with fewer components, which provides hassle-free drilling even in depth points. It is an advance air engineering in which air blocks in the undercuts of barrel, which lifts the piston automatically and again due to blocking of air in the undercuts of piston it beats the drilling bit simultaneously. The drill hammers have reversible barrel, which ensures longer hammer life and higher penetration for a long time.

Goodwill Enterprises, Dist Latur 413 512 .Tel: 02382-641110, Fax: 02382-240606, Mob: 09822455100Email: [email protected], Website: www.goodwilluniversal.com


MINING

MINING CABLES

North Eastern Cables & Conductors offers superior quality mining cables for different industrial requirements. These

mining cables are known for their accuracy in performance and are engineered to endure the most extreme demands of the toughest mining applications. With a reinforced, two-layer, lead-cured thermoset jacket, the mining cables ensure ultimate protection against worst hazards conditions of mining and reduce any chances of failure.

North Eastern Cables & Conductors Pvt Ltd, Jaipur 302 016.Tel: 0141-2281654, Fax: 0141-2281540, Mob: 09414062461Email: [email protected], Website: www.khetan-group.com

ROCK DRILLS & SPARES

Singhvi Traders manufactures and offers air-flushed drills that are useful for a variety of

surface drilling applications at stone quarries, granite-marble mines and construction jobs. Each rock drill spare part is precision engineered and heat-treated for tolerance level required for the best performance in the rock drill. Technical specifications include: hose connection 19 mm; rotation 240 RPM; impact rate at 2050 blows/min; piston stroke 60 mm (2.4 inch); drill steel (hex) 22 mm x 108 mm (7/8 x 4¼ inch); air req at 6 bar (87 PSI) 3.4 m³/min (119 CFM); length 575 mm (22.5 inches); and weight 26 kg (56 lb).

Singhvi Traders , Udaipur 313 001.Tel: 0294-2424029, Mob: 09829006761Email: [email protected]; Website: www.singhvitraders.com

ROTARY DRILL RODS

Navdeep Industries (Regd) offers rotary drill rods. Diamond sections of 19/16” are used with

111/16” rotary coal drill bits as per BS specification 2593/1964 for dry drilling and fast penetration in friable material. Turbine sections of 19/16” drill rods up to 6” are used with 111/16” rotary stone drill bits as per BS specification 2593/1964 for wet drilling in abrasive rocks.

Navdeep Industries (Regd), Sirhind 140 406.Tel: 01763-220067, Fax: 01763-222267, Mob: 09417322767Email: [email protected]: www.navdeepindustries.com

MINING & LASHING CHAINS

Mega Link Chains (I) offers a wide range of mining and lashing

chains, which is extensively used for mining and lashing purposes. These chains are made of superior quality raw material procured from reliable vendors. The use of proper material makes them abrasion corrosion & further makes them function under all

extreme conditions.

Mega Link Chains (I) Pvt Ltd, Dist Thane 421 506.Tel: 0251-2620238, Fax: 0251-2621774, Mob: 09833091410Email: [email protected]: www.megalinkchains.com


MINING

MINING GAUGES

Afriso, Germany, manufactures measuring and control devices for pressure, temperature

and level as well as measuring, control and monitoring devices for flue gases. Parts of this range are mining gauges. These are suitable for mining, cement applications or in any areas where there is a harsh environment, which will damage the gauges.

Afriso India Pvt Ltd, Pune 411 005.Tel: 020-2551 4336, Fax: 020-2551 4336Email: [email protected], Website: www afriso.in

MINING CABLES

Central Cables manufactures and offers mining cables that are armoured PVC and XLPE cables. These cables are suitable

for use in mines with the following additional requirements for coalmines: copper as conductor and armour conductivity at least 75 per cent of main conductor conductivity. The cables are differentiated with (mining) embossed on the outer sheath.

Central Cables Ltd, Nagpur 440 001.Tel: 07104-237564, Fax: 07104-236819Mob: 09822698468 Email: [email protected]: www.centralcables.co.in


MATERIAL HANDLING

FORKLIFT TRUCKS

Salzgitter Hydraulics offers forklift trucks that are designed keeping

the Indian conditions in mind, like rough terrain, weathering, etc. These trucks are ergonomically designed for operator comfort. Optional accessories are available upon customers’ request. Features are designed to suit the Indian environment. Other features include: ease of maintenance in a rugged terrain; liquid level sensors; independent meter; spacious seat; absorption system; more space for maintenance; and offer 1-year warranty.

Salzgitter Hydraulics Pvt Ltd, Hyderabad 500 037.Tel: 040-2308 8578, Fax: 040-2308 6532, Mob: 09440800223Email: [email protected], Website: www.shplcylinders.com

FLOORING NAILERS

Kaymo Fastener Company offers flooring nailers (model FNPT-1838M) that weigh 1.8 kgs and have 18-gauge cleat nail type.

The head dimension is 7.31 mm x 1.61 mm, wire gauge at 18 g and leg lengths from 32 mm to 38 mm. Features include: perfect tool for installation of solid hard wood tongue & groove joint; non-marring mallet (1.3 kg) accompanies the tool for operation; tool has easy jam-free operation & can accommodate up to 120 cleat nails; portable tool, which can be taken to sites as no electricity is required at all; large base to increase stability and minimise damage to pre-finished floors; quick loading magazine with spring-loaded pusher; tool recommended for solid wood having 8 mm to 15 mm thickness; tool shoots a cleat nail at 45-degree angle into wood; and cleat nails minimise wood splitting and still allows expansion & contraction of the wood material.

Kaymo Fastener Company, Mumbai 400 011.Tel: 022-2495 2966, Fax: 022-2493 6823Email: [email protected], Website: www.kaymo.com

PIPE PARTING EQUIPMENT

Current methods of cutting pipe into suitable lengths are either of

sawing or grinding with a cutoff wheel. Unipunch Toolings has developed an equipment, that press works parting of the tube/pipe, which is f irst scored and later parted with a blade. Suitable hydraulic actuation and electrical controls makes it ideal for quality cutoff. These equipments are suitable for volume of production. They accept interchangeable die holders for different sizes of tubes and pipes. Scrap due to parting is kept to the minimum.

Unipunch Toolings Pvt Ltd, Chennai 600 058.Tel: 044-2625 2348/3436, Fax: 044-2625 2349Email: [email protected], Website: www.fabmachinesindia.com

AIR TURBO VENTILATORS

Windop air turbo ventilators offered by Powertrac are developed from Korean technology and assure 24-hours,

365 days ventilation at zero operating cost to the industrial and domestic building. These ventilators are also used to exhaust pollutant particles, like smoke, dust, fumes poison gases, humidity, etc, from the building. Features include: top/bottom ring made of SS & blades made from aluminium; self-lubricated Teflon brush, UV-based glassfibre casing;

no maintenance, rust-free, rain proof; f ire-retardant, corrosion-resistance; economic & environment-friendly; easy installation & adaptable to all kinds of people; available in different sizes & shapes; designed to withstand winds in excess speed; powder-coated on aluminium vanes; anti-block design to distribute water while heavy rain; micro-balanced to avoid vibration & run in low wind; and comprehensive 5-years guarantee.

Powertrac, Vapi 396 195.Tel: 0260-2997004, Mob: 09909954612Email: [email protected], Website: www.powertracgroup.com

DOWEL SPRING PINS

R K Engineering Co manufactures and offers dowel spring pins as per DIN-1481 and IS:5988 specifications. These dowel spring

pins are manufactured from high carbon spring steel (EN-42J) having HRC 44-51 and also from SS-304, SS-316 materials. They can be used in place of rivets, nuts, bolts, washers, clevis pins, retaining rings, setscrews and other threaded components. The dowel spring pins are easy-to-

insert due to their flexibility and can absorb shocks & vibrations. They can be removed and reutilised, as there is no interlocking. Non-standard pins are also offered to suit customers’ specific requirements.

R K Engineering Company, Mumbai 400 023.Tel: 022-2267 1141, Fax: 022-2265 5255Email: [email protected]

FUNNEL MAGNETS

Jaykrishna Magnetics manufactures and offers funnel magnets that are widely used in ceramic

industries. These funnel magnets are supplied along with aluminum/stainless steel funnels. The magnetic rod incorporates modern anisotropic permanent magnets. Iron contamination in ceramic body & glaze is in the form of small particles and are removed when it passes through the uniform gap between the funnel & magnet. The funnel magnets are available in standard and special sizes.

Jaykrishna Magnetics Pvt Ltd, Ahmedabad 382 415.Tel: 079-2287 0071, Fax: 079-2287 0070, Mob: 09824048706Email: [email protected], Website: www.jkmagnetics.com


MATERIAL HANDLING

HYDRAULIC DIE-LOADERS

Hertz Controls (India) manufactures and offers technically precise range of hydraulic die-

loaders that are robust in construction and deliver enhanced performance. These die-loaders are used for loading and unloading dies, press tools of varying weight and size. The are manufactured in different models and load capacities varying from 300 kgs to 2000 kgs. The hydraulic die-loaders are offered with revolving and fixed wheels, hydraulic hand pumps or in powerpack operated versions. Height of the hydraulic die-loaders varies from 1000 mm to 3000 mm.

Hertz Controls (India) Pvt Ltd, Ghaziabad 201 002.Tel: 0120-2780531, Fax: 0129-4782682, Mob: 09811225961Email: [email protected], Website: www.hertzfeeders.com

PALLET FLOW CONVEYORS

Conmat Systems offers pallet flow conveyors. Flow storage consists of two elements, ie, a static rack structure and

dynamic flow rails. The flow rails are a track/roller system set at a decline along the length of the rack. Flow rails allow loads to move by gravity from the loading end to the unloading end. Each flow lane includes self-energised speed controllers


(brakes) to gently control the speed of movement within the flow lanes. As a load is removed, the loads behind it move forward to the unloading position. The flow system depth, height and width are limited only by the size of your facility and the capabilities of your material handling equipment. Flow storage solutions are used in situations where storage density and inventory rotation are priorities. The picking and replenishment aisles are separate. Gravity flow conveying system along with transfer trolleys can be provided.

Conmat Systems Pvt Ltd, Vadodara 390 010.Tel: 0265-2647276, Fax: 0265-2630763, Mob: 09898870278Email: [email protected], Website: www.conmatindia.com

VACCINE CARRIERS

Gmemco offers vaccine carriers that are boxes with airtight lid, easy to handle, and strong to face all hurdles during

transportation. These vaccine carriers are used to carry vaccines, maintaining temperature required during transportation. They contain ice packs, which provide constant low temperature for

a longer duration. The airtight lid does not allow air to enter in. Thus, vaccines are safe against all tensions during transit, like virus, breakage, etc.

Gmemco, Delhi 110 051.Tel: 011-2209 0997, Fax: 011-2209 4144, Mob: 09717098703Email: [email protected], Website: www.vaccinecarrier.com

ABRASIVE BLASTING MACHINES

Prism Surface Coatings offers air-powered blasting machines manufactured by Clemco GmbH, Germany, that are used

to clean, deburr, shot peen, remove coatings. Besides the most popular model SCWB-2452 of 200 litres capacity, the other fast moving models available are of 20, 60 and 100 litres capacity.

The 4,500 litres capacity unit, which supports 4 blasters, is widely used for long duration of blasting in ship building industry and on site

structures and large fabrications. The BNP 220 pressure blast cabinets deliver efficient, affordable media blasting to clean, peen, deburr, or finish parts. The larger enclosure (50” x 39” x 43” tall) accepts powered turntables. The BNP 220 suction blast cabinet comes with the unique pilot actuated air logic system to maximise airflow to the blast gun. A 4 double-wall, sound-insulated doors, with industrial quality lift off hinges, all-welded construction, with precisely formed bends, forms a rigid, long-lasting cabinet shell.

Prism Surface Coatings Pvt Ltd, Bengaluru 562 158.Tel: 08810-417999, Fax: 08119-417900, Mob: 09844400285Email: [email protected]: www.prismsurface.com

MATERIAL HANDLING


MATERIAL HANDLING

VARIABLE SPEED POLISHING MACHINES

Power Master double-ended variable speed polishing machines

manufactured by Prem Brothers are designed for working at different speeds to achieve different types of finish using the same or different buffs. Stepless speed variation (500 to 2900 RPM) is available by turning a knob fitted in front of the machine, operating through AC frequency drive panel. A wide range of machines is available (1 HP to 10 HP) to suit different job requirements.

Prem Brothers, New Delhi 110 064.Tel: 011-2811 7456, Fax: 011-2811 7464Email: [email protected], Website: www.powermaster-india.com

ELECTRIC WIRE ROPE HOISTS

Trident Precision International manufactures and offers electric wire rope hoists (type-

E & type-U) that are available in compact designs and are known for their smooth performance. These are compact designed monorail hoist with low headroom dimensions and two direct drive cross travel motors. The cross travel trolley is adjustable to suit various flange widths. These most cost-effective and frequently ordered hoists have a load range from 1 ton


MATERIAL HANDLING

to 12.5 tonnes SWL. Salient features include: two-speed hoisting drive in 6/1 ratio with soft start/stop feature; two-speed cross travel drive in 4/1 ratio with built-in flywheel & soft start/stop feature; extremely low noise levels during operation; all motors are pole changing crane duty motors with class-F insulation; easy service electrical control system; and variable frequency drive available as an option on hoist as well as cross travel drives.

Trident Precision International, Gurgaon Tel: 011-4142 5326, Fax: 011-2592 7181Email: [email protected], Website: www.trident-precision.com

CABLE GLANDS

Sumitron Exports offers non-metallic nylon cable glands (CC-PG11-G series) manufactured by Thomas & Betts Corporation,

USA. These cable glands have a sturdy cable sealing mechanism that results in superior strain relief. The compact size ensures quick and easy installation in cramped spaces. Non-metallic construction provides excellent corrosion, chemical and impact resistance. The cable glands

have long threads along with locknuts also available. Salient features include: halogen-free, flame-retardant UL 94V0, rated IP 68 5 BAR, suitable for NEMA 4 enclosures, UL listed, CSA listed for certain ranges of cable, working temperatures -30ºC (-86ºF) to +80ºC (176ºF), continuous +150ºC (276ºF) intermittent, and meet VDE ratings.

Sumitron Exports Pvt Ltd, New Delhi 110 028.Tel: 011-4141 0631, Fax: 011-4141 0494, Mob: 09810344240Email: [email protected], Website: www.sumitron.com

ELECTRIC WIRE ROPE HOISTS

Venus Engineers offers electric wire rope hoists that conform to IS-3938-1983. These wire rope hoists are specified for medium,

heavy-duty and rugged performance. Their unique modular construction becomes easy for repairing and maintenance purpose.

Absolute reliability is one of the most important features for a wire rope hoist to ensure the highest possible reliability levels in day-to-day operation. The electric wire rope hoists are produced using the most advanced technology available and continue to bear witness to their reliability, safety and durability year after year, from motor to rope, gearbox,

brake, and electrical & electronics systems. A part from quality, versatility is an outstanding feature of the electric wire rope hoists. These units cover an extremely wide load capacity range from 1 ton to 50 tonnes, and the comprehensive standard equipment means that even a standard electric wire rope hoist is a versatile unit right from the start.

Venus Engineers, Delhi 110 041.Tel: 011-2548 3102, Fax: 011-2596 5079Email: [email protected], Website: www.venusengineers.com

PLASMA CUTTING MACHINES

Techno Crafts offers the new flatbed plasma cutting machines (model HF 3015-160i) manufactured by Boschert GmbH &

Co KG, Germany. These plasma cutting machines come with a stable, rigid portal design and are equipped with a sophisticated linear guide system as well as a double axle CNC control system.


MATERIAL HANDLING

Dynamic drives ensure positioning speeds of up to 18 meters/minute, with a guaranteed positioning accuracy of ±0.1 mm. The worktable is 3,000 mm x 1,500 mm (X/Y traveling axes) with a compact overall machine length and width of 4,000 mm x 2,500 mm. Work feeders can be adjusted between 10 and 8,000 mm/min, and therefore can be optimally adapted to the material to be cut and the material thickness. The Kjellberg system HiFocus 160i, which has proven itself time and again in industrial use, is used as the plasma source. Standard equipment includes two plasma torch replacement inserts.

Techno Crafts, Pune 411 004.Tel: 020-2542 5551, Fax: 020-2544 6496, Mob: 09422319755Email: [email protected], Website: www.boschert.de

EOT CRANES

Single girder and underlung EOT cranes offered by Eddycranes Engineers are designed in accordance with IS:807-1976 code

of practice for design manufacture, erection and testing (structural position) of cranes and hoists and IS:3177-1999 code of practice for design of overhead travelling cranes. In the design of components adequate factor of safety as per relevant codes is allowed. Impact fatigue, wear and stress concentration factors is taken into account whenever applicable. Tested quality


MATERIAL HANDLING

steel or equivalent is used in the manufacture of the main load bearing members of the crane structure. Hoist is complete with motor driven trolley/hand geared trolley for cross traverse motion. The long travel motion is achieved through long travel mechanism placed at the centre of the bridge or by means of two motor drive arrangements driving each wheel. The cranes are controlled from floor through pendant pushbutton station hanging from the hoist. They are tested at 25 per cent overload.

