pg no 8 IMTMA appoints P Ramadas as new President Indian Machine Tool Manufacturers’ Association (IMTMA) elected P. Ramadas, Managing Director, Ace Manufacturing Systems Ltd as its President at its 71st Annual General Meeting (AGM) held at Bangalore International Exhibition Centre (BIEC) on 6th September in Bengaluru. Indradev Babu, Managing Director, UCAM Private Ltd has been elected as the Vice President of the Association. Ramadas graduated as a Mechanical Engineer from Karnataka Regional Engineering College, Surathkal and got his M.Tech in Machine Tools from Indian Institute of Technology (IIT) - Madras, Chennai in 1970. He later joined Hindustan Machine Tools as a Design Engineer and developed indigenous machine tools. Ramadas was part of the design team which developed the first NC Lathe in 1972-73 and led the development of the first CNC Grinding machine later. Ramadas has worked in MMC, Widia and Mysore Kirloskar. He later joined hands with the promoters of Ace Designers Ltd and started Ace Manufacturing Systems Ltd in 1994 to produce machining centres. IMTMA is focused on creating an environment conducive for development of machine tool industry in India. To achieve this, IMTMA partners with industry and the Government of India as well as state governments through various advisory and consultative processes. IMTMA is the single point of contact for the Indian machine tool industry in the country. ------------------------------------------------------------------------------- DMG MORI, Dürr, Software AG, ZEISS, ASM PT form JV for Industry 4.0 Through the joint venture ADAMOS (ADAptive Manufacturing Open Solutions), DMG MORI, Dürr, Software AG and ZEISS as well as ASM PT are establishing a strategic alliance for the future topics of Industry 4.0 and the Industrial Internet of Things (IIoT). Germany’s first alliance of well-known industrial and software companies wants to establish ADAMOS as global standard for the industry and attract other machine builders to become partners. ADAMOS is customised to meet the specific needs of machine and plant builders and their customers: The open IIoT platform ADAMOS is non-proprietary and brings together the most up-to-date IT technology and industry knowledge. It enables engineering companies to offer tried and tested solutions for digitally networked production to their customers with little effort. Machine tool builders as well as their suppliers and customers will benefit from this as ADAMOS is a platform service that offers data autonomy and access to leading software solutions. The jointly developed ADAMOS platform will be available worldwide as of 1st October. Christian Thönes, Chief Executive Officer of DMG MORI AKTIENGESELLSCHAFT said, “Regarding digitisation the machine and plant building industry has to set its own standards and drive development. This can only work with strong partners. That is why we are offering an open network with ADAMOS together with leading machine building, production and software/IT know-how – from machine builders for machine builders, their suppliers and customers.” Ralf W. Dieter, Chief Executive Officer of Dürr AG comments, “As a machine builder we know our customers‘requirements and know what is important. In the ADAMOS App Factory we bring industry knowledge for intuitively operated applications together with the design of digital marketplaces. The ADAMOS App Factory is a cooperation between machine builders and software companies that is closely linked with the partners.” Karl-Heinz Streibich, Chief Executive Officer of Software AG said, “Software AG’s technology leadership and digital expertise is based on a total investment of more than one billion euros. Our industry neutrality and global presence combined with the know-how of leading machine and plant builders worldwide form the foundation of ADAMOS.” ---------------------------------------------------------------------------------------------------------------------------------------------------- pg no 10 Leoni expands cable manufacturing facility at Chakan Leoni, an European provider of cables and cable systems to the automotive sector and other industries, has enhanced its location at Chakan near Pune. The company inaugurated an electron beam accelerator, which allows to provide high performance cables to customers from various industries such as railway or solar. Bruno Fankhauser, member of Leoni AG’s Board of Directors with responsibility for the Wire & Cable Solutions Division said, “India is an important country for the realisation of the company’s globalisation strategy. The expansion at Chakan will strengthen our leading position in the country and enable it to support India’s economic development as well as generate employment opportunities both for the high skilled and well trained workforce in the Pune region.” Leoni has invested more than EUR 10 million into the expansion of its Chakan location. Now, the combined production area has increased to more than 20,000 square metres and a capacity to manufacture 80,000 kilometres per year of electron beam cross linked cables, which ensure a higher degree of safety, superior performance and greater efficiency. In the e-beam process, Leoni treats its cables with extremely accelerated