Eddycranes Engineers Pvt Ltd, Mumbai 400 034.Tel: 022-2352 1798/2710, Fax: 022-2352 1886Email: [email protected], Website: www.eddycranes.com

ELECTRIC WALKIE TRUCKS

Jowalk electric walkie trucks offered by Jost’s Engineering Company are

available in 1,000 kgs capacity. These walkie trucks are specially designed to reduce operator fatigue as the 1,000 kg load can be moved by merely pressing a switch. As the trucks are battery operated, noise and smoke pollution are totally eliminated. Ideal applications for the electric walkie trucks exist in factories, warehouses, pharmaceutical & chemical industries, textile mills, foundries, docks, ordnance factories, food grain godowns, banks, railway platforms and workshops.

Jost’s Engineering Company Ltd, Mumbai 400 001.Tel: 022-2266 1150, Fax: 022-2266 18951Email: [email protected], Website: www.josts.com

FILTERS

Cole-Parner India offers new filters for auto paints industry. Cole-Parmer India offers CP filters developed by Chisso Filter

Co, Japan. These are true classifying filters, ideal for automotive paints that remove all unwanted contaminants while allowing the

pigments and flakes to pass through, ie, they remove large undesirable particles that contaminate the paint while desired pigments, metallics and micas pass through it.

Moreover, the filters are rigid that will not unload contaminant into the paint, thus maintaining the desired filter pore size regardless of the differential pressure and provide consistent particle removal efficiency. CP filters utilise state-of-the-art f ibre technology combined with innovative process technology. It is supplied in polyolefin-based materials that is compatible with almost all the automotive paints. They exhibit excellent classif ication, rigid structure, depth filtration, are free of media migration and provide long service life. The product grades have nominal ratings from 1 μm through 350 μm and are clearly differentiated by fibre diameter.

Cole-Parmer India, Mumbai 400 022.Tel: 022-6716 2222/2253, Fax: 022-6716 2211, Mob: 09967060106Email: [email protected]: www.coleparmer.in



METALLIC CONVEYOR BELTS

T N F Engineering manufactures and offers metallic conveyor belts that are achieve high standards of engineering and

construction. One can choose from different types of standards. Belt weaves are often used for diverse belt applications across the entire span of industry. When additional strength is required and belt-tracking needs to be controlled, chain-driven belts are best. Flat wire belts are economical strongman of the conveyor belt family. Available in different belt specifications, the metallic conveyor belts are manufactured with various types of belt edges.

T N F Engineering, Navi Mumbai 400 705.Tel: 022-2761 9185, Fax: 022-2767 0780Email: [email protected], Website: www.tnfengg.com

METAL FABRICATION SERVICES

Arfa Impex offers metal fabrication services that have served the requirements of various organisations over the years (claims

the company). The components are fabricated using only the highest grade raw materials, and are cut, shaped and assembled with accuracy and in accordance with all national and international standards. These components find their application across many engineering industries.

Arfa Impex Pvt Ltd, Chennai 600 058.Tel: 044-2624 5578, Mob: 09884454332Email: [email protected]

ENGINEERING PLASTIC RAW MATERIALS

Nagpal Enterprises offers superior quality engineering

plastic raw materials that find various applications in automobile industries and other purposes. These plastic raw materials are manufactured while keeping in mind various laid quality standards that provides strength to the products. These are further tested to check their quality and strength so that they result in the manufacturing of the most superior quality products for clients.

Nagpal Enterprises, Delhi 110 039.Tel: 09811951977, Mob: 09810079099

MS STRUCTURAL STEELS

Vybrant Trading Company offers a wide range of MS structural steels that are supplied as per the Indian standards with

specific shapes, correct chemical composition and tensile strength. These durable and highly functional MS structural steels are ideally used for industrial fabrications & steel construction work. Structural steel sections are mainly hot rolled products, with a cross section of special form like: angles (equal & unequal), channels,

and beams/joints (I-beam, H-beam & narrow parallel beams). Applications are in construction of buildings, bridges, transmission line towers (TLT), industrial sheds & structures, ships, etc.

Vybrant Trading Company, Mumbai 400 001.Tel: 022-2265 0786, Fax: 022-2265 0786, Mob: 09869127864Email: [email protected], Website: www.vybranttrading.com

POLYURETHANE COMPONENTS

Nand Composites offers polyurethane components

that are manufactured by injection moulding process. These components are used for various engineering, wheels and casters applications. They come with hardness ranging from 60

shore A to 75 shore D.

Nand Composites Pvt Ltd, Pune 411 001.Tel: 022-2712 0382, Mob: 09822016337Email: [email protected] , Website: www.nandcomposites.com

POLYETHYLENE FOAM

Shri Ekvira Manufacturers & Coats offers polyethylene foam that is a strong closed cell foam, used for shock absorption, loose fill

and vibration dampening. It is most commonly used in cushioning the products during packing. Polyethylene is a shatterproof, lightweight, f lexible foam and is resistant to mould, rot, mildew and bacteria. This product finds application in industries including fishery, building & civil construction, sports insulation, and in the packing of electronic

goods and fruits. Customisation is also offered as per customers’ requirements.

Shri Ekvira Manufacturers & Coats Pvt Ltd, Nashik 422 010.Tel: 0253-6521272, Fax: 0253-6601173, Mob: 09822548442Email: [email protected]

ENGINEERING PLASTICS

Bhilwara Polymers manufactures and offers ultra high molecular weight high-density polyethelene UHMW-PE new generation

engineering plastics, which is prepared with the help of Ziegler catalysts. These UHMW-PE products are manufactured by

compression mould method with heavy presses under the guidance of highly technically qualif ied personnel. Thus a highly homogeneous and non-welded single block material in size 3350 mm

long x 515 mm wide x 10 to 130 mm thick is offered. Any machine part, linear and any other components as per drawings are offered from full-f ledged workshop having technicians. The UHMW-PE products have a molecular weight range in excess five million, which are approximately ten times higher, that of molecular weight HDPE. Applications are in dewatering element for paper industries, dewatering element for cement asbestos pipe & sheets, food industry, pharmaceutical industry, machine construction,



electroplating, textile industry, coal industry & mining, electrical industry, refrigeration, etc.

Bhilwara Polymers, Bhilwara 311 001.Tel: 01482-227693, Fax: 01482-239634, Mob: 09829047693Email: [email protected], Website: www.bhilwarapolymers.com

POLYMER PRODUCTS

Periyar Polymers has topnotch infrastructure and meets every norms prescribed by the ISO:9000 system standard to

maintain quality in the production of polymer products. From choosing raw materials to packaging finished products, every stage of production process is carried out under the strict surveillance of various departments headed by dedicated professionals of relevant spheres. To maintain the international standard on product quality and to deliver the best to the customers always, a number of quality checks are implemented by the Quality Assurance Cell on each and every piece of polymer product come out bearing the celebrated hallmark of Periyar Premium.

Periyar Polymers, Dist Ernakulam 683 550.Tel: 0484-2461317Email: [email protected],Website: www.periyarpremium.com




Metalon engineering plastics from Quadrant EPP Surlon are available in various materials, such as Metalon 6SA, Metalon

6PLA, Metalon GSM, Metalon oilon gold, Metalon MC-901, etc. Metalon 6SA an extruded nylon grade offers optimal combination of mechanical strength, stiffness, toughness, mechanical damping properties and wear resistance. Metalon 6 PLA is most widely used cast nylon in industry, especially as bearing material. Metalon GSM is cast, partially cross-linked, nylon 6 material with additives, which gives excellent resistance, self-lubrication and low friction characteristics. Metalon oilon gold is specially developed to extend the wear-resistance properties of unduplicated or dry lubricated materials. Metalon MC-901 is tough, heat stabilised cast nylon 6, which is easily distinguished from the other cast nylon products. Applications are in sheaves, wear pads, outrigger pads, gears, locomotive parts; and a host of other tough applications, where wear, noise & lubrication are problems.

Quadrant EPP Surlon India Ltd, New Delhi 110 092.Tel: 011-2216 4542, Fax: 011-2216 3541Email: [email protected], Website: www.quadrantplastics.com

ADVANCED FIBRE SYSTEMS

DuPont Kevlar is an advanced technology that helps transform the ordinary to the extraordinary. It combines high strength

(5 times stronger than steel) with lightweight, and comfort with protection. Products made with Kevlar brand fibre help those

who use them to do more, to go farther, to be even better at what they do. Whether it is working in a plant, or handling sharp edge materials, at construction site or in a forest. Whether it’s reinforcing optical f ibre, saving the precious life of nation guarding personnel, efficient way of conveying materials, or winning world hockey cup. Whether it’s protection from the hazards they face on the job every day, or the comfort and lightweight strength they rely on to help them achieve their personal best.

E I DuPont India Pvt Ltd, Chennai 600 014.Tel: 044-2847 2800, Fax: 044-2847 3800, Mob: 09841002509Email: [email protected], Website: www.in.dupont.com


Classic Polymers offers ultra high molecular weight polyethylene (UHMW-PE) U Gd worldclass engineering plastics. These

are lightweight, non-hygroscopic materials having good thermal and insulating properties. The materials have excellent wear, abrasion and corrosion-resistant properties. They are superb lining materials offering low friction, chemical resistance, high stress crack resistance, non-stick surface and are recommended for working temperatures up to 82°C. Typical product applications are in: sprockets, star wheels, liners, conveyor rollers, idlers, feed screws, wiper blades, bottling plant conveyor profiles. These materials are manufactured in the form of rounds from ½inch to 4-inch diameter in meter lengths and blocks ranging from 10 mm to 150 mm thickness, profiles and custom components.

Classic Polymers & Resins, Mumbai 400 016.Tel: 022-2446 0090, Fax: 022-2445 4371Email: [email protected], Website: www.classicpolymers.com



SOFT BLOW HAMMERS

Endeavour Engineering offers soft blow hammers that are

most advanced type of hammers fabricated with polyurethane heads, designed and engineered for silent and maintenance-free long lasting service. The pipe and body is f irmly dowelled rather than welded, for more safety. Special property of PU used at the heads that attribute to its sturdiness and wear resistance when compared to conventional mallets available in the market, are high elasticity, irrespective of hardness, f lexibility at wide range of temperature ranging from -40°C to +110°C, good resistance to all adverse weather conditions, even at high energy radiation, good resistance to oil, grease and many more chemicals and solvents as also to rotting, extreme high wear resistance and impact strength, available in two sizes 35 mm E and 50 mm E.

Endeavour Engineering, Ahmedabad 380 022.Tel: 079-6512 3263, Fax: 079-2546 7633Email: [email protected]: www.endeavourengineering.com


Kumbhojkar Plastics offers engineering plastic products, like cable carrier assemblies, plastic flexible coolant pipes, plastic

& bakelite knobs, bakelite handles & wheels, signal stickers, safety signs, barrier tapes, computer clips & cable carriers for



round curve. The cable carrier assemblies are 100 per cent safe innovative cable trailing systems (claims the company). These avoid leakage of electric current and facilitate free and easy movement. Drag chains are available in various sizes useful for electric cable hoses. The signal/sign stickers are printed on PVC in the size of 185 mm x 250 mm. Pendent control station can accommodate cables ranging from 8 mm to 26 mm diameter. The selector switches are of standard companies. Oil hand pump is a chemical-resistant pump and can be used for oil, kerosene, acids, alkalies and water. Plastic f ilters are strainer buttons, valves useful for chemical industries, water softening plants and filtration.

Kumbhojkar Plastics, Pune 411 030.Tel: 020-2445 0055/60, Fax: 020-2448 0544Email: [email protected], Website: www.plamoulds.com

CONVEYOR & PROCESS BELTS

A G Engineers manufactures and offers conveyor and process belts that are manufactured by using specially developed fabrics, with

covers made of PVC, PU, PE, polyester or silicone rubber. The standard range comprises of more than 80 belt types and a large number of accessories. These products meet latest industry standards and requirements. Latest developments in industry are monitored closely. New

and improved products are constantly added to the product range.

A G Engineers, Ghaziabad 201 009.Tel: 0120-415 9660-62, Fax: 0120-415 1360/9662Email: [email protected], Website: www.agengineers.net



HELICAL GEARBOXES

Reva Industries offers high efficiency parallel helical gearboxes constructed for design excellence. These gearboxes are based

on modular concept with centre distances, ratios, and dimensions corresponding to R10, R20 and R40 series. Hardened and profile ground gears for all stages running noiseless in vibration-free graded cast iron housings duly stress relieved and machined on precision machines with weight/power optimised due to use of case-hardened steels of high strength. Computer-aided design based on Buckingham method resulting in compact and robust gearboxes with factory of safety > 1.5 both in wear and strength for gears and pinions. Integral pinion shafts supported between bearings to make these resist torsional and bending stress, taking advantage of recent advances in the gear technology. Reduction ratios follow R-20 series from 1.6 to 6.3 in single stage, 6.3 to 22.4 in two stages, 22.4 to 112 in three stages and 112 to 625 in four stages.

Reva Industries Ltd, Faridabad 121 009.Tel: 0129-406 9967/68, Fax: 0129-406 9969Email: [email protected], Website: www.reva.com

FASTENERS

Kundan Industries offers high tensile 8.8/10.9 class fasteners in austenitic stainless steel grade by cold forging process without

heat treatment. A wide range of products like bolts, screws,



studs, nuts, washers, etc, are manufactured. Hex bolts are made with in-built flange. Having integral making facility of bolt with washer, integral fastener aids in faster production at assembly line of automobile. The integral fasteners

reduce labour cost, making production fast and also have technical advantages. The major production of fasteners is in stainless steel and remaining 10 per cent in carbon steel including non-ferrous. Grades are austenitic 304 & 316, martensitic, B8, B8M, etc. Size range includes: 1.6 mm to 42 mm dia; and 4.0 mm to 200 mm length. Standards followed are IS, ANSI, BS, DIN, JIS, ASTM, etc.

Kundan Industries Ltd, Mumbai 400 066.Tel: 022-6152 1234, Fax: 022-6152 1359Email: [email protected], Website: www.kundan.com

COMPOSITE ENGINEERING MATERIALS

Permali Wallace offers composite engineering materials. These engineering materials find application in almost every industry.

Some of the industries that are served include: electrical, defence, railways, automobile, foundries, forgings, textile machineries, telecommunications, chemical, petroleum, construction, automotive energy, etc.

Permali Wallace Pvt Ltd, Bhopal 462 011.Tel: 0755-2550085, Fax: 0755-2550504, Mob: 09826050516Email: [email protected], Website: www.permaliwallace.com



GEARBOXES

Elecon Engineering manufactures and offers gearboxes with pinion stand for the drive of wire rod mills. The set of these

gearboxes consist of total 14 nos, 7 horizontal and 7 vertical, having higher ratio in the beginning and tapering into lower ratio at the tail end. The size varies from SCF 710/480 at the bigger end to KAF 315/285 at the small end. All the gear internals are out of case carburising steel duly carbusised and hardened and precisely ground with profile corrections on all pinions and longitudinal corrections depending on the load, so as to keep the noise level as low as up to 80 db. Forging ratios for the gear internals are specially monitored as well special care is taken in the sealing arrangement. All the bearings as well almost all gear meshing are spray lubricated, which get adequate supply of lubricating oil from the common force lubrication system.

Elecon Engineering Company Ltd, Vallabh Vidyanagar 388 120.Tel: 02692-236513, Fax: 02692-236527Email: [email protected]: www.elecon.com


NEW LAUNCHES

GAS & FIRE DETECTION CONTROL PANELS

Detection Instruments (India) offers Crowcon’s highly successful Vortex range of multi-channel gas and fire detection control

panels that has been extended to include an ATEX certif ied extended flameproof version (the Vortex FP), which can be used in Zone-1 and Zone-2 hazardous areas. Capable of monitoring up to 12 gas detectors, the Vortex FP is also compatible with smoke/heat and flame detectors and up to three of its input channels can be used for fire detection. Each channel has one fault and three alarm levels, which can be combined to trigger up to 32 output relays, allowing connection to a range of external alarms and safety devices. Intrinsically safe safety barriers can also be incorporated for use with IS gas or fire detectors. Sealed to IP65, the Vortex FP features simple push button operation and visual status indicators for each channel, ensuring that the system can be checked at a glance.

Detection Instruments (India) Pvt Ltd, Navi Mumbai 400 710.Tel: 022-2761 7663, Fax: 022-2761 2103Email: [email protected], Website: www.detection-india.com

MEMBRANE DRYERS

Besides filtration, compressed air drying contributes considerably to an increase in the process reliability. Humidity

in compressed air systems causes corrosion and promotes the growth of microorganisms. In individual cases, condensate may even emerge at the point of withdrawal. Pneumatic controls may break down where humidity is introduced, wear & tear of tools is enhanced or disturbances occur in the production process. Thus, the industrial process is consistently at risk where users employ compressed air. Therefore, efficient drying of compressed air is of essential importance. This applies in particular for the drying directly at the compressed air consumer. There, drying orientates not only on the application itself but also on the ambient conditions, for eg, on trains & ships, in open manufacturing shops or outdoors. For these cases AVS offers the new generation of Drypoint M membrane dryers as a solution, by means of which almost any degree of drying may be achieved.

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

FUNCTION GENERATORS

Kusam-Meco has introduced new function generators (model KM-2002) that have 5-digit LED frequency display, 3-digit

LED amplitude display synchronously. These are accurate testing instruments that have different output function wave: sine wave, square wave, rectangle wave, saw tooth wave and triangle wave. Sine wave distortion is <2 per cent, triangle wave linearity is >99 per cent and square wave rise edge times/fall edge times is <100 ns. The frequency, amplitude and duty cycle can be adjusted continuously. Frequency range is 0.2-2 MHz. Signal frequency stability is <0.1 per cent/minute. Amplitude is (2 Vp-p~20 Vp-p) ±20 per cent. Attenuation is 20 dB/40 dB. Output signal impedance is 50 ohms. Duty cycle is 20~80 per cent (±10 per

cent). Measurement error is <0.5 per cent. The instruments operate on 220 V / 110 V ±10 per cent, 50 Hz/60 Hz ±5 per cent, power <15 W. Dimensions are 270 mm (W) x 215 mm (L) x 100 mm (H). Weight is 1.6 kgs approximately.

Kusam Electrical Industries Ltd, Mumbai 400 015.Tel: 022-2412 4540, Fax: 022-2414 9659, Mob: 09867000456Email: [email protected], Website: www.kusamelectrical.com

RETRO-REFLECTOMETERS

Mangal Instrumentation has introduced compact, highly sensitive retro-reflectometers to test retro-reflective

performance of retro-reflective sheeting/retro-reflective material, etc. These retro-reflectometers are designed to measure retro-reflection of sheeting material for quality control and engineering purpose in the material and testing laboratory. They can test one-inch measurement area with measuring range of 0-1999.9 and show the reading in 4½ LED digital display. The retro-reflectometers consist of optical head containing precision optics, light

source, filter, sensor, etc, along with standards of different colour.

Mangal Instrumentation, New Delhi 110 065.Tel: 011-6584 5192, Fax: 011-2984 1033, Mob: 09811117940Email: [email protected]: www.mangalinstrumentation.com

PROGRAMMABLE POWER SUPPLIES

K B Electronics have developed programmable power supplies, which can be remote controlled using serial port. These SMPS

units accept 0-10 V signal or 4-20 mA signal to control the output voltage or current as per requirements. The power supplies are designed using latest state-of-the-art current mode pulse width modulation controller. Output is protected for overload, overvoltage and short-circuit. Power factor correction is available as an option. Other products are DC-DC converters and SMPS based battery chargers for telecom and material handling application.

K B Electronics, Mumbai 400 025.Tel: 022-6452 6057, Fax: 022-2436 4668Email: [email protected], Website: www.kbelectronics.co.in

GEAR FLOW METERS

VSE gear flow meters offered by BEDA Flow Systems are volume rate measuring sensors, based on mesh gear principle. These

are designed for use with any liquid that can be pumped, and have known lubricant properties, for eg, petrol, paraffin, kerosene, diesel, skydrol ( jet-fuel), mineral oils, hydraulic oils (including fire resistant fluids), inks, dyes, paints, greases, polyurethane, polyol &

isocyanates, aroldite, glues, pastes & creams, resins, waxes, etc. Two precisely matched gear wheels are enclosed in a very accurately machined housing. Gear rotation is sensed by a non-contacting signal pick- up system. The space between the gear teeth (when fully enclosed on both sides by the housing) constitutes measuring


NEW LAUNCHES

chambers. Fluid flow causes the gears to rotate and the incoming flow is separated into discreet volumes with in these chambers. Applications are in automotive industries, hydraulics, dyes & paints, plastic technology, chemical industries, etc.

BEDA Flow Systems Pvt Ltd, Noida 201 301.Tel: 0120-4329990, Fax: 0120-4080022, Mob: 09212289411Email: [email protected], Website: www.bedaflow.com

VIBRATORY BOWL FEEDERS

Elscint Automation has recently manufactured bowl feeders for feeding of steel tubes of various sizes. There were a total of

6 tubes. In case of some the diameter was more than the length while in some cases the diameter was less than the length (length being more). The orientation required was standing for one machine while for another it was rolling. A linear vibratory track was provided in case of the standing orientation while in case of rolling, gravity chute was provided. These bowl feeders are supplied along with stands, level controls as well as auto-switch off mechanisms wherein once the chute or the linear track is full, the vibrator is switched off. The vibratory bowl feeder (model 400) comes with a cast aluminum bowl. The bowls are coated with Elscinthane PU coatings and the tooling is manufactured in stainless steel.

Elscint Automation, Pune 411 026.Tel: 020-2712 2059, Fax: 020-2712 2994Email: [email protected]; Website: www.elscintautomation.com


NEW LAUNCHES

LOW DROPOUT REGULATORS

Texas Instruments Inc, USA has introduced the industry’s first -36 V low dropout regulators (LDOs). Model TPS7A30 is

paired with the positive voltage, while model TPS7A49 provides designers with a total solution for powering precision analogue applications. These devices feature ultra-high power supply rejection ratio performance and as low as 16 uVrms of output

noise. Model TPS7A30 generates 200 mA, while model TPS7A49 manages 150 mA. Power for precision analogue LDOs help meet that requirement with wide input voltages, lowest noise and maximum amount of transient headroom. The TPS7A30/TPS7A49 linear regulator family is stable with any output capacitance greater than 2.2 uF. The LDOs come in an adjustable version with an output voltage ranging from 1.22 V to 34 V. They are designed for noise-sensitive applications, such as test equipment; industrial, networking and telecom equipment; base stations; microwave and radio links; noise filtering for receive, transmit and power amplif iers; and medical applications.

Texas Instruments India Pvt Ltd, Bengaluru 560 093.Tel: 080-4138 1665, Fax: 080-2504 8308Email: [email protected], Website: www.ti.com

TRANSMITTERS

Siemens has introduced a new family of WirelessHart products for wireless communication, including two new transmitters,

the Sitrans P280 and the Sitrans TF280. The Sitrans P280 transmitter for pressure measurement and the Sitrans TF280 transmitter for temperature have a WirelessHart interface as well as a graphical display with backlight functions and are easy to operate via push buttons. An integrated battery supplies the transmitters with power for up to five years, with a display that shows the exact number of remaining days. Additionally, all other Siemens process instruments without WirelessHart interfaces can be integrated into WirelessHart communication with

the new Sitrans AW200 adapter. The Sitrans AW200 adapter has an integrated battery, which can also power a connected process instrument. If an external power supply is used, up to four conventional process instruments can be connected to the WirelessHart adapter simultaneously.

Siemens Ltd, Dist Thane 400 601.Tel: 022 2764 5791Email: [email protected]: www.siemens.com

SIGNAL ISOLATION TRANSDUCERS

Meco-G has introduced the highly reliable, low-cost, accurate DC signal isolation transducers that convert a DC signal like

mV, mA, V, A into standard DC signals, like 4-20 mA, 0-10 V DC, etc, with optical isolation. The output is linearly proportional to the measured input signal. These transducers have 0.5 per cent accuracy class as standard. The signal isolation transducers are available in flame-retardant case and operate on 110 V AC, 230 V AC, 24 V DC, 48 V DC, 110 V DC, 220 V DC auxillary supplies. They are suitable for


NEW LAUNCHES

telemetering, dataloggers, PLCs, SCADA systems and control applications.

Goliya Instruments Pvt Ltd, Mumbai 400 015.Tel: 022-2414 9657, Fax: 022-2413 0747Email: [email protected], Website: www.goliyainstruments.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


GENERAL PRODUCTS

COOLANT FILTERS

S & C Invotek manufactures and offers coolant filters with magnets that are

designed for filtering metal working coolants and fluids. These coolant filters are available with/without magnets. The magnets hold heavy metal chips to avoid damage to the filter bags. Also offered are simplex filter housings, duplex filter housings, multi-baskets & bag units, dual capacity units, carbon adsorption units, all-polypropylene bags, beta bags, surface filter bags, cotton-wound cartridge elements, membrane cartridges, stainless steel f ilter elements, etc.

S & C Invotek, Bengaluru 560 070.Tel: 080-2672 1569, Fax: 080-2679 3748, Mob: 09844035677Email: [email protected], Website: www.invotekfilters.com

WIRE DRAWING & FORGING OILS

Mahathol Drala 66 from Mahatha Petroleum is a thick viscous dark-coloured mineral oil incorporated with special additives

to withstand high temperatures encountered in the deep drawing and die forging operations. These oils have excellent oxidation stability and die cooling effect. They also have extreme pressure additives and anti-wear additives for their effective performance. The wire drawing and forging oils are recommended for deep drawing and forging operations steel, ferrous, nickel metals, tubes and their alloys. They can be applied by spray. This enhances the die life and ensures sticky-free operations in reduction or final polish.

Mahatha Petroleum Pvt Ltd, Chennai 600 117.Tel: 044-2247 1542, Fax: 044-2247 3800, Mob: 09444065754Email: [email protected]: www.mahathapetroleum.com

COMMUNICATION MODULES

Hilscher offers communication modules CA-type CANopen-Master that are a simple and economical solution for

implementation of fieldbus interfaces. As a compact plug-in board it contains the entire CANopen including the potential-free driver interface. The data exchange with the Host systems is carried out via an easy to handle interface, which has a dual-port memory that is the same on all models. Here, the process variables are carried in a process image, whilst commands are transferred over a mailbox. The module accepts the data and carries out the data exchange via the CANopen network, independently without any load on the Host system. The configuration can be carried out with the aid of the SyCon System Configurator, eg, via the RS232C diagnostic interface. Some of the facts include: compact & economical CANopen interface; direct connection to the CANopen network; direct access to the process data in the Dual-Port-Memory; identical easy-to-use application interface to all COM modules; and interchangeable with COM modules of other fieldbuses.

Hilscher India Pvt Ltd, New Delhi 110 001.Tel: 011-4051 5640/41, Fax: 011-4051 5642Email: [email protected]: www.hilscher.com

AUTOMATION SOLUTIONS

RightVision (India) offers automation solutions from Lasco for forming tasks, such as a fully automatic hammer forging unit,

in which two forging robots replace the blacksmith. This had been regarded as infeasible for a long time because of the complex tasks the operator has to accomplish when forging in the closed die. Taking this into account Lasco developed special gripping tools adapted to the dynamic processes when holding the work pieces as well as software to enable the forging robots to fulf ill their tasks precisely and reliably. The complex developments have been protected by a series of patent specifications.

The experience of almost twenty users worldwide show that the advantages surpass the mere rationalisation effect by far. Exact reproducibility of all processes and their sequence create stable conditions, which bring about a clear increase in quality and a decrease in the reject rate.

Rightvision (India) Pvt Ltd, Noida 201 303.Tel: 0120-4261026, Fax: 0120-4261026, Mob: 09810526627Email: [email protected], Website: www.rightvision.biz

PRODUCTION LINE MONITORING SYSTEMS

In a manufacturing industry, investment on the machinery is significant. Production operations by workers/machinery

are carried out based on scientif ic management. At any cost production shouldn’t be affected by lack of timely supply of components or breakdown of machinery or non-availability of required tools. Process Care Systems offers production line monitoring systems (PLMS) to communicate production parameters to a centralised system, to record those parameters and to use them for generating reports facilitating

better management. In these systems machines are networked by connecting each machine to a PMI (data logger). The PC receives the data from the PMI and stores them. The PLM systems are complete solution for maintaining the quality of product and effective utilisation of machine time. They provide accurate and timely information on the real causes of downtime to enable increased output. The systems also free supervisory personnel to do more value added work and production target information displayed on every PMI unit keeps operator busy.

Process Care Systems (India) Pvt Ltd, Bengaluru 560 058.Tel: 080-4352 1111, Fax: 080-4352 1140, Mob: 09731900027Email: [email protected], Website: www.datacareindia.com

INVESTMENT CASTINGS

Hi-Tech Investment Casting manufactures and offers investment castings. They can handle castings in carbon steel, low alloy

steel, stainless steel, duplex steel, aluminum alloys, copper alloys, etc. Cobalt and nickel alloys are manufactured from few grams to 60 kg per piece in weight up to a dimension of 650 mm. The company has captive


GENERAL PRODUCTS

tool room, captive CNC machine shop, captive heat treatment facilities and technical back-up capable of designing wax moulds and machining jigs/fixtures. The back-up services include in-house rapid prototyping facility and designing of parts using FEM analysis. The company is a one-stop shop for all value-added requirements on castings, like machining, zinc plating, polishing, surface coating, electro-polishing, painting as well as assembling of castings using other processes like bar turned parts and sheet metal parts.

Hi-Tech Investment Casting Ltd, Dist. Bhavnagar 364 240.Tel: 02846-222427, Fax: 02846-222971Mob: 09426598378Email: [email protected], Website: www.hitecind.com

INVESTMENT CASTINGS

Amtech Investment Casting manufactures and offers investment castings. All kinds of in-house

testing facilities, like ARL spectrometers (Fe, Co & Ni Base), universal testing machines, impact testing machines and hardness testers, etc, are provided. Pump casting metals, such as SS-304, SS-304L, SS-316, SS-316L, carbon steel, hastalloys, carbon alloys, etc, are manufactured. The product range includes: investment castings, aluminium investment castings, prototype investment castings, alloys investment casting, wax investment casting, etc.

Amtech Investment Casting Pvt Ltd, Rajkot 360 002.Telefax: 0281-2782244, Mob: 09879817994Email: [email protected], Website: www.amtechcast.com


GENERAL PRODUCTS

FORGED COMPONENTS

Silver Forge manufactures and offers quality-forged products for manufacturers of auto components, diesel engines,

compressors and other OEMs. They have complete in-house facilities for production, testing and supply of all types of forgings from prototype development to machined finished c o m p o n e n t s . R a w materials are sourced from approved steel plants such as RINL,

ISSAL, MUSCO, and TISCO, etc. All incoming raw materials are checked thoroughly in the chemical lab, by qualif ied metallurgists. Various types of forging components, like connecting rods, crankshafts, camshafts, gears, gear blanks, pinions, crown wheel, gear shifter forks, torque converter covers, universal joint components, bucket tooth, etc and many more intricate components with fully CNC Machined and finished parts are manufactured.

Silver Forge Pvt Ltd, Metoda 360 021.Tel: 02827-28799, Fax: 02827-287996, Mob: 09426254299Email: [email protected], Website: www.silverforgeindia.com

STEEL FIREPROOF DOORS

Sehgal & Sehgal Industries offers steel f ireproof doors. They manufacture a customised range of high tensile premium

quality stainless steel doors that are extensively used in various industries for multifarious applications. Available in varied finishes, like etched, patterned, bead blasted, embossed, colored, etc, these stainless steel doors are anti-corrosive and heat-resistant. Types of stainless steel doors manufactured are: bullet resistant doors, blast resistant doors and thermal protection doors. The range of products include: fireproof metal door frames, stainless steel doors, special purpose doors, pressed

steel doors, f ire resistant doors, etc.

Sehgal & Sehgal Industries, New Delhi 110 064.Tel: 011-2811 4613, Fax: 011-2811 7907, Mob: 09891139441Email: [email protected], Website: www.firedoorsehgal.com

MIG WELDING MACHINES

Global Medi Weld manufactures and offers CO2/MIG welding machines. Gas metal arc welding (maw) is frequently referred

to, as MIG welding. MIG welding is a commonly used high deposition rate welding process in which wire is continuously fed from a spool. MIG welding is therefore referred to as a semi-automatic welding process. Some of the benefits are: higher deposition than SMAW, less operator skill required, long welds can be made without starts/stops, minimal post welds cleaning is required, all position capability, etc. Features include: weld mild steel, aluminum & stainless steel wires and bronze alloys wires; suitable for

solid wires as well as flux cored wires; easy connection system


GENERAL PRODUCTS

for torch plug-in to wire feeder; coarse/fine controls for proper selection of voltage; and sleek & most flexible torch.

Global Medi Weld, Hooghly 712 235.Tel: 033-6453 9830, Fax: 033-6453 9830, Mob: 09230507639Email: [email protected], Website: www.globalmediweld.com

HANDHELD MOBILE COMPUTERS

Exim International Trade Consultants offers handheld mobile computers (model MC-3000) with brick configuration. These

advanced mobile computers are small, lightweight & rugged, and are designed for applications & environments requiring high-quality data capture and high-performance real-time computing. They can be customised to the specific demands of individual jobs, allowing employees to complete their work faster and with better results. The well-balanced brick form factor is ideal for scan-intensive environments, offering the best in comfort for workers throughout an entire shift. The handheld mobile computers excel at bar code scanning and wireless mobile computing within retail stores, warehouses, on loading docks, postal routes or any location demanding application performance and ruggedness.

Exim International Trade Consultants, New Delhi 110 030.Tel: 011-2664 6430, Fax: 011-2664 6430, Mob: 09899867897Email: [email protected], Website: www.eitc.in


GENERAL PRODUCTS

ETHERNET SWITCHES

Dax Networks offers the DX-526 series industrial-grade Ethernet switches which enable rapid network

recovery. These Ethernet switches are targeted at automation, transportation, semiconductor and heavy industrial factories.

They feature Dax’s new range of networking access and connectivity products, introduced to enhance the company’s networking infrastructure solutions portfolio. The Ethernet switches are designed to meet critical network environment standards with IP30 enclosure and have been tested under extensive industrial EMI and safety standards. They support X-ring and a fast network recovery with a reaction time of under 10 milli seconds over 250 switches. Network recovery protection between X-ring groups is ensured by dual and couple ring technology. Dual homing is present

as a backup to the X-ring groups when connecting to upper layer or core switches. The Ethernet switches’ relay-contact-to-alarm system immediately notif ies users of power and/or port failures by instantly sending an email to pre-defined addresses.

Dax Networks Ltd, Chennai 600 020.Tel: 044-4292 3558, Fax: 044-4292 3567Email: [email protected], Website: www.daxnetworks.com

ETX CPU MODULES

Advantech offers its most cost-effective ETX CPU module (SOM-4463) with Intel Atom single/dual core processors.