electrons, thus cross-linking their chemical structure. As a consequence, the cables obtain the properties of comparatively more expensive, usually more difficult to process high performance products. The e-beam process makes cables, for example, more dimensionally stable when subjected to heat, more resistant to chemicals, solvents and temperature fluctuation as well as harder and more resistant to abrasion. Pushpendra Singh, Managing Director of Leoni Cable Solutions India Pvt Ltd comments, “This is the next phase of our evolution in India. We began to develop this market in 2010 with an engineering office and a manufacturing facility for automotive wiring systems. Since the opening of the Chakan cable plant in 2013, we also have a strong foundation in the country with regard to special cables for dynamic industries. Leoni’s new commitment will help us to further innovate and create beneficial solutions for India’s economy. The Chakan facility will drive synergies and economies of scale both for our domestic operations as well as exports.” -------------------------------------------------------------------------------------------------------- HARTING bags ‘Railsponsible’ award from European Rail Industry HARTING Technology Group receives Railsponsible CSR Award in Berlin. “The company has been committed to sustainability for over 20 years and is a pioneering force in the field of environmental management. We can rely on HARTING products and services – not least because of their externally audited CSR Management System,” is how Uwe Günther - CPO Deutsche Bahn AG and Chairman of Railsponsible - described the Technology Group’s achievements at the award ceremony. In his own speech, Deutsche Bahn Chairman Dr Richard Lutz highlighted the importance of a sustainable supply chain to Deutsche Bahn and congratulated HARTING on its achievement. In his acceptance speech, HARTING Charmain of the Board Philip Harting remembered his grandfather Wilhelm Harting, who - as a railway engineer himself - would certainly have been very proud of the award. The Charmain of the Board stressed that the Railsponsible CSR Award came as a source of both duty and encouragement. “HARTING is the ideal partner for quality and sustainability”, said Philip Harting. The selection was made by a cross-disciplinary jury from the European rail vehicle industry sustainability initiative - Railsponsible. The initiative set itself the goal of implementing minimum social and ecological standards and fair competition practices at all stages of the supply chain. Railsponsible members use a common tool to assess their suppliers’ sustainability performance. The Transportation market is one of most important markets as far as the HARTING Technology Group is concerned. At this year’s 5th Railway Forum Berlin, the Technology Group is exhibiting digitalisation solutions for the rail sector, such as RFID-based wireless temperature monitoring. HARTING supplies connection technology for the transmission of data, power and signals. Today’s rail vehicles are modular - as a solution to the huge time and economic pressures on operators and manufacturers. HARTING is pursuing the trend with connectors that enable modular construction. Whether it’s braking, train protection, monitoring and passenger information systems or robust drive links – HARTING offers the right connectivity solution for every scenario. ------------------------------------------------------------------------------------------------------------------------------------------------------------------------ pg no 12-16 Milling Technology: 5 New Trends Highlighting the most significant developments in milling technology. The development of machining technologies and practices over recent years has reached to a level which were difficult to manufacture with required tolerance and quality, can now be attained by much more ubiquitous equipment with added value. A broader picture of change exists outside of the field of machining as manufacturing companies demonstrate a trend to concentrate on core competencies and retain their internal capabilities in design, product assembly and niche skills. However, Vikas Taneja, Vice President – Marketing at Jyoti CNC Automation Ltd observes, “The sector is underpinned by mature, robust technologies that through a more general appreciation of their capabilities can bring benefits to users, delivering bottom-line benefits in productivity, quality and market response.” He continues: “There are mainly three areas which have made revolutionary movement in milling technologies – Digital evolution, Bridging CAD/CAM gap and Additive Manufacturing. Due to development in these areas standalone machining has been moved to automation and robotic aligned manufacturing.” Make It Easy Machining of much complex component with desired quality outcome can be possible with software incorporations. “Additive Manufacturing has moved to part prototyping and low-volume production to making mass manufacturing and it is going to shape up future of the existing technology with a different concept of designing and manufacturing,” said Taneja. He adds, “Capabilities of extending 3-axis to 5-axis machining in milling technology has made it most versatile way of metal cutting process with mass and precision.” High productivity milling options “Milling developments are primarily moving in two directions. One direction is towards very high speeds and low chip cross-section. More the case for high-speed machining centres with 30 to 40,000 rpm. The second direction is towards high feeds and depths of cut at moderate cutting speeds to increase metal removal rates,” opines Naveen Vastrad, Senior Manager – Marketing (Products), TaeguTec India. He informs, “TaeguTec is concurrently working in both directions to offer optimum solutions to customers, based on application and machine capabilities. In this connection, we have an entire range of high productivity milling options.” For instance, TaeguTec’s chip splitter inserts, which reduce cutting forces during heavy milling, while achieving high table feed without the vibrations and the noise. The insert’s helical cutting edge geometry enables double feed rates and improved chip evacuation with minimal heat generation. These chip splitter inserts are an economical option and development over the conventional and expensive vibration dampening cutters, claims Vastrad. Traditionally, when vibrations and unfavourable conditions were encountered (long reach, unstable fixture, chip removal issues, machine power limitations), anti-vibration milling cutters were considered, but chip splitters are easily an optimum and convenient alternative. Increasing demand for fast metal removal solutions In the last few years, there have been many exciting developments in high-speed machining relative to machining centres and controls, tooling and CAD/CAM systems. Today, according to Vastrad, the machining centre market constitutes at least 60 per cent of the total market, primarily used for milling and drilling operations in small, medium and large batch production. He believes, “Tools and designs which significantly increase the metal removal rates (MRR), particularly in roughing operations, with shorter cycle times, fewer tool changes and inventories can go a long way in ensuring bottom line growth for customers.” Among TaeguTec’s fast metal removal solutions are the very successful and popular Chase Feed and Chase2Feed Families which make possible high-productivity high-feed milling: maximum feed or tooth up to 5 mm at 1 mmDOC. One cutter, many choices According to Gautam K. Ahuja, Managing Director, Dormer Tools India Pvt Ltd, the most significant milling technology developed this year, in Dormer Pramet is one of the most versatile cutters in the world – “One Cutter, Many Choices”. A wide range of insert shapes can be used in operations from roughing to finishing – octagonal, round and square inserts can be mounted on the same cutter, depending on application. The new SOD05 cutter, developed under the Pramet brand, reduces tool change-over time and inventory costs with its universal pocket capable of carrying octagonal (OD), round (RD), and square (SD) inserts. The OD insert has eight cutting edges and low cutting forces, promoting an economical option for face milling, while the RD inserts are suitable for high feed roughing, shallow profiling and ramping. Its SD inserts have four cutting edges and offers a 90-degree option for square shoulder milling, providing high depths of cut up to 10mm. All types of inserts have the same radial and axial positions of edges – allowing for easier CNC programming and manual operations. “The user-friendly cutter, available in a wide range of diameters from 32 – 125 mm, can perform face milling, shoulder milling, slotting, plunging and ramping in steel, stainless steel, cast iron and non-ferrous materials,” Ahuja informs. Highly rigid clamping tools “The recent development of HELLER by introducing the 160 mm diameter face clamping with XPC spindle unit makes the clamping of tool very rigid by which we can go with very high feeds,” said Mahesh Tyagi, Managing Director at HELLER India Pvt Ltd. Latest development is to use new cutter bodies that offer better heat resistance with differential pitch for vibration-prone applications. The light-cutting insert geometries and high-performance grades of this cutter provide secure milling in all material groups. “At the end the development of the new milling technology directly relates with the spindle and the XPC unit is the best example,” he adds. A success story Automated precision milling in the medical technology sector Fetzer Medical GmbH & C. KG is a medium-sized company based in Tuttlingen/Germany, which was established in 2008 by Peter Fetzer. In order to build further on the family business’ long-standing tradition in the development and manufacture of surgical instruments and medical devices, Peter Fetzer took the decision. With the aim of operating exclusively as an independent OEM, establishing all the necessary human and technical resources to that end, Fetzer Medical launched an extensive capital investment, qualification and certification programme, beginning its five-axis machining in 2008. This was rolled out with the aim of offering a flexible and swift approach to delivery for varying product and batch sizes. All relevant materials, including titanium, are machined and Fetzer Medical supplies its customers with ready-to-use products - from prototypes/individual parts to large production runs and complete systems. The business currently employs 45 highly-qualified employees and state-of-the-art equipment. Roughly 75 per cent of the work involves complex milling/drilling operations which have been performed at Fetzer Medical from day one using high-performance five-axis machining centres from Maschinenfabrik Berthold Hermle AG in Gosheim. From manual single part fabrication to industrial production Fetzer Medical production manager Bernd Zepf comments on the choice of Hermle machines: “The Hermle machines featuring a robust gantry design, the machine concept of three-axis in the tool and two-axis in the workpiece, which results in optimum tool accuracy, and last but not least excellent accessibility are ideal for five-axis complete machining in one or two setups. Further, our employees, including myself, had already had very good experience in the past with Hermle machines: their control and programming, their comparatively simple operator control, including responsive and highly competent service backup. That experience helped us to immediately get started with five-axis technology, which we launched in 2008 by acquiring a Hermle C 40 U high-performance five-axis CNC machining centre.” As the business flourished, capacity had to be increased, and a number of Hermle machining centres – some of them highly automated – were added. Fetzer Medical today runs five machining centres assuring the prompt execution of its OEM production orders. While the first purchased five-axis C 40 U machining centre was initially used to cement the business’ manufacturing expertise and add valuable additional know-how, the machine is now primarily used for pre-fabrication and for machining prototypes, samples and short runs. Additionally, two further C 22 U high-performance five-axis machining centres are equipped with 11-pallet changers/magazines of type PW 150, and are used for the automated flexible production of a wide range of components in runs of up to 300 pieces. Validated and certified: Production processes on Hermle machining centres A further automation level includes a C 12 U high-performance five-axis machining centre combined with an RS 05 robot cell for the production of modular designed scissors. A C 800 V CNC machining centre was added to the range of Hermle machines to provide flexible and universal operation in pre-production, including making reference surfaces and jigs and fixtures. Since all the installed Hermle machining centres are essentially based on the same concept and on the same control and operating philosophy, operators are quickly familiarised with running the various machines, and staff confidence and acceptance of the machinery is enhanced as a result. This is definitely advantageous in terms of the productivity of the machines which are run basically in single-shift mode under operator control. Since – according to specifications of EU and US institutions – production and quality assurance equipment needs to be fully validated and certified in the surgical and medical technology sector, it is a major advantage in terms of US certification that many US medical technology firms use already validated Hermle machining centres for their production lines. This also ensures simpler and faster validation cycles for Fetzer Medical, thus resulting in a faster time-to-market for the company’s customers. ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 18-20 How to optimise milling operations? An in-depth analysis on how to achieve best performance and economy in milling operations. Rigidity of structure is most essential Shorter product cycles and steadily increasing quality requirements combined with equally important demand for economically viable machining is permanently present in the field of milling technology. “In metal cutting process, the rigidity of structure is most essential to achieve demanding performance, stable and longer work life of machine with retained accuracy and quick reacting accessories,” opines Vikas Taneja, Vice President – Marketing, Jyoti CNC Automation Ltd, Rajkot. The key of success in milling is as less as vibration on tool and spindle. “We need to have very rigid clamping on spindle as well as rigid fixture which sustain the load of cutting,” reiterates Mahesh Tyagi, Managing Director HELLER India Pvt Ltd. Nowadays, tools which are running on very high cutting speeds demand a strong base. So the key of success is rigid system. Tyagi acknowledges, “If you have vibration in system then inserts will have no life and whole economics will go down. You can select various grades and coatings from tooling suppliers. Spindle should looks like this, its Heller spindle system.” Success lies in selecting proper tools Economic factors are attained by bringing down non-cutting time with rapid active accessories such as rapid movement of axis, fast Automatic Tool Changer (ATC), quick indexing palletisation and automated work handling. High speed and power of spindle with rapid acceleration or deceleration assures desired performance under demanding cutting parameters. According to Taneja, “Proper cutting tool selection considering metallurgy, process parameters and cutting condition