Supporting the latest Intel Atom N450/D510 single and dual core processors with ICH8M chipset, the SOM-4463 offers low power

consumption and is the first Intel Atom based dual-core D510 solution (claims the company). In a basic form factor of 114 mm x 95 mm, SOM-4463 fits the embedded ETX 3.0 standard. It has two SATA interface and an upgraded Intel Gen 3.5 DX9 graphic engine supporting MPEG2 hardware decoding, and dual

independent LVDS/VGA display output. With its advanced display features and I/O extensions, the SOM-4463 presents developers with a superb cost/performance CPU module with all the benefits of low power consumption. Powered by the new Intel Atom D510/N450 processors and ICH8M chipset, SOM-4463’s economic performance will appeal to system integrators looking for the best value for money.

Advantech India, Bengaluru 560 055.Tel: 080-2337 4567, Fax: 080-2337 5898Email: [email protected], Website: www.advantech.in

DC WELDING RECTIFIERS

Fricon Systems manufactures and offers DC welding rectif iers that are basically meant for converting alternating current to

direct current. Generally, all applications require DC supply for operation, but since the main supplies are AC, hence, rectif iers find their use in this area, as they effectively derive DC current from AC supplies. Another usage of the power rectif iers comes when the need to convert DC current to DC current arises. The company’s rectif iers can also be used for efficiently detecting the amplitude-

modulated signals.


GENERAL PRODUCTS

Fricon Systems, Faridabad 121 004.Tel: 0129-3256052, Fax: 0129-4154159, Mob: 09811906899Email: [email protected], Website: www.friconsystems.com

RETRACTABLE GATES

Hongmen gates offered by Gandhi Automation stand out among others because they blend perfectly with their

surroundings. They not only complement the building installed with the gates, but are a piece of eye-catching architectural work with high functionality and aesthetic value. These gates are made from high strength alloy aluminium and mounted with sparkling silver, stainless steel plastic plates. They are equipped with anti-crash intelligent infrared double detectors. Patented electronic soft starter and mechanical buffer device ensures smooth run. Patented wind-resistant device enable the electric gate to operate in strong winds. Horizontal4-direction even pull straight-line technology with absolute trackless operation and reliable performance. Each hole of the retractable piece is mounted with a wear-resistant PA push to eliminate any irritating noise during operation. Composite self-locking wear-resistant connection technology revolutionises the traditional perforated twist joint structure, making it stronger and more durable. Concealed wiring gives the gate a neater appearance.

Gandhi Automations Pvt Ltd, Mumbai 400 064.Tel: 022-6672 0200, Fax: 022-6672 0201Email: [email protected], Website: www.geapl.co.in


GENERAL PRODUCTS

ROUTERS

Nippon Electrical Industries offers contemporary routers (model

TR-12R) that are available in 12 mm (1/2”) designed for woodworking jobs centered on grooving and chamfering of powerful 1300 W. These routers have specially designed motor and high RPM for smooth cutting. They also feature easily selectable three-stage of cutting depths, with all ball bearing construction for long tool life and aluminium die-cast base for heavy-duty shopwork. The routers are meant for optimum use and have been exactly similar to other international brands with all the spare parts interchangeable.

Nippon Electrical Industries, Ahmedabad 382 330.Tel: 079-2282 2750, Fax: 079-2280 0119Email: [email protected]: www.nipponpowertools.com

MINI VACUUM BLASTERS

Close-circuit mini vacuum blasters (model KUV-14P) manufactured by Kushal

Udhyog perform blast cleaning operation with on-the-spot instant recovery of blasted media and dust. The operation is safe and dust-free with no risk of f lying abrasives and dust in surrounding. The abrasive blasting and abrasive recovery in these systems is simultaneous. Spent abrasive is confined in small vicinity on the job itself and the same is pneumatically sucked and fed to abrasive storage for re-cycling. The mini vacuum blasters are lightweight machines weighing only 3.7 kgs; and can hold abrasives up to 1.7 kgs of metallic grit. These require 40 to 60 CFM at 90 PSI. Fine abrasives like aluminium oxide, plastic grit or agro-based abrasives is mostly used. Salient features are lightweight, nozzle can be positioned overhead/downhead or sideways, do not require setting time, no electric connection, need only compressed air, wide pattern, etc.

Kushal Udhyog, Jodhpur 342 005.Tel: 0291-2720072, Fax: 0291-2724400, Mob: 09414301701Email: [email protected], Website: www.kushaludhyog.com

SURFACE GRINDING MACHINES

Pinnacle Engineering Enterprise offers horizontal surface grinding machines with manual table drive. These surface grinding

machines are available in model GSM-4520 with table size 450 mm x 200 mm, model GSM-4525 with table size 450 mm x 250 mm and model GSM 6030 with table size 600 mm x 300 mm. They are designed with new concept having linear guideways for easy table movement with wire rope drive to avoid pitch marks usually observed in rack and pinion drive (charter) on the job ground. Also offered are surface grinding machines in full range, named as Sumo series, viz, GSH-50 Sumo,


GENERAL PRODUCTS

GSH-75 Sumo, GSH 5025, GSH 6030, GSH-100, GSH-8, GSH-8 Jumbo, GSH 15050, GSH 15060, etc. These are hydraulic as well as automatic 3-axes, automatic 5-axes and CNC version surface grinding machines. The Sumo series of machines have robust base structure and have internationally accepted fixed column design.

Pinnacle Engineering Enterprise, Surendranagar 363 002.Tel: 02752-231167, Fax: 02752-231913Email: [email protected], Website: www.pinnaclegrinder.com

LATHE MACHINES

Balaji geared head heavy-duty lathe and extra heavy-duty machines (VGH series) offered

by Vinit Engineering Works are available with different height of centre ranging from 267 mm to 455 mm, length of bed ranging from 1675 mm to 6100 mm, admit between centres ranging from 525 mm to 5000 mm and main spindle hollow ranging from 50 mm to 104 mm. These lathe machines have 12 nos of speeds ranging from 30 to 1060 RPM. All gears are of 20 MN CR5 materials and hardened and ground. The main spindle nose isA 2-6 and A 2-8 designed. Also offered are electromagnetic pedal brakes and electrical switch shafts in the machine. The other range of geared head lathe machines includes light-duty VGL series and medium-duty VGM series.

Vinit Engineering Works, Rajkot 360 004.Tel: 0281-2311734, Fax: 0281-2312091Email: [email protected], Website: www.balajilathe.com

One StateMany Opportunities!

Karnataka

This November Investment Destination, a special edition with SEARCH, focusses on an undisputed investment destination Karnataka. Always at the forefront of Industrial Growth in India, Karnataka – with its inherent capabilities coupled with its enterprising citizens – offers vast business opportunities across sectors providing the ideal choice for investment opportunities.

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

BusinessGrowth

Invest in

Future

New Business

AvenuesSmart

Business

AmpleOpportunities


GENERAL PRODUCTS

MECHANICAL SHEARING MACHINES

Shailesh Machine Tools offers mechanical shearing machines that are

available in two versions, ie, under-crank and over-crank, having capacities starting from 500 mm to over 3000 mm and thickness varying from 2 mm to 12 mm. These shearing machines incorporate several standard and optional features, like hold-down systems (mechanical), hydraulic manual or auto lubrication systems (mechanical back gauge), ball roller or ball transfers, extension squaring arm finger guard, etc. Special versions can also be offered to meet specific production requirements.

Shailesh Machine Tools Pvt Ltd, Rajkot 360 002.Tel: 0281-2461102, Fax: 0281-2461665Email: [email protected], Website: www.shaileshmachines.com

UNIVERSAL JOINTS

Tradelink Services offers universal joints that have manufactured by Flli Aramini srl, Italy. These universal joints are all metal

couplings between two shafts, allowing for radial and axial misalignment and simultaneously transmitting torque, even at variable speeds. The couplings have the ability to transmit power even at high working angles (up to 45-degrees) in a minimal amount of space. Models AL & A (for speeds up to 800 RPM) and Model V (fitted with needle bearings & used

for speeds up to 5000 RPM). Diverse models cover a bore range from 6 mm to 50 mm shaft diameter with option of a round/square/hexagon bore and bore+ keyway. Male pin, quick release, single & double, hi-speed joints with a central cross are standard options in the large range. Stainless steel joints in single/double are also available. Rotar universal joints are used in different types of industries, namely printing, packaging, machine tools, equipment testing, automation equipment, material handling, nuclear plants, paper machines, etc.

Tradelink Services, Chennai 600 058.Tel: 044-2623 1267, Fax: 044-2836 1741, Mob: 09282433591Email: [email protected], Website: www.tradelinkservices.in

WHEEL BEARING GREASES

Mahathol Grease WB-2 and WB-3 offered by Mahatha Petroleum are lithium-based greases having fibrous structure,

excellent performance, shear stability, and are adhesive to metal surfaces. These greases maintain their structural stability even over long service periods and withstand excessive churning operations effectively. They also possess the required consistency for pumpability for application by grease guns. The wheel bearing greases are recommended for wheel bearings, universal joints, high temperature clutch release, generator and fan bearings, and all other automotive applications where these greases are not exposed to direct water or moisture.

Mahatha Petroleum Pvt Ltd, Chennai 600 117.Tel: 044-2247 1542, Fax: 044-2247 3800, Mob: 09444065754Email: [email protected]: www.mahathapetroleum.com


GENERAL PRODUCTS

CASTINGS

Twinkle Stars Engineers manufactures and offers castings for pump impellers of various models, like open impeller grade

CF-8M, CO2 and no-bake moulding, closed impeller vein of 7 mm grade WCB, CO2 moulding, closing impeller, passivated, 8 mm vein and closed impeller water quenched grade CF8M, CO2 and no-bake moulding, carbon steel impeller 6 mm gap, 65 mm opening, grade WCB, CO2, no-bake moulding, closed impeller passivated, low gap vein, small opening, CF-8M, CO2 and no-bake moulding. Each of the impellers is in various dimensions and weight. The impellers are vital components of the pumpsets. Castings are undertaken for pump impellers as per drawings, specifications, material details and samples provided by the customers, OEMs, assemblers, repairers, traders and exporters, etc.

Twinkle Stars Engineers, Rajkot 360 002.Tel: 0281-237 9404; Email: [email protected]

MITRE CUTTING BANDSAW MACHINES

ITL Industries offers fully-automatic motorised swiveling-type mitre cutting bandsaw machines that are used to cut angles

in range of 30°-90°-30°. Model LMG mitre series is equipped with swiveling cutting head enabling to cut the job at various 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

INDUSTRIAL PLUGS & SOCKETS

Connectwell Industries manufactures and offers industrial plugs and sockets that provide a versatile and robust connection

system for industrial f ield and factory connection applications. These are designed and manufactured as per IEC 60309-1 and IEC 60309-2 standards. The housings of the plugs and sockets are made of halogen-free, V0 grade polyamide 6 materials and hence

are non-flammable with a very high impact resistance. Contacts are made from electroplated copper alloy offering high corrosion resistance and very low contact resistance. By virtue of their design these industrial plugs and sockets enable low insertion and extraction forces while maintaining excellent electrical contact. A wide range is available in 16, 32 and 63 A versions with a choice of IP44 or IP67 protection class and in 3-, 4- and 5-pin configurations to suit various applications. The industrial plugs & sockets are extremely safe and reliable for the field & factory connections.

Connectwell Industries Pvt Ltd, Dist Thane 421 204.Tel: 0251-287 0766, Fax: 0251-287 0889Email: [email protected], Website: www.connectwell.com


GENERAL PRODUCTS

SHOP INFORMATION INDOOR DISPLAYS

Process Care Systems (India) offers shop information indoor displays that are made to work with a variety of power

sources, for eg, 24 V DC, 12 V DC, 230 V AC/DC, 110 V AC/DC, etc. All these displays in the range work on serial ports conforming to either RS232 (generally referred to as COM port) or RS485 interfaces. Proprietary protocol suitable to multi-drop several displays can be shared with the system integrators. Optional message designer, designing software running on PC is also available. All the displays can be of various dimensions with respect to pixel matrix or mechanical dimension of the pixel itself. All the other communication interface devices that may be required to network such displays are also available. There are at least 20 different serial communication interfaces designed in-house and are used by several customers for various other applications (claims the company).

Process Care Systems (India) Pvt Ltd, Bengaluru 560 058.Tel: 080-4352 1111, Fax: 080-4352 1140, Mob: 09731900027Email: [email protected], Website: www.datacareindia.com

INVESTMENT CASTINGS

Shri Hari Cast Industries offers investment casting of components in ferrous and non-ferrous metals and alloys

through lost wax process. These precision investment castings are supplied for use in automobile industries, aircrafts, artif icial limbs, aerospace, boiler mountings & accessories, bottling industries,


GENERAL PRODUCTS

compressors parts, crimping tool industries, diesel & gas turbine equipment, dairy equipment, electrical, earth movers, electronic industries, f ire-fighting equipment, food processing machinery, gauges, hydraulic pumps, instrumentation, machine tools equipment, power plants, industrial pumps, pneumatics equipment, pharmaceutical equipment, plumbing fixtures, process machinery, textile machinery, valves & fittings and in general engineering. They are also used in any industries where a component is diff icult or uneconomical to be made by other conventional processes. The precision investment castings are supplied (by lost wax process) in ferrous and non-ferrous metals and alloys or any other alloys as per customers’ requirements with all tests of materials.

Shri Hari Cast Industries, Ahmedabad 380 008.Tel: 079-2545 1819, Fax: 079-2277 1112, Mob: 9825039727Email: [email protected], Website: www.shriharicast.net

PRECISION INVESTMENT CASTINGS

Hi-Bond Strips manufactures and offers precision investment castings of ferrous and non-ferrous metals, alloys and super

alloys of f inest quality. These precision investment castings are manufactured by lost wax process, which is most modern, flexible and cost-effective metal forming technique of designing and manufacturing components for a wide range of manufacturing


GENERAL PRODUCTS

sector. The investment castings are manufactured in 10 MT per month, like tiny product as minimum as few grams up to 30 kgs, single piece as cast, linear up to 600 mm. It is the company’s metal arrangement to cast virtually any metals or alloys. The precision investment castings have applications in pumps and

industrial valves, automobile spares, material handling equipment, defence, aeronautical, oil engines, compressors, impellers, chemical plant machinery, textile machinery spares and other engineering line components.

Hi-Bond Strips Pvt Ltd, Dist Rajkot 360 003.Tel: 02827-252152, Fax: 02872-2385120Email: [email protected], Website: www.hibond.com

PRECISION INVESTMENT CASTINGS

Hi-Con Technocast manufactures precision investment castings by lost wax process. A negative replica of the part

or component is prepared in the form of metallic die, for creation of wax pattern, which matches the configuration and finish of the final metal part. Multiple numbers of wax patterns are made, connected and assembled by gates to wax sprue to form

a tree or cluster. Successive coats of ceramic slurry and refractory is sent, fused silica is applied on assembled clusterfree with

intermediate drying time to form a self-supporting shell called mould. The specified molten metal alloyed in induction melting furnace is then poured in the pre-heated and hot-baked hollow shells (moulds) ensuring complete filling of the entire shell cavity. Upon cooling, the ceramic shells are removed by usual knocking out operations by mechanical vibration and chemical cleaning. Finished products of casting are carefully inspected for compliance with client’s drawings and specifications.

Hi-Con Technocast Pvt Ltd, Rajkot 360 021.Tel: 02827-287901/3, Fax: 02827-287902, Mob: 09824519346Email: [email protected], Website: www.hicontechnocast.com

SPHEROIDAL GRAPHITE IRON CASTINGS

Kalson Alloy Cast manufactures and offers quality spheroidal graphite (SG) iron castings (nodular cast iron/ductile casting)

and undertakes development & manufacturing of any components by SG iron casting as per drawings, specifications, required

quantity details, material details and samples of customers. Moulds are moved by mould car on track lines for efficient movement. For melting, induction melting furnace of 250 kW is employed, with 2 nos of crucibles each having 300 kg capacity. Strict

quality control at each stage of production is ensured at quality control laboratory by performing chemical analysis for determining various elements in casting, by studying microstructure and determining hardness and checking tensile strength/elongation of


GENERAL PRODUCTS

the casting. SG iron casting is taken-up in the capacity of weight range from 0.5 kg to 500 kgs per single piece.

Kalson Alloy Cast Pvt Ltd, Rajkot 360 021.Tel: 02827-287574, Fax: 02827-287574Email: [email protected], Website: No website

INVESTMENT CASTINGS

Alltech Technocast manufactures and offers offer a wide range of stainless steel investment

castings that are produced from quality raw materials. These castings are highly durable, corrosion-resistant, and possess high tensile strength. The products are used in different industries, which include chemical, food & beverage products, petrochemical, pulp & paper equipment, power generation, and waste treatment. Steel castings are available with in standard as well as customised configurations according to our client specifications.

Alltech Technocast Pvt Ltd, Dist Rajkot 360024.Tel: 02827-252240, Fax: 02827-252440, Mob: 09879476066Email: [email protected], Website: www.alltechcastings.com

ENGINEERING COMPONENTS CASTINGS

Standard Techno Cast manufactures and offers engineering components castings by ferrous or non-ferrous quality

investment casting as per drawings, specifications and samples provided by customers. Engineering components are made by

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.”


GENERAL PRODUCTS

investment castings from a few grams to 70 kgs per single piece. There are also arrangements to cast virtually any metal-alloys, such as steel, alloy steel, carbon steel, nickel-based steel, super alloys, hastalloys, inconel, monel, ductile irons, aluminium alloys,

copper-based alloys, bronze alloys and many other ferrous and non-ferrous metals. Also offered are investment castings for engineering components applicable to industrial pumps & valves, impellers, material handling equipment, aeronautical & aircraft, automobile, defence,

dairy machinery & equipment, industrial clamps, hoists, chain & lifts, medical surgical orthopaedic & dental equipment, packaging & printing machinery, pneumatic tools & controls, steam traps, textile & pharmaceutical machinery, agricultural machineries, air compressors, engines, cranes, hardware, earthmoving equipment, electrical engineering, farm equipment, fire fighting equipment, flow meters, gas turbines, gears, gymnastic equipment, refrigeration plants and general engineering.

Standard Techno Cast, Rajkot 360 001.Tel: 02827-287792, Fax: 02827-287709Email: [email protected]: www.standardtechnocast.com

SPHEROIDAL GRAPHITE IRON CASTINGS

Perfect Auto Cast manufactures and supplies quality spheroidal graphite (SG) iron castings (nodular cast iron/

ductile castings). Manufacturing of any components by SG iron castings is undertaken as per drawings, specifications, material

details and sample provided by customers. Quality, accuracy and timely delivery are maintained. Development of SG iron castings are taken up in the capacity of weight range of 0.5 kg to 500 kgs per single piece, while the production capacity is up to 3000 tons annum in

materials as per ASTM, BS, DIN, EN, SAE, ISO, IS and other international standards or as per the need of customers. The spheroidal graphite iron castings have application in the field of automobiles, internal combustion engines, compressors, machine tools, hydraulics, pumps & valves, pipe fittings, electrical power transmission & switchgear industries, heavy equipments, material handling equipments, food process machineries, leather machineries, rolling mills, etc.

Perfect Auto Cast, Dist Rajkot 360 002.Tel: 02827-253870, Fax: 02827-253880, Mob: 09824225830Email: [email protected]: www.perfectautocast.com

PISTON COMPRESSORS

Statex Engineering offers portable piston compressors. These piston compressors are used in car & truck tyre inflation,

testing instruments, clinical lab equipment, by dentists, and by artists (spray guns). Salient features include: single cylinder mini air compressor, high quality oil-less self-lubricated pistons & rings, compact in size & portable; die cast aluminum body with vibromount base fitted with auto start/stop for preset pressures; and as optional, 1 litre or 2 litres air tank can be supplied.


GENERAL PRODUCTS

Technical specifications are power of 1/5HP; voltage at 220-240 V / 50 Hz, 220 V / 60 Hz; maximum pressure 7 bar (100 PSI); air output 23 litres per minute; auto stop/start at 30 PSI & stop at 60 PSI (special pressure available); f ittings are pressure gauge with special sensor regulator & air filter; connection 1/8 BSP; pressure tank (optional), net weight at 3.6 kgs; and dimensions of 245 mm x 135 mm x 170 mm.

Statex Engineering (P) Ltd, Coimbatore 641 021.Tel: 0422-2673232, Fax: 0422-2672464, Mob: 09943022722Email: [email protected], Website: www.statexengg.com

VACUUM HEAT TREATMENT FACILITIES

Assab Sripad Steels offers vacuum heat treatment facilities for plastic moulds, die-casting, extrusion & forging dies and tools

for cold work applications. These are imported from Austria. The vacuum heat treatment facilities have a chamber size of 600 mm x 600 mm x 900 mm with a designed load of 600 kgs per charge. The maximum furnace temperature can go up to 1250°C, suitable to harden high-speed steels. There is a guaranteed temperature uniformity of ±5°C. A quenching pressure of 10 bar with two-speed fan and a convective fan is also provided. The furnace is run by advanced control system from Demig with Scada support system for process repeatability. The furnace is validated according to NADCA for PDC dies.

Assab Sripad Steels Ltd, Chennai 600 028.Tel: 044-2495 2371, Fax: 044-2495 2273, Mob: 09600040849Email: [email protected], Website: www.assabsripadsteels.com

ELECTRONIC BALLASTS

Venson Engineering Company offers electronic ballasts that are very lightweight and have an elegant look. These ballasts save

50 per cent of electricity (claims the company). They have instant start and work at low voltage. Other features include: no flickering, easy installation, saves money, no need of starter & condenser, one year guarantee, etc.

Venson Engineering Company, Bengaluru 560 010.Tel: 080-2335 8366, Fax: 080-2338 2591, Mob: 09448079756Email: [email protected], Website: www.vensonlite.com

AVIATION OBSTRUCTION LIGHTS

J B Industries offers neon and LED aviation lights, such as single aviation obstruction lights of neon spiral are available with built-

in 75 VA step-up transformer, die-cast aluminum alloy housing, heat-resistant, clear thick glass and accessories; LED single aviation obstruction light comes in die-cast aluminum alloy housing with polycarbonate dome; and LED double aviation obstruction lights


GENERAL PRODUCTS

with die-cast aluminum alloy housing with polycarbonate dome. Salient features include: give omni-directional light; protection: weather-proof IP55; material of construction: cast aluminum (LM 6); transparent part: polycarbonate red glass dome; gasket of neoprene; light source: high power light emitting diodes, mounted on glass epoxy PCBs; operate directly on 230 V / 50 Hz AC, can withstand high voltage fluctuations; multiple light elements reduce chances of complete blackout due to any unlikely lamp failure; approximate life of around 100000 hours; and earthing terminals provided.

J B Industries, New Delhi 110 015.Tel: 011-2510 4159, Fax: 011-2544 2097, Mob: 09871888634Email: [email protected], Website: www.jbindustries.in

AIRCRAFT PLASTIC MOULDING DIES

Catering to the needs of aerospace industries, Magna Tech CNC offers a wide range of aircraft

plastic moulding dies. High-grade plastic is used for fabricating these dies. These dies are offered in various innovative designs, dimensions, sizes and finishes. The range can also be customised to suit the exact requirements of clients.

Magna Tech CNC, Bengaluru 560 091.Tel: 080-2836 3518, Fax: 080-2836 3518, Mob: 09980097314Website: www.magnatechcnc.com


INTERNATIONAL PRODUCTS

INTEGRATED PLANNING TOOLS

One of the novelties from X-Visual Technologies is the Visual Net-Planner, a planning tool for plant engineering and

network planners. The new software solution for the planning and documentation of complex data networks and telecommunication distributors reportedly enables fast and efficient planning processes. In particular, the automated documentation is said to guarantee a high degree of planning security and company-wide quality assurance.

X-Visual Technologies GmbH, GermanyTel: +49-30-63926125, Fax: +49-30-63926127Email: [email protected], Website: www.x-visual.net

GRINDING BELTS

Hermesit long-life grinding belts offered by Hermes Abrasives Group special hollow spheres covered with grain and

produce typical Hermesit f inish, called Hermesit bright effect. When grinding with Hermesit abrasives, the rough ness depth of the surface of the ground workpiece is the same throughout the entire lifetime of a belt. When grinding with conventional abrasives, an even surface quality can be achieved for only a relatively short time. The abrasive grain becomes blunt and the desired initial roughness depth drops considerably. As the hollow spheres coated in abrasive grain wear down, new grain is constantly being exposed. Some of the benefits include: consistent surface finish & roughness values on workpiece, throughout tool life; 3-5 times the tool life improves economy compared to conventional grinding belts: reduced grinding belt change times & reduced disposal costs for used grinding belts; and lower grinding temperatures.

Hermes Abrasives Group, GermanyTel: +49-40-83300, Fax: +49-40-8330230Email: [email protected]: www.hermes-abrasives.com

CNC VERTICAL LATHES

You Ji Machine Industrial Company manufactures CNC vertical lathes

(YN-200 series). The compact design of the YV series provides advantages, such as space saving and high rigidity for excellent accuracy. The versatile and flexible design greatly improves loading and unloading processes to ensure accurate work-piece location. 8-station turret and gang-type tool holders are available to meet specific production requirements. The vertical turning lathes are equipped with C-axis (VDI turret) for drilling and tapping operations in addition to turning operation.

You Ji Machine Industrial Company Ltd, TaiwanTel: +886-7-6983068, Fax: +886-7-6983071Email: [email protected], Website: www.youji.com

AIR-OPERATED RAIL CUTTERS

Phoenix Contact GmbH Co manufactures air-operated rail cutters for standardised mounting rails. These PPS comfort

compressed air-operated rail cutters are used for rapid cutting of the four regular mounting rail sizes NS-35/7.5, NS-35/15, NS-15 and NS-32, as well as the NLS neutral bus, and cut virtually

without burrs and to exact dimensions. The cutters are equipped with a hydro-pneumatic drive, which simply has to be connected to a 6-bar compressed air source to be put into operation. The movable length stop on the 1 metre long measuring bar can be set to the desired rail length to within less than a millimeter. Simply by pressing the compressed air key it is possible to cut any desired number of mounting rails without diff iculty. It is

also possible to make fixing holes, by adding stamping bits. The rail cutters are available for both round boles and slots, in varying dimensions.

Phoenix Contact GmbH & Co KG, GermanyTel: +49-5235-341512, Fax: +49-5235-341825Email: [email protected], Website: www.phoenixcontact.com

NON-CONTACT INFRARED PYROMETERS

Raytek offers CI non-contact infrared pyrometers that are compact and easy-to-install. Designed for easy integration

into a standard 4-wire system, these infrared pyrometers can easily replace traditional contact probes with a J-type or K-type thermocouple output. The onboard electronics of these

p y r o m e t e r s a r e protected by a rugged IP65 (NEMA-4) stainless steel housing, allowing the instruments to

function in ambient temperatures to 70°C (160°F) without cooling. With water-cooling, the pyrometers can withstand ambient temperatures to 260°C (500°F). Some of the features include: cover temperature ranges from 0°C to 500°C (32°F to 932°F); easily replace traditional probes & thermocouples; accessories for cooling & air purging; and stainless steel electronics housing.

Raytek GmbH, GermanyTel: +49-30-4780080, Fax: +49-30-4710251Email: [email protected], Website: www.raytek.de

IMAGE SENSOR PROCESSING SOLUTIONS

Altera Corporation and Apical Ltd have announced the world’s first high-definition wide dynamic range (WDR) CMOS image

sensor processing solution for video-surveillance cameras. Altera and Apical’s complete solution ensures superb video-image quality regardless of varying lighting conditions, a major stumbling block

for previous generations of surveillance cameras. Featuring Altera’s Cyclone III and Cyclone IV FPGAs, and Apical’s intellectual property (IP), this solution supports Aptina’s new MT9M033

high-definition WDR CMOS image sensor. Standard CMOS image sensors are limited by the vast range of brightness levels, from low light to direct sunlight, that can black out or wash out a video subject. WDR CMOS image sensors correct this problem, but present a design challenge. The large amounts of data (up to 20 bits per colour x 1.2 Mpixels at 60 frames per second) generated by these image sensors must be processed in the Image Sensor Pipeline (ISP), but are too much to be handled on-chip.

Altera Corporation, USATel: +1-408-5446397, Fax: +1-408-5446403Email: [email protected], Website: www.altera.com



MOTION CONTROLLERS

GE Intelligent Platforms has announced the availability of its latest update to its advanced motion controller (PACMotion

firmware version 1.5). The PACMotion is designed to control up to 40 axes of synchronised motion all at the exact same servo update loop rate of 1ms independent of the number of motion axes. It is the motion controller of choice in a host of new areas, including packaging, material handling, and automated assembly. By enabling connectivity to a wider variety of off-the-shelf devices, users will f ind PACMotion available to serve many more applications, which can lead to lower system cost. Firmware version 1.5 features two axis analogue servo control allowing control of one or two third-party amplif iers using a 10 V DC analogue speed or torque command. A PACMotion module controls four axes, and each module can use two of those axes for third-party servos through this upgrade.

GE Intelligent Platforms, USATel: +1-508-6987456Email: [email protected], Website: www.ge-ip.com

OPERATIONAL AMPLIFIERS

Texas Instruments Inc has introduced high-linearity, low-distortion, fully-differential operational amplif iers (op amp) that

deliver 16-bit full-scale precision up to 200 MHz IF to maximise signal chain performance for wireless base stations, high-speed data acquisition, test & measurement, medical imaging & defense applications. The THS770006 op amp has an output third-order intercept (OIP3) of 48 dBm and the lowest distortion in its class,



with a third-order inter-modulation distortion (IMD3) of -107 dBc at 100 MHz, at least 14 dB better than competitive amplif iers. Features include: best-in-class distortion & high linearity help designers meet the stringent sensitivity & bit-error rate (BER) requirements of emerging wireless standards; seamlessly drives TI high-speed analogue-to-digital converters (ADCs), including the new 16-bit, 130-MSPS ADS5493, with full-scale, 3-V peak-to-peak dynamic range for optimal design flexibility & signal-to-noise ratio (SNR) performance; and provide fast overdrive recovery of 7.5 ns (maximum) to help minimise the impact of lost or erroneous data from jammers and blockers.

Texas Instruments, Inc, USATel: +1-972-6445580, Fax: +1-972-9276377Email: [email protected], Website: www.ti.com

TIMERS/COUNTERS & ANALYSERS

Tektronix, Inc has announced the FCA3000 and FCA3100 series of timers/counters & analysers and the MCA3000

series of microwave counters & analysers. These instruments smoothly integrate with other Tektronix bench instruments, such as

oscilloscopes & arbitrary/function generators, and deliver industry-leading frequency & time resolution coupled with lower cost of

ownership. Instruments, such as the FCA and MCA series are used for measurement and analysis of frequency, time or phase signal parameters in design, production, and calibration labs or in field applications, such as radar equipment monitoring and test. Critical factors in this segment include high-performance for better accuracy, analysis tools to quickly find answers to design problems and support for fast data transfer rates. The new timers/counters & analysers compliment the PWS4000 and PWS2000 series power supplies also introduced by Tektronix separately. With industry-leading performance, the new timers/counters & analysers allow design engineers to make over 13 different frequency, period, time, pulse, or phase measurements with high resolution.

Tektronix, Inc, USATel: +1-800-835 9433Email: [email protected], Website: www.tektronix.com

HYDROCARBON DEW-POINT ANALYSERS

Michell Instruments offers Condumax II hydrocarbon dew-point analysers for automatic, online measurement of

hydrocarbon and water dew point in natural gas. Some of the salient features of these hydrocarbon dew-point analysers include: fully automatic online analysis; objective & highly repeatable; 0.5°C hydrocarbon dew-point accuracy; fundamental cooled mirror principle; patented detection technique; self-cleaning; no purge or cooling gas needed; optional water dew point analysis; and modbus RTU.

Applications are in natural gas processing, protection of turbo-expander plant, gas quality measurements at custody transfer, transmission pipeline monitoring, confirmation & control of fuel gas superheat to turbine power plant.

Michell Instruments, Inc. USA Tel: +1-978-4840005, Fax: +1-978-8437669Email: [email protected], Website: www.michell.com/us



MULTI-FUNCTION CONTROL PLATFORMS

Semikron Electronik manufactures and offers multi-function control platforms for IGBT modules and systems. The digital

driver SKYPER-52, which has already proven to be a success in driving IGBT modules, is also being used in these systems. This driver boasts a wealth of functions with a minimum of components, making the digital driver even more flexible and robust than before.SKYPER-52 offers a high level of signal integrity, providing reliable immunity from interference signals. The digital driver communicates via CAN input/output, providing the optimum interface between controller and power module. As a result, this driver is particularly suitable for use in systems that integrate power semiconductor, cooling, capacitors, driver and controller hardware. The SKYPER digital driver transmits the commands of the controller for the power semiconductor with a high level of signal integrity, ie, clear logic levels.

Semikron Elektronik GmbH & Co KG, Germany Tel: +49-911-6559234, Fax: +49-911-6559262Email: [email protected], Website: www.semikron.com

GRAVITY SEPARATORS

Enviro-Tech Systems offers gravity separators (API 421) that are atmospheric horizontal vessels designed and built for free oil

and solids removal. Oily water and solids enter the separators, via a pre-separator for flow equalisation and collection of bulk



oil, trash, and grit. The flow exits the separator forebay and is reduced to laminar flow as it passes through a distribution plate. The distributed flow then enters into each of the separator’s bays, via gateways, where free oil, solids, and sludge are separated using Stoke’s Law. Solids and sludge settle to a sludge storage hopper directly under the inlet chamber. As the oily water flows through the separator, oil and solids continue to separate. A flight skimmer mechanism pulls oil toward the skimmer and moves any solids that settle to the bottom of the vessel in the reverse direction, toward the sludge collection area.

Enviro-Tech Systems, USATel: +1-985-8096480, Fax: +1-985-8096422Email: [email protected]: www.envirotechsystems.com

SERVO ROTARY TABLES

Brushless servo rotary tables manufactured by Haas Automation, are

right for medium-size parts. In these servo rotary tables the 110 mm (4.33”) platter has three drilled and tapped hole patterns for flexible, secure workholding. The table turns with 65 ft-lb of torque, and has 80 ft-lb of brake torque (40 PSI) for accurate cuts. Compact design allows lots of room on the machine table for other tools and accessories.

Haas Automation, Inc, USATel: +1-805-2781800, Fax: +1-805-9886918Email: [email protected], Website: www.haascnc.com

WELDING HELMETS

Alfa welding helmets from Kemppi Oy are welding helmets intended for arc welding, carbon arc

gouging, and plasma cutting. These welding helmets are used to protect the welder’s eyes, head, and neck from arc radiation, reflected radiation from the environment, and welding spatters. The helmets can also be used as protective gear during grinding

and skimming while keeping the filter glass in the upright position.