would be added advantage to performance and economical operation.” Efficient and effective chip removal system fulfils the need of uninterrupted machining with reduced operators fatigue. The new concept of tooled up solution includes fixture designing, tooling and cutting parameters selection would assure increase in performance and economy. “Total Productive Maintenance (TPM) is an added feature to modern machine tool building to retain the machine performance for longer time which increases the economic performance. Synchronising tool monitoring system and probes would also reduce possible damage and ideal setting time,” Taneja adds. Moreover, Gautam K. Ahuja, Managing Director, Dormer Tools India Pvt Ltd observes, “To achieve the best performance and economy in milling, we need to start right from the initial stage – during the finalisation of the machining centre. We need to ensure that the spindle motor of the machine has sufficient power, so that the roughing operation is preferably done in a single pass. We should go for a through coolant spindle, and prefer an HSK taper, for the most rigid connection.” The next stage to ensure high performance is while designing the fixture. “We should have proper locations and maximum number of supports, to arrest all vibrations. The wall thickness of the fixture and clamps should be sufficiently high, since many times we under-estimate the high forces developed during milling,” Ahuja recommends. Once we have the right machine and fixture, we need to select the cutter, which is capable of taking the roughing depth in a single pass, and yet have low cutting forces on the spindle, to ensure its longevity. For roughing, Ahuja suggest, the cutter should have medium to close pitch, depending on the material to be cut, to ensure a high feed rate and metal removal rate. The inserts should be having high multiple edges, for maximum economy. The geometry and grade selection should be done carefully, to withstand high hot temperatures, and still achieve the maximum tool life, at desired parameters. “We should go for through coolant milling cutters which ensure that even at high RPM, the coolant reaches the tip of the inserts, leading to a longer tool life,” Ahuja points out. Achieving milling economy In any machining application, economy is strongly linked to performance. It is not possible to delink the two, since the customer’s expectation, invariably, is excellent performance combined with highest value for money. A significant way in which milling economy is achieved is by producing more number of cutting edges in any insert, says Naveen Vastrad, Senior Manager – Marketing (Products), TaeguTec India. Citing an example, he said, an insert with 2 cutting edges is now effectively replaced for equivalent performance with an insert with 4 cutting edges. Similarly, traditionally 4 cutting edge operations are done faster and more productively by 8 cutting edges; 12 edges have been superseded by 14 cutting edges etc. “Combined with rake geometry and geometry of TaeguTec grades, we are able to offer best economy and optimised cost per edge advantages to our customers,” claims Vastrad. “Another instance of design advancements facilitating cost optimisation is use of serrated cutting edge in long overhang applications. Also, double-sided positive cutting with shredded geometries in cavity and profile milling where, traditionally, single sided round inserts were in use.” -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 22-24 Top Manufacturing IT Trends An analysis on the most significant trends in the manufacturing information technology. Globally, the manufacturing industry is undergoing a major transformation with the increasing economic and industrial activities in emerging nations. Manufacturers want to keep their businesses thriving despite increasing global competition, cost of energy and raw materials, customer demand for quality products etc. As the growth of industrial automation increases, the technology trends are expected to change the face of the industry. Industrial Internet of Things (IIoT) According to Rahul Khare, Regional Business Leader (India & South Asia) - Honeywell Connected Plant, “The Industrial Internet of Things (IIoT) is the most important trend which has an ability to deliver meaningful information where and when it is needed most. The network is the delivery mechanism, connecting sensors, other edge devices and mobile devices to offer control room operators new perspectives on the way a plant is run, improving safety and efficiency, and sometimes uncovering new revenue streams.” He adds, “The emergence of the IIoT represents a digital transformation of manufacturing that shifts the source of competitive advantage away from physical machinery and towards information. As the pressures on manufacturers grow, the way in which data moves between people, between devices, and what is done with it, is increasingly creating the most value. The more relevant and timely the information, the more empowering it is, enabling employees at every level to make instant decisions that directly impact productivity. Therein lies the power of IIoT.” The drivers of digital transformation – Smart manufacturing or IIoT Sudhir Dembi, General Manager (