Kemppi Oy, Lahti, FinlandTel: +358-3-89911, Fax: +358-3-899428Email: [email protected], Website: www.kemppi.com

HOT-AIR COMPONENTS

Leister Process Technologies offers hot-air components that regulate process parameters, such as temperatures and

application time of the hot air jet, precisely and comprehensibly. The smallest configuration is the Leister LE Mini air heater with a 400 W power rating, the largest works with 40 kW. These air heaters include heating element protection and an alarm output. They can be connected with a regulator or a PLC device, via a galvanically isolated 4–20 mA interface. The diversity of Leister standard nozzles allows customer-specific configurations. This makes it possible, for instance, to pass different parts across the same jet of hot air. All necessary components, such as nozzles, air heaters, temperature regulators and blowers, from a single source are offered.

Leister Process Technologies, SwitzerlandTel: +41-41-6627474, Fax: +41-41-6602061Email: [email protected], Website: www.leister.com



RECIPROCATORS

Spraymation Inc manufactures and offers reciprocators that are electronically reversible electronically programmable

reciprocators providing precise repeatable motion and painting. A simple operator interface offers immediate push-button control of speed, stroke length, and position. Model 360176 reciprocator is a member of the new S3 generation of reciprocators. It is a completely new design that continues the heavy-duty tradition of Spraymation painting machines. Salient features include: vertical column is only 10½” (267 mm) wide; base is 13” (330 mm) wide; stroke can be designed for strokes up to 15’ (4.5 m) using modular design; carriage travels on a square track using ball bearing wheels; carriage is driven by heavy-duty chain; adjustable counter weight is used on a separate track to balance the spray applicators; and designed for a payloads of 20 Lb (9 kgs) or 40 Lb (18 kgs).

Spraymation Inc, USATel: +1-954-4849700, Fax: +1-954-4849778Email: [email protected], Website: www.spraymation.com

LEAK DETECTION RELAYS

Dwyer Instruments offers new series of SLD single channel leak detection relays. These relays are used to monitor the shaft

seal of a submersible pump to detect a leak before pump failure. A leak is detected by sensing the status of a float or conductivity switch installed in the seal cavity. When this resistance drops below the set sensitivity, the output relay energizes and the LED indicator illuminates. The relays offer normally open and normally closed relay contacts to energize an alarm and de-energise the pump in

the event of a leak. When the seal failure condition clears, the relay automatically resets. Installation is made simple with the standard 11-pin socket mount. The single channel leak detection relays are available in three different sensitivities: 470 ohm fixed, 470 to 10 k ohm adjustable, and 4.7 k to 100 k ohm adjustable.

Dwyer Instruments Inc, USATel: +1-219-8798000, Fax: +1-219-8729057Email: [email protected], Website: www.dwyer-inst.com

MINERAL INSULATED CABLES

AerOpal mineral insulated cables offered by Tashika Boeki Shokai KK, is a combination of high quality metallic sheath,

ceramic powder insulation and thermocouple, heater or electric conductors. Single core or multi-core mineral insulated cables are available in standard sizes ranging from 0.15 mm to 12.5 mm

OD. Choice of metal sheaths and insulation material can be made as per the application. Mineral insulated cables features long life and flexibility. They are processed in cleanroom conditions using controlled techniques during manufacturing and inspection to ensure quality

conforming to international standards. The mineral insulated cables have a variety of applications in the field of temperature measurement, heating and data transmission.

Tashika Boeki Shokai KK, JapanTel: +81-78-2419035, Fax: +81-78-2422105Email: [email protected], Website: www.tashika.co.jp



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

PORTABLE CABLE TESTERS

HT Italia manufactures and offers portable cable testers (model LanTest-8050) for complete verification of LAN cabling up to

2000 MHz (cat 5). Continuous diffusion of computer networks make it necessary to use instruments for testing and verification of LAN cabling, for control of both proper connection and cable positioning. The LanTest-8050 permits to effect all measurements easily and quickly. It permits to test and check LAN cabling according to category 5E both with RJ45 and coaxial cables. Tests can be affected according to the standards (EN50173, ISO/IEC11801, TIA cat5). With the TDR and TDCrossTalk modes, it is possible to trace the fault point quickly. Some of the functions include: control of cable wiring; measurement of cable resistance and impedance; measurement of cable length; attenuation measurement; return loss measurement; NEXT measurement (near end crosstalk); propagation delay measurement; ACR measurement; AutoTest function; TDR and TDRnext functions; identif ication of cable connectors through locators; and full duplex voice communication.

HT Italia srl, ItalyTel: +39-546-621002, Fax: +39-546-621144Email: [email protected], Website: www.htitalia.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.

2D-3D conversion 532-wire transmitters 123D modelling 53

Abrasive blast rooms 215Abrasive blasting machines 65, 204, 215AC motors 57Access control systems 256Acoustic enclosures 185Adapter sleeves 106Adaptors 212Adhesives 97Adjustable shock absorbers 58, 147Adsorption dryers 184Advanced fibre systems 212Aerator gearboxes 118Aerobridge installation & maintenance 207Agitator seals 142AGVs 226Air compressors 67, 163, 194Air purifiers 113Air receivers 184Air turbo ventilators 202Air-cooled reciprocating compressors 67Aircraft plastic moulding dies 253Air-operated/airless shot blasting machines 61Airport equipment & service providers 207Airport passenger baggage trolleys 223All material handling items 242Alloy wheels 223Alu-cera polymers 11, 17Aluma coats 11, 17Aluminium extrusions 145, 220Aluminium oxide ceramic composites 11, 17Appliance switches 31Area sensors 63, 105AS-interface systems 225Assembly technology 69Auto drains 260Automated guided vehicles 226Automatic rolling shutters 25Automatic weighing systems 207Automation & storage systems 51, 225Automation solutions 222Automation 12, 141, 280Aviation obstruction lights 245

Baking ovens 61Balancers 79Ball & roller bearings 70Ball bearings 221Ball transfer units 223Ball valves 235, 238Balls 217Basket strainers 235Battery operated pallet trucks 95Beam lights 139Bearings 14, 70, 167, 169, 221Belt-type magnetic concentrators 152Bending machines 241Bends 238Best CAD 53

Product Pg No

Billet shearing machines 16Bin vibrators 206Bio toilets 257Blast room paint spray booths 61Blasting media 215Blowers 158Bollards 25Bow shackles 242Brake motors 43, 57, 124, 224Brakes 224Brass castor wheels 223Breather valves 235Brine chillers 201Bronze wheels 223Building automation 280Butterfly valves 238

Cable carriers 14Cable clamps 101Cable connectors 14Cable glands 206Cable glands 47, 101, 213Cable ID printers 237Cable markers 101Cable movers 216Cable reeling drums 152Cable ties 101Cable trolleys 228Cables & leads for fixed instaction 51Cables for bus systems 51, 225Cables glands 258Cables handling & processing systems 51, 225Cables scanps 51, 225Cables 19, 43, 88, 257CAD programs 53CAD software 53Cage hoists 245Calibrators 12CAM express 53CAM followers 224CAM 53Capacitive & magnetic sensors 225Carbide rods 137, 212Carbide 212Cargo lashing 242Cargo systems & sort equipments 207Cast/extruded 239Castings 238Castor wheels 223Castors 223CCTV surveillance 256CED coating machines 280Center drills 212Centralised lubrication systems 78Centrifugal blowers 67Centrifugal compressor package 67Centrifugal oil cleaners 257Centrifugal oil water separators 257Centrifugal pumps 41Ceramic adhesive cements 11, 17Ceramic electrical heater parts 11, 17

Product Pg No

C-frame power presses 16Chain hoists 203, 245Chain pulley blocks Front gatefold,124, 149 203, 216, 242, 245, Chain slings 242Chain wheels 214Chains 14Chair castors 223Channel magnets 253Check valves 231, 235Chemlok coating machines 280Chucks 212Circular motion vibratory screens 152Circular vibratory screens 152Circular/gyrator vibro machines 253Cistern type manometers 235Clamps 206Cluster hammers 198Clutch & brakes 22Clutch brake combinations 224Clutches 224CNC cutting machines 280CNC horizontal boring mill titan 189CNC laser cutting machines 280CNC machine solutions 160, 172CNC machines 217, Back inside coverCNC oxyfuel cutting machines 280CNC plasma cutting machines 280CNC toolings 212CNC turning centres Back inside coverCNC vertical lathe titan 189CNC vertical machining centres 15, Back inside coverCNC/VMC machines 99Coating machines 280Coating plants 280Coating systems 280Cold saw blades 204Cold storage dockhouses 25Cold storage doors 25Collet chucks 212Collets 212Communication modules 222Composite engineering materials 216Compressed air division 203, 223Compressed air dryers 184Compressed air systems 52Compressors 45, 52, 67, 163Concrete vibrators 152Conductors 227, 257Conduits & connector systems 31Connectors accessories 51, 225Connectors 8, 14, 25, 47, 213Construction electric hoists (modular) 133Contactless multi-axis joysticks 199Container cranes 111Contrast/colour scanners 123Control & automation 19Control cables 88Control dampers 215Control panel accessories 31

Product Pg No

PRODUCT INDEX


Control systems 205Controllers 12Conventional pallet racking 231Conveyor & process belts 214Conveyor belts 162Conveyor castor wheels 223Conveyor chains 127Conveyor trolleys 223Conveyorised painting lines 187Conveyors and automation systems 25Conveyors 96, 102, 162Coolant filters 222Coolant rotary unions 58, 147Cooling water treatment 279Core cutting machines 199Coromills 1Corothread 1Counters & power supplies 7Counters rate products 12Counters 105Crab assemblies 119Crab hoists 124Crabs 149Crane kits 119Crane-duty gearboxes 118Crane-duty motors 43, 124Cranes Front gatefold, 20, 96, 117, 119 124, 130, 133, 146, 149 203, 211, 245Crawler cranes 117Crimp contact & tools 51, 225Cross belt-inline magnetic separators 152Cushion dock shelters 25Custom-made cables 51, 225Cutting machines 280Cutting tools 137Cylinders 256Cylindrical grinders 217Cylindrical sensors 123

Data cables 51, 225DC motors 57DC power packs 243DC welding rectifiers 228Dehumidifiers 201Demagnetisers 49, 261Desiccant dryers 67Diaphragm valves 238Digital almen gauge & almen strips 151Digital mark sensors 63Digital panel meters 105, 200, 208Digital readouts 238Digital soft starters 253Digital temperature controllers 208Dip spin coating machines 280Disc brakes 227Display units 105Distribution boards 18Dock levelers & dock shelters 25

Product Pg No

Door runners & tracks 223Door side sensors 105Dosing feeders 152Double column metal cutting band saw 235Double drum & triple drum magnetic separators 261Double girder EOT cranes 119Double sheet monitoring 123Dowel spring pins 202Down shop leads 244Drawer magnets 253, 261Drill chuck arbours 212Drill chucks 203, 223Drill hammers 199Drill mills 212Drilling machines 79Drivers & controllers 105Drives 23, 213Drum trolleys 223, 231Drum-type magnetic separators 152, 253Dry vane pumps 185D-shackles 242Dust collectors 215DVRS 256

Earthmoving equipment 130Electric controls 69Electric dock levellers 231Electric drives 69Electric drum lifters 231Electric forklift trucks 25Electric lifting platforms 231Electric scissor lift tables 231Electric stackers 231Electric walkie stackers 231Electric walkie trucks 208Electric winches 216Electric wire rope hoists 20, 119, 124, 133 203, 205, 206, 211, 214Electrical & maintenance contractors 207Electrical CAD/CAE software 211Electrical connectivity 227Electrical pallet trucks 231Electrical products cable ties 47, 213Electrical systems 19Electro-lifting magnets 206Electro-magnetic bin vibrators 152Electro-magnetic disc brakes 227Electro-magnetic feeders 206Electro-magnetic ferro-filters 152Electro-magnetic vibratory feeders 253Electro-mechanical feeders 206Electronic ballasts 245Electronic barriers 256Electronic connectors 208Electronic drain valves 184Electronic speed switches 253Electronic timers 32, 34, 36, 38, 208Electronics For You Expo-2011 232

Product Pg No

Electronics products 47, 213Electro-permanent lifters 49Electro-permanent magnetic chucks 49Element shrink discs 224Elevators Front gatefoldEmergency lighting systems 139Emergency shock absorbers 58, 147Encoders 7End caps 238End carriage assembly 119End mills 212Energy conservation 135Energy efficient pumps Front inside coverEnergy meters 208Engineering class chains & sprockets 127Engineering components castings 243Engineering plastic plugs & sockets 32, 34, 36, 38Engineering plastic raw materials 210Engineering plastics 210, 212, 213, 239EngineeringExpo exhibition 177, 195Engines 194Entrepreneur magazine 263EOT cranes Front gatefold, 20, 96, 124 133, 203, 207, 211, 214, 216,EOT jib cranes 146EOT/HOT cranes 149, 245Ethernet switches 228ETX CPU modules 228Everything About Water Expo-2011 234Excavators 194Exhausters 158Exhibitions 109, 177, 195, 232, 234Extended trolleys 119External grinding spindles 217Eye bolts 242Eye hooks 242

Fabricator & turnkey projects 207Fabtec India-2011 109Facility management 207Factory automation 141, 280, Back gatefoldFailsafe brakes 227Fasteners 79, 215, 219Feed units 256Femap 53Ferrous & non-ferrous castings 220Fiber sensors 63Fiberoptic amplifiers 123Fiberoptic sensors 105Filter cocks 238Filters 184, 208Filtration 279Finishing machines 253Fire shutters 25Fixed mounting hoists 119Fixtures 206Flame arresters 235Flameproof hoists & cranes 245Flameproof hoists 149

Product Pg No

PRODUCT INDEX


Flameproof lights 139Flameproof motors 57Flameproof products 12Flange motors 43Flange mounting motors 57Flanging machines 241Flat cables for submersible pumps 51Flat high-tension single-twin igniting electrodes 11, 17Flexible cables & wires 51Floor scrubbers & dryers 273Flooring nailers 202Flooring 257Flow control valves 231Flow indicators 238Flow instruments 171Flow rate indicators 12Flow switches 235Fluid 193Fluidised bed coating machines 280Flush bottom valves 235Flux generators 152Foot mounting motors 43Foot valves 238Force actuation 179Force-feed lubricators 256Forged components 220, 224Forging presses 16Forked photoelectric sensors 123Forklift trucks 129, 202Forklifts 102, 117, 130Forks 130Freewheel-oneway-clutches 224Friction drop hammers 16Friction screw presses 16FRL spares valve spares 260Front axles 130Function generators 218Funnel magnets 202, 253Furniture castor wheels 223Furniture castors 223

Gantry cranes 119, 124, 146, 216Gap frame presses 239Gas & fire detection control panels 218Gas springs 58, 147Gauge accessories 171Gear boxes 149, 193, 214, 259Gear couplings 214Gear drives 165Gear flow meters 218Gear grinders 189Gear motors 22, 193, 214, 259Gear shapers 189Gearboxes 217Geared & flexible couplings 193Geared boxes 75Geared brake motors 224Geared couplings 96Geared motors 75, 124, 259Gears 165, 193, 214Glide coating machines 280Globe valves 235Goliath cranes Front gatefold, 124, 133, 149Goods lifts 96, 146, 149, 245Grab buckets 133

Product Pg No

Graphic panels 105Grill magnets 253Grinders 217Grinding machines 217Grinding media 11, 17Grinding spindles 217Grinding 79Grip pliers 206Guard monitoring systems 256Gyratory screens 206

Haconan-free cables 51Halogen searchlights 139Hammers 16Hand magnets 253Handheld mobile computers 227Handheld vibratory motors 152Hannover-2010 104Hard chrome plated bars 241Heat shrink tubings 47, 213Heat shrinkable sleeves 233Heat shrinkable tubes 233Heating elements 238Heavy-duty castor wheels 223Heavy-duty castors 223Heavy-duty industrial castors 223Helical gearboxes 214, 215Helical geared motors 20, 211Helical gears 214Helical inline geared motors/reducers 259H-frame power presses 16High intensity roller type magnetic separators 253High-alumina wear resistant ceramic tiles 11, 17High-carbon chrome 217High-carbon steel balls 217High-intensity induced roll magnetic separators 152High-intensity rare earth magnetic separators 253High-pressure blowers 22High-pressure cleaners 273High-speed doors 25HOC dryers 67Hoist drives 203Hoists with trolley 119Hoists Front gatefold, 96, 133Holdbacks 224Home automation systems 256Hooper magnets 253, 261Horizontal CNC machines Back inside coverHorizontal handle clamps 206Horizontal machining centres Back inside coverHorizontal screens 206Hose clamps 228Hot oil rotary unions 58, 147HP-speed blast wheels 61HRC fuse bodies 11, 17HRC fuse fittings 208Hump magnets 152, 253, 261Hydraulic bore grinders 217Hydraulic cylinders 207, 243, 244, 256Hydraulic cylindrical grinders 217Hydraulic dampers 58, 147Hydraulic die loaders 203Hydraulic dock levellers 25Hydraulic dock shelters 25Hydraulic drum lifters 231Hydraulic gear pumps 243

Product Pg No

Hydraulic hand pumps 256Hydraulic hoses 70Hydraulic manual pallet trucks 95Hydraulic pallet pumps 256Hydraulic pallet trucks 231Hydraulic power packs 207Hydraulic power units 231, 243Hydraulic presses 231, 239Hydraulic pumps & valves 243Hydraulic pumps 231, 243Hydraulic punching machines 241Hydraulic rotary unions 58, 147Hydraulic shearing machines 239Hydraulic shock absorbers 58, 147Hydraulic steel working machines 241Hydraulic systems 243Hydraulic valves systems 256Hydraulics cylinders 231Hydraulics 69

IC counterbalanced forklifts 25Identification systems 225Imaging & vision systems 280Impellers 238Inclined tube manometers 235Indexing machines 215Indicators 12Induction seals/wads 227Inductive proximity switches 31Inductive switches 123Inductive 225Industrial automation 141, 205Industrial batteries 19Industrial ceramics 11, 17Industrial connectors 51, 225Industrial control & sensing devices 7Industrial cooling systems 201Industrial cranes 111Industrial electric power distribution systems 18Industrial flooring 257Industrial heating elements 238Industrial motion control equipment 224Industrial overhead doors 25Industrial services 167Industrial shock absorbers 58, 147Industrial shoes 77Inline drum-type magnetic separators 253Inline shaft mounted helical geared motors/reducers 259Instrumentation & controls 25Instrumentation made cables 51, 225Instrumentation 213Insulated conductor systems 244Insulated doors 25Insulated power rails 244Inter-and after-coolers 184Interiors 207Inter-locking doors 25Internal grinding spindles 217Inverter/variable frequency drives 7Investment castings 222, 223, 239, 243Investment destination - Karnataka 236Isolators 87

Jacks 256Jib cranes 20, 119, 124, 149, 211

Product Pg No

PRODUCT INDEX


Jigs 206Joining 179Joystick controllers 199

Keyless transmission elements 224

Laboratory testing rerods 152Large bearings 70Laser markers 63Laser sensors 63Lathe machines 235Lathes 255Lawn mowers 194LED module pilot lights 208LED signal tower lights 32, 34, 36, 38LEDs 31Level controllers for liquids 219Level controllers 7Level gauges 235Level indicators for liquids 219Level switches for liquids 219Level switches for solids 219Level transmitters for liquids 219Lift & conveyor cables 51Lift trucks services 111Lifting hooks 130Lifting machines 216Lifting magnets 261Lifting tackles 242Lifts Front gatefoldLight lifting 111Light-duty castors 223Lighting systems 139Limit switches 31, 32, 34, 36, 38, 208Linear motion vibratory screens 152Linear motion 69Load break switches 31Loaders 117, 129Loading bay equipment 25Lock nuts 106Lock washers 106Long neck pipe ends 238Loom switches 208Loop powered indicators 12Loop powered isolators 12Lorry loaders 129Low dropout regulators 220Low lift pallet trucks 25Lubrication 167

Machined components 220Machines 241Magna rolls 152Magnetic chucks 49Magnetic coolant separators 253Magnetic equipment 206Magnetic floor sweepers 152, 253Magnetic grill & housing 206Magnetic head pulleys 206Magnetic lifters 49Magnetic particle brakes 224Magnetic pulleys 152, 261Magnetic racks 261Magnetic separators 49Magnetic tools 49Maintenance sprays 9Manometers for measuring low pressures 235

Product Pg No

Manual electric stackers 231Manual pallet trucks 25Manual stackers 231Master controllers 228Material handling equipment 20, 95, 102, 124 130, 162, 207, 211MCBs 87MCCBs 19Measuring & monitoring relays 7Measuring sensors 63, 123Mechanical seals 142Mechanical shearing machines 237Mechanical vacuum boosters 158Membrane dryers 218Metal bins 231Metal cutting tools 159Metal fabrication services 210Metal pallets 231Metallic conveyors belts 210Metering solutions & relays 19Meters 19Micro milling beads 11, 17Micro-control switches 208Micro-drives 10Microswitches 32, 34, 36, 38, 208MIG welding machines 224Mill lining blocks 11, 17Milling cutters 137Milling grades 1Mini sensors 123Mini vacuum blasters 233Miniature microswitches 208Mining & drilling equipment 198Mining & lashing chains 200Mining cables 200, 201Mining drilling rigs 198Mining DTH hammers 198Mining gauges 201Mining products 198Mobile control valves 207Modernisations 111Moisture separators 184Monorail trolleys 149Motion controls 7Motor control centres 19Motor protection circuit breakers 31Motorised boom barriers 25Motorised chain pulley blocks 149Motorised vibratory feeders 253Motors 43, 57, 224Moulded cable assemblies 208MS structural steels 210Multi-functional tools 137Multi-level car parking systems 207Multiple joysticks and handle options 199Multi-wire cable trolleys 228MV switchgears 19

Needle roller bearings 70Needle valves 235Network axis controllers 238Non-maintained lights 139Non-return valves 238Nuts 106

Oil cleaning centrifuging machines 257

Product Pg No

Oil seals 242Oil/coolant coolers 201On/off controllers 12Optical-touch switches 63Oscillating tools 79Ovens 187Overband magnetic separators 206, 253Overhead doors 25

Packaging solutions 227Packaging test equipment 227Paint booths 187Paint shop equipment 280Paint shop machines 280Paint sludge removal systems 187Paint spray booths 215Pallet flow conveyors 203Pallet pumps 256Pallet stackers 25Pallets trucks 102Panel air-conditioners 201Paperless recorders 200Passenger lifts 96PBEGL geared motors 57PD blowers 67Pedestrian & rider-operated counter-balanced pallet trucks 95Pedestrian low lift pallet trucks 25Pedestrian pallet stackers 25Peeing machines 151Perimeter protection barriers 93Permanent lifting magnets 206Permanent magnetic chucks 261Permanent magnetic drum pulleys 253Permanent magnetic drum-type separators 261Permanent magnetic lifters 152Photoelectric sensors 7, 63, 105, 225Photoluminescent signages 139Pick & carry cranes 117Pick & move cranes 129PID controllers 12PID temperature controllers 105Pilot lamp holders 208Pilot lights 31Pipe bending equipment 202Pipe bending machines 241Piston compressors 244Planners 255Plano millers 255Plasma cutting machines 206Plate bending machines 241Plate castor wheels 223Plate lifting clamps 242Plate magnets 152, 253, 261Plat-trucks 223PLCs 213, 217Plugs & sockets 31Pneumatic products 260Pneumatic rotary unions 58, 147Pneumatics 69, 70Pole rings 238Polyacetal 239Polyester webbing 242Polyethylene foam 210Polymer products 211Polypropylene 239

Product Pg No

PRODUCT INDEX


Polyurethane components 210Polyurethane 239Portable blasters 215Powder coating booths 187Powder coating guns & equipment 187Powder coating/speedy painting equipment 261Power cables 88Power controllers 105Power magnets 261Power pack units 256Power packs 256Power presses 239Power quality management systems 19Power supply for cranes/hoists 244Power supply stem material handlings 244Power transmission chains & sprockets 127Power transmission products 22Precision components 167Precision fabrication works 206Precision ground bars 241Precision investment castings 241, 242Precision rolling bearings 70Precision switches 31Prefill valves 231Press brake machines 239Press technology 179Pressure blasters 215Pressure boosting 279Pressure gauges 12, 171Pressure sensors 63, 105Pre-treatment systems 280Process controllers 200Process cranes 111Process water treatment 279Product assemblies 220Production line monitoring systems 222Programmable logic controllers 7Programmable power supplies 218Programmable terminals 7Prong magnets 152Protective-conduit systems 51, 225Proximity sensors 7, 32, 34, 36, 38, 63, 105Proximity switches 253PTFE/Teflon 239Pull action clamps 206Pull studs 212Pulleys 214Pulling lifting machines 242Pulling machines 216Pump seals 142Pumps 13, 41, 185, 188, 209, Back coverPunching machines 241Push buttons 25Pushbutton switches 208PVC flap/strip doors 25

Radio remote controls 220, 228Rapid flexible doors 25Rapid roll-up doors 25Ratchet lashing 242Ratchet liver hoists 242RCCBs 87Reach trucks 25Reamers 212Rear cylinder hydraulic press brakes 239Recovery unit & consumables 61

Product Pg No

Re-crystallised alumina tubes 11, 17Rectangular lifting magnets 152Re-drawer & hopper magnets 152Reducers 238Refrigerated dryers 67, 184Relay sockets 208Reliable flooring 257Relief valves 231, 235Re-magnetic rods 152Remanufacture & repair services 167Repair services & retrofitting for CNC machines 205Resistance boxes 228Retractable gates 231Retro-reflectometers 218RFIDs 7Rigging solutions 181Right-angled helical bevel geared motors/reducers 259Right-angled helical worm geared motors/reducers 259Robotic cables 51Robotic shot peening machines 61Robust joystick controllers 199Rock drills & spares 200Roll lifters 231Roller-type magnetic separators 253Roots blowers 185, 188Rope guides 119Rotary cam switches 31Rotary clean flow magnets 152Rotary drill rods 200Rotary drills 79Rotary encoders 105, 225Rotary joints 58, 147Rotary screens 152Rotary screw air compressors 67Rotating electrical connectors 227Rotating unions 58, 147Round endless slings 242Routers 233RTD sensors 12Rubber products 242

Sack trucks 223Safety laser scanners 63Safety light curtains 7Safety protection devices 31Safety relief valves 235Safety shock absorbers 58, 147Safety shoes 77Sawing & cutting machines 79SCADA & DCS implementation 280Scanners 12Scissor lift tables 231Scissor lifts 25Scoops 238Scrap-circular lifting magnet 152Screw jacks 216Sealants 97Seals 70, 167, 242Sectional overhead doors 25Security seals 55Security systems 113, 256Seminar-2010 246Sensor controllers 105

Product Pg No

Sensors 63, 225Serial converter modules 105Servo made bore grinders 217Shearing machines 239Sheet metal machines 241Sheet metal working machines 79Shipyard cranes 111Shoe brakes 227Shop information indoor displays 239Shot blasting hoses 215Shot blasting machines 151, 187Shot blasting rooms 187Showels 238Shrouded DSL systems 244Side lock adaptors 212Sight flow indicators 235Signal isolation transducers 220Signal isolators 12Simplair anodised aluminum piping 67Single axis fingertip joysticks 199Single girder EOT cranes 119Sleeves 106Slew cranes 117Slings 242Slipon flanges 238Slip-ring crane-duty motors 57SMPS systems 208Sockets & switches 25Soft blow hammers 213Solar solutions 258Solder pastes 227Solderless terminals 47, 213Solenoid valves 260Solid carbide drills 159Solid carbide mills 159Solid carbide reamers 159Solid carbide special drills 159Solid carbide special reamers 159Solid edge 53Sorting systems & automation 207Spades 238Special refrigeration equipment 201Special tools 212Specialised grooving & parting tools 137Special-purpose machines 255Spheroidal graphite iron castings 242, 244Spindle nose tooling 137Spiral bevel gearboxes 22Spiral cables 51, 225Spiral cum helical gearboxes 193Spray guns 203, 223Spray painting equipment 265Spur gears 214Stacker pumps 256Stackers 102Stainless steel 217Star lifts 207Static control devices 63Steam engineering 135Steam rotary unions 58, 147Steel balls 217Steel fireproof doors 224Steel mill duty & flameproof cranes 133Steel working machines 241Steels 167Stepping motors 105

Product Pg No

PRODUCT INDEX


Storage systems 102Straight line action clamps 206Suction blasters 215Summit 240Surface grinders 217Surface grinding machines 233Surface preparation 65Surface processing 79Surface treatment 97Suspension magnets 152, 206, 253Sweeping machines 273Switches 87Switchgear products 19Switching power supplies 105Switching relays 7System integrators 213

Tacho/speed/pulse (rate) meters 105Tail lifts 25Team centers 53Technical ceramic 11, 17Tees 238Telescopic doors 25Telescopic truck loading conveyors 162Temp/humidity transducers 105Temperature controllers 7, 200Temperature instruments 171Temperature-resistant cables 51Tensioner nuts 224Terminal blocks 208Terminal strips 208Thermocouples 12Thread whirling tools 1Throttle valves 231Thruster brakes 228Tie mounts 101Timers 7, 12, 105Timing belts 214Timing pulleys drives 214Timing pulleys 214Toggle action clamps 206Toggle presses 206Tooling solutions 19Tools 212Torque motors 22Totalisers 12Toughened glass & round glass 235Tower cranes 117, 129Tower lights 105Track rollers 224Transfer trolleys 149Transmitters 220Trap magnets 253Travel drives 203Travelling machines 20, 211Tri lobe roots blowers 158Triple drum-type magnetic separators 152Trolley castor wheels 223Trolleys 223Truck-dumper body vibrators 152Tube magnets 152Turbine gearboxes 118Turn buckles 242Turned components 220Turning holders 137Twin extruder gearboxes 118Twin lobe roots blowers 158, 188

Product Pg No

Twist drills 212Two stage vacuum pumps 188

Uf exiter vibratory screens 152UHMW-PE products 239Ultra sonic flowmeters 200Ultrasonic sensors 123, 225Unbalanced vibratory motors 152Uni-force exiters 152Unigraphics nx 53Universal joints 237U-tube manometers 235

Vaccine carriers 204Vacuum blasters 215Vacuum booster pumps 185Vacuum cleaners 113Vacuum heat treatment facilities 245Vacuum systems 185Validation of packs 227Valves 235, 238, 260Variable speed polishing machines 205Ventilators 221Vertical handle clamps 206Vertical order pickers 25Vertical turning machines 255Vertical turning-cum-boring machines 255Vibrating equipment 206Vibrating motors 22, 253Vibrating screen machines 253Vibratory bin activators 152Vibratory bowl feeders 219Vibratory bowls 253Vibratory conveyors 152Vibratory feeders 152Vibratory fluidised bed dryers 152Vibratory furnace chargers 152Vibratory grizzly feeders 152Vibratory knockout tables 152Vibratory motors 206Vibratory spiral elevators 152Vibratory tables 152Vices 203, 223Vision sensors 7

Wall top security 93Washers 106, 238Waste-water treatment 279Water analysers/combustible & toxic gas detectors 213Water chillers 201Water faucet & tap parts 11, 17Water filtration 65Water purifiers 113Water ring vacuum pumps 188Water rotary unions 58, 147Water treatment 279Water-cooled reciprocating compressors 67Waterjet cutting machines 65Wear parts 137Wearing sleeves 130Welding equipment 203, 223Wet & dry vacuum cleaners 273Wet drum-type magnetic separators 152Wheel assemblies 214Wheel barrows 223Wheel bearing greases 237

Product Pg No

Winches 96, 133, 146, 216Wire connectors 47, 213Wire drawing & forging oils 222Wire rope clamps 242Wire rope drums 214Wire rope hoists 149, 245Wire rope slings 242Wire ropes 242Wires 88, 257Wiring accessories 101Wiring ducts 258Withdrawal sleeves 106Worm gear speed reducers 22Worm gears 193, 214

Y-type strainers 235, 238

Zirconia polycrystal ceramics 11, 17

Product Pg No

Air-operated rail cutters 254Apparel & footwear 255CAD drawings 255CNC vertical lathes 254Cranes 48Drives 21Elevators 48Gear reducers 64Gravity separators 257Grinding belts 254Hoists 48Hot-air components 258Hydraulic dock levellers 205Hydrocarbon dew-point analysers 256Image sensor processing solutions 254Industrial products 255Integrated planning tools 254IS interfaces remote 199Leak detection relays 260Mineral insulated cables 260Motion controllers 255Multi-colour LED scoreboard 21Multi-function control platforms 257Non-contact infrared pyrometers 254Operational amplifiers 255Operator interface series 21PID controllers 21PLCs 21Portable cable testers 261Programmable logic controllers 21Reciprocators 260Screw compressors 24Servo rotary tables 258Switches 199Timers/counters & analysers 256Transmitters 199Truck tailgate lifts 205Welding helmets 258


ADVERTISERS’ LIST


Our consistent advertisers

Acme Air Equipment Co Pvt Ltd 158

T: +91-79-25831985

E: [email protected]

W: www.airequipments.com

Acropolis Engineering Ltd 220

T: +91-22-26441180


W: www.acropoliscranes.com

Action Construction Equipments Ltd 129

T: +91-11-40549900


W: www.ace-cranes.com

Advanced Micro Services (P) Ltd. 205

T: +91-80- 41624368


W: www.amsindia.net

Allied Electronics Corporation 8

T: +91-22-26616619


W: www.aecconnectors.com

Amsak Cranes Private Limited 146

T: +91-44-26273486


W: www.amsakcranes.com

Atlas Copco (India) Ltd 45

T: +91-20-30722222


W: www.atlascopco.com

Autonics Automation India Pvt Ltd 105

T: +91-22-27814305


W: www.autonics.com

Ballkings 217

T: +91-161-2534501


Bhagirath Heavy Transmission 214

T: +91-11-32222661


Bhardwaj Cranes & Elevators 96

T: +91-161-2847081


W: www.bhardwajcranes.com

Boge Compressed Air System 52

T: +91-44-43009610


W: www.boge.in

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

Bonfiglioli Transmissions (Pvt) Ltd 23

T: +91-44-24781035


W: www.bonfiglioliindia.com

Bosch Rexroth (India) Limited 69

W: www.boschrexroth.co.in

Buildcon Consultants Pvt Ltd 257

T: +91-141-4012629


W: www.buildcon.in

C&S Electric Ltd. 87

T: +91-11-3088-7520-29


W: www.cselectric.co.in

CBS Technologies Pvt Ltd 257

T: +91-11-22613408


W: www.cbsenergy.com

Cenlub Systems 78

T: +91-129-4113771


W: www.cenlub.com

Ceratizit India Pvt Ltd 137

T: +91-33-24947146


W: www.ceratizit.com

Chamunda Equipments 206

T: +91-79-27522437


W: www.chamundaequip.com

Chemical & Industrial Engineers 235

T: +91-22-28822740

Cheng Day Machinery Works Co., Ltd 48

T: +886-4-2688-1581


W: www.chengday.com.tw

Classic Polymers & Resins 239

T: +91-22-24465251


W: www.classicpolymers.com

CM Hydro Systems Pvt Ltd 231

T: +91-40-23222287


W: www.cmhydraulics.com


Coatec India 280

T: +91-172-5063436


W: www.coatecindia.com

Confederation Of Indian Industry 246

T: +91-22-24931790

Connectwell Industries Pvt Ltd 26

T: +91-251-2870636


W: www.connectwell.com

Cosmos Impex (India) Pvt. Ltd. 160; 172

T: +91-265-3927000


W: www.cosmos.in

Crane Control Eqpts 228

T: +91-11-26388401


W: www.cranecontrolequipments.com

CRI Pumps (Pvt) Ltd 13

T: +91-422-3260011


W: www.cripumps.com

Danfoss Indus Pvt Ltd 10

T: +91-44-66501555


W: www.danfoss.com

Darling Pumps Pvt Ltd 209

T: +91-731-2720558


W: www.darlingpump.com

Delair India Pvt Ltd 201

T: +91-124-4091111


W: www.delair.com

Digital Marketing Systems Pvt Ltd 213

T: +91-731-3046800


W: www.digitalcontrols.org

Dongguan Dacheng Machinery Make Co., Ltd. 205

T: +86-769-8321-7777


W: www.cn-dc.com

Durga Bearings Pvt Ltd 169

T: +91-44-26440414


W: www.durgabrgs.com


ADVERTISERS’ LIST



Engineering Expo 177; 195T: +91-09819430607E: [email protected]: www.engg-expo.com

Entrepreneur 263T: +91-9819264108E: [email protected]: www.entrepreneurindia.in

Escorts Construction Equipment Ltd 117T: +91-129-2306582E: [email protected]: www.ecel.com

Essen Deinki 208T: +91-172-4600600E: [email protected]: www.essendeinki.com

Eureka Forbes Limited 113T: +91-80-30251500E: [email protected]: www.eurekaforbes.com

Everest Blowers 185T: +91-11-45457777E: [email protected]: www.everestblowers.com

Fabtec India 2011 109T: +91-422-2221582E: [email protected]: www.fabtecindia.codissia.com

Fein Power Tools India Pvt. Ltd. 79T: +91-44-43578680E: [email protected]: www.fein.in

Fenzgard India Pvt Ltd 93T: +91-422-2646178E: [email protected]: www.fenzgard.com

Finechrome Shafts Pvt Ltd 241T: +91-22-29203647E: [email protected]

Fontus Water Ltd 279T: +91-11-43100536E: [email protected]: www.fontuswater.com

Forbes Marshall Pvt Ltd 135T: +91-20-27145595E: [email protected]: www.forbesmarshall.com

Forging Machinery Manufacturing Co 16T: +91-161-5011755E: [email protected]: www.nkhhammers.com

EA Water Pvt Ltd 234

T: +91-11-43100519


W: www.eawater.com/expo

East Coast Magnets (P) Ltd. 49

T: +91-40-23098262


W: www.sardamagnets.com

East India Bearing Co. (P) Ltd. 70

T: +91-22-40939200


W: www.eibc.in

Eddycranes Engineers Pvt Ltd 133

T: +91-22-23522710


W: www.eddycranes.com

EFY Enterprises Pvt Ltd 232

T: +91-11-26810601


W: www.efyexpo.com

Elecon Engineering Company Limited 193

T: +91-2692-236469


W: www.elecon.com

Electro Flux Equipments Pvt. Ltd. 206

T: +91-44-26243317


W: www.electrofluxequipmentspvtltd.com

Electro Magnetic Indus 152

T: +91-265-3241361


W: www.electromagneticindia.com

Electronica Hitech Engineering Pvt Ltd 99

T: +91-20-30435400


W: www.electronicahitech.com

Elitech Machine Tools 217

T: +91-2752-228220


W: www.teksolgrinders.com

Emco Dynatorq Pvt Ltd 224

T: +91-22-25405490


W: www.emco-dynatorq.in

Empire Cable Industries Pvt Ltd 88

T: +91-11-23874632


W: www.empirecables.com

Advertisers’ Name & Contact Details Pg No Advertisers’ Name & Contact Details Pg No

G A Industries 227T: +91-79-25895577E: [email protected]: www.gaindustries.net

G L Brothers 223T: +91-22-66047000E: [email protected]: www.pilotindia.com

G W Precision Tools India Pvt Ltd 159T: +91-80-40431252E: [email protected]: www.gwindia.in

Gandhi Automations Pvt Ltd 25T: +91-22-66720200E: [email protected]: www.geapl.co.in

General Elek Mek Systems 162T: +91-120-2535064E: [email protected]

Global Sleeve Solutions 106T: +91-09501040477E: [email protected]: www.globalsleeves.com

Grundfos Pumps India Pvt Ltd 284T: +91-44-24966800E: [email protected]: www.grundfos.in

H G Shah & Co 214T: +91-79-25621431E: [email protected]: www.timingpulley.in

Hafa Hoists Pvt Ltd 119T: +91-22-27694837 / 838E: [email protected]: www.hafahoists.com

Hannover Fairs India Pvt Ltd 104T: +91-22-40050683E: [email protected] W: www.mda-india.com

Havells India Ltd. 43T: +1800-11-0303;011-41660303E: [email protected]: www.havells.com

Heattrans Equipments Pvt.Ltd. 220T: +91-79-25840105E: [email protected]: www.heattrans.com

Henkel Adhesives Technologies India Ltd 97T: +91-80-25357771E: [email protected]: www.loctite.com


ADVERTISERS’ LIST



Hensel Electric India Pvt. Ltd. 18

T: +91-44-24541669


W: www.hensel-electric.de

Hi-Fab Engineers Pvt Ltd 142

T: +91-22-28879351


W: www.hi-fab.com

Hitachi India Trading Pvt Ltd 163

T: +91-11-40605252


W: www.hitachi.com.sg

Hitech Robotic Systemz 226

T: +91-124-4715100


W: www.hitechroboticsystemz.com

Honda Siel Power Products Ltd 194

T: +91-120-234 1050-59


W: www.hondasielpower.com/

Igus India Pvt Ltd 14

T: +91-80-39127800


W: www.igus.in

Ingersoll Rand (India) Ltd 67

T: +91-79-22820123


W: www.ingersollrand.co.in

ITL Industries 235

T: +91-731-2722372


W: www.itl.co.in

Jaibalaji Controlgears Pvt. Ltd., 32; 34; 36; 38

T: +91-44-26251279


W: www.jaibalaji.firm.in

Jay Equipment & Systems Pvt Ltd 231

T: +91-250-2481806


W: www.jayequipment.com

Jayashree Electron Pvt Ltd 253

T: +91-20-27121295


W: www.jayashree.co.in

Jaykrishna Magnetics Pvt Ltd 253

T: +91-79-22970452


W: www.magneticequipments.com


Jindal Aluminium 145T: +91-80-23715555E: [email protected]: www.jindalalumium.com

Jrew Engineering Ltd 130T: +91-129-4132844E: [email protected]: www.jrew.in

Jyoti Ceramic Industries Pvt Ltd 11; 17T: +91-253-2350120/338E: [email protected]: www.jyoticeramic.com

Jyoti Cnc Automation 281T: +91-2827-287081E: [email protected]: www.jyoti.co.in

Jytra Engineering Services 53T: +91-40-66663747 / 9246553857 E: [email protected]: www.jytra.com

Kanefusa India Pvt Ltd 204T: +91-124-4208440E: [email protected]: http://www.kanefusa.net

Kapasi Fastners / Inc 219T: +91-80-22279217E: [email protected]

Klipco Pvt Ltd 228T: +91-22-28684221E: [email protected]: www.klipcohoseclamps.com

Knowell International Pvt Ltd 221T: +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 181T: +91-22-67859999E: [email protected]: www.slingset.com

Kushal Udyog Manufacturers & Engineers 215T: +91-291-2720072E: [email protected]: www.kushaludhyog.com

Lapp India Pvt Ltd 51T: +91-80-7826000E: [email protected]: www.lappgroup.com


Larsen & Toubro Ltd 19

T: +91-22-67525656


W: www.larsentoubro.com

Liberty Shoes Ltd 77

T: +1748-251120


W: www.libertyshoes.com

Lokpal Industries 102

T: +91-120-3065372


W: www.lokpal.com

Lubi Electronics 63

T: +91-79-39845300


W: www.lubielectronics.com

M+V Marketing - Leuze Electronic 123

T: +91-80-40854444


W: www.leuze.in

Maco Corporation India Pvt. Ltd 58; 147

T: +91-33-40224129


W: www.macocorporation.com.com

Macro Tech Equipment Pvt Ltd 95

T: +91-33-24666261


W: www.macrotechcal.com

Magtorq Private Limited 165

T: +4344-276897


W: www.magtorq.org

Manmachine (India) Private Limited 273

T: +91-120-2422727


W: www.manmachine.in

Mather And Platt Pumps Ltd 6

T: +91-20-27442100


W: www.matherplatt.com

Mecshot Blasting Equipments P Ltd 61

T: +91-291-2740609


W: www.mecshot.com

Millenium Instruments Ltd 171

T: +91-11-22456571


W: www.miepl.com


ADVERTISERS’ LIST



Misumi India Pvt Ltd 282T: +91-20-66470000E: [email protected]: www.misumi.co.in

Mitsubishi Electric Asia Pte. Ltd. 141T: +91-124-4630300E: [email protected]: www.messung.com

Nanfang Pumps India Pvt Ltd 41T: +91-22-25425540E: [email protected]: www.nanfangpumps.com

NI Systems India Pvt Ltd 29T: +91-80-41190000E: [email protected]: www.ni.com

NIA Controls 215T: +91-22-26736864E: [email protected]: www.tscindia.com

Ningbo Xinda Screw Compressor Co., Ltd 24T: +86-574-8833-6868E: [email protected]: www.augustcompressor.com

NMT Group 224T: +91-79-22821527E: [email protected]: www.nmtgindia.com

Novoflex Mktg Pvt Ltd 101T: +91-33-22260733E: [email protected]: www.novoflexgroup.com

Nu-Teck Engineering Co. Pvt. Ltd. 118T: +91-20-27120644E: [email protected]: www.nuteckindia.com

Oil Seals Mfg Co Pvt Ltd 242T: +91-22-22047943E: [email protected]

Omron Automation Pvt. Ltd. 7T: +91-80-40726400E: [email protected]: www.omron-ap.com

Onyx Equipments (India) Pvt Ltd 237T: +91-20-65106213E: [email protected]: www.onyxindia.in

P.P.I. Pumps Pvt Ltd. 188T: +91-79-25832273E: [email protected]: www.ppipumps.com


Paras Enterprises 233T: +91-11-25820571E: [email protected]: www.parasenterprises.com

Pathak Machines International 241T: +91-161-2510401E: [email protected]: www.pathakeuromachines.com

Pepperl+Fuchs(India) Pvt Ltd. 225T: +91-80-28378030E: [email protected]: www.pepperl-fuchs.com

Pidilite Industries Ltd 9T: +91-22-33087613E: [email protected]: www.pidilite.com

Pilot Pneumatics Pvt Ltd 203T: +91-22-66047000E: [email protected]: www.pilotindia.com

Pin Hong Technology Co., Ltd 64T: +886-2-2978-7348E: [email protected]: http://www.pht-gear.com.tw

Pioneer Cranes & Elevators Pvt Ltd 2T: +91-161-2491935E: [email protected]: www.pioneer-cranes.com

Power Build Ltd 259T: +91-2692-231070E: [email protected]: www.pbl.co.in

Premier Engineering Technics Pvt Ltd 207T: +91-22-26852233E: [email protected]: www.premiertechnics.com

Premium Transmission Ltd 75T: +91-20-27488886W: www.premiumtransmission.com

Prism Surface Coatings (P) Ltd 187T: +91-08110-417999E: [email protected]: www.prismsurface.com

Procon Technologies Pvt Ltd 200T: +91-79-27492566E: [email protected]: www.procon.co.in

Progressive Engineering 227T: +91-22-32944289E: [email protected]: www.progressiveengineers.net


Prolite Autoglo Limited 139

T: +91-22-26763090


W: www.prolite.in

Pull-Mac Mech & Structural Works 211

T: +91-120-2788260


W: www.pullmaccranes.com

Puriflair India Pvt. Ltd. 184

T: +91-265-6567666


W: www.puriflair.com

Radix Electro Systems Pvt Ltd 12

T: +91-22-42537784


W: www.radix.com

Rajindra Machines (P) Ltd 255

T: +91-1871-242763


W: www.rajindra.net

Red Lion Controls 21

T: +91-09879540503

W: www.redlion.net

Regulateurs Georgin 199

T: +33-01-46126000


W: www.georgin.com

Reid Supply Company 255

W: www.reidsupply.com

Reva Industries Ltd 20

T: +91-129-4185400


W: www.revacranes.com

Rexello Castors Pvt Ltd 223

T: +91-22-4091777


W: www.rexellocastors.com

Rittal India Pvt Ltd - Eplan Division 211

T: +91-22-39527200


W: www.eplan.in

Robin Precision Products Pvt Ltd. 212

T: +91-2827-287631


W: www.bloodtools.com

Ruby International 216

T: +91-120-2702193


W: www.rubyinternational.com


ADVERTISERS’ LIST



S&T Engineers 15T: +91-422-2590810E: [email protected]: www.stengineers.com

Safcon Security Seal 55T: +91-33-22295486E: [email protected]: www.safconsecurityseal.com

Safex Equipment Pvt Ltd 245T: +91-79-25842836E: [email protected]: www.safexcranes.com

Sandvik Coromant India 1T: +91-20-27104725E: [email protected]: www.sandvik.coromant.com/in

Search - Investment Destination- Karnataka 236T: +91-22-30245000E: [email protected]

Shailesh Sales Corporation 239T: +91-281-2461102E: [email protected]: www.shaileshmachines.com

Shilpa International (Impex) Pvt Lt 199T: +91-40-27849020E: [email protected]: www.shilpagroup.com/si

Shree Prayag Air Controls (P) Ltd 260T: +91-120-4733333E: [email protected]: www.spacpneumatic.com

Shree Saikrupa Hydro Marketing 243T: +91-79-22800836E: [email protected]: www.bosspumps.in

Shridhan Automation Pvt Ltd 219T: +91-80-28431847E: [email protected]: www.shridhan.com

Simtech India 238T: +91-79-22200198E: [email protected]: www.parthvalves.com

SL Leadership Summit 240T: +91-22-30245000E: [email protected]

Sonal Magnetics 261T: +91-79-22872349E: [email protected]: www.sonalmagnetics.com


Sreelakshmi Traders 221T: +91-44-24343343E: [email protected]: www.sreelakshmitraders.com

Statfield Equipments Pvt. Ltd. 261T: +91-20-22922180-82E: [email protected]: www.statfieldequipments.com

Sumitron Exports Pvt Ltd. 47; 213T: +91-11-41410631E: [email protected]: www.sumitron.com

Surface International 151T: +91-09413329749E: [email protected]: www.surfaceint.com

Susheel Engineering Corporation 244T: +91-22-25007976E: [email protected]

Tandem Hydraulics Pvt. Ltd. 207T: +91-120-4159611E: [email protected]: www.tandemhydraulics.com

Techno Industries 149T: +91-79-25830742E: [email protected]: www.technoindustries.com

Teco Werkzeugmaschinen Gmbh Co.Kg 189T: +49 (0) 2103 3682-1E: [email protected]

Teknic 31T: +91-22-26592392 / 94E: [email protected]: www.teknic.co.in

The Indian Electric Co 57T: +91-20-24474303E: [email protected]: www.indianelectric.com

Theeta Electricals Pvt Ltd 238T: +91-124-4387400E: [email protected]: www.theeta.com

TIDC India 127T: +91-44-42235507E: [email protected]: www.tidcindia.in

Timken Engineering India Pvt Ltd 167T: +91-80-40053100E: [email protected]: www.timken.com


Tox Pressotehnik India Pvt Ltd 179

T: +91-20-66538300


W: www.tox-de.com

TPG Motors & Drives (India) Pvt Ltd 22

T: +91-44-23634199


W: www.tpg-tw.com

Trident Precision International 203

T: +91-11-41425326


W: www.trident-precision.com

Trident Products Pvt Ltd 244

T: +91-124-4300626


Trinity Touch Pvt Tld 258

T: +91-11-30895900


W: www.trinitytouch.com

Utkal Engineers 242

T: +91-79-40065598


V R Coating 265

T: +91-20-30781022


W: www.vrcoatings.com

V.V. Mineral 65

T: +91-4637-272647


W: www.vvmineral.com

Vantage Integrated Security 256

T: +91-120-4632200


W: www.vantagesecurity.com

Venus Engineers 124

T: +91-11-32222661


W: www.venusengineers.com

Werner Finley Pvt Ltd 201

T: +91-80-23289889


W: www.wernerfinley.com

Zenith Hydromatic 256

T: +91-79-22812945


W: www.hydraulicsystemsindia.com


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.

284

Search - October 2010

Documents

Transcript of Search - October 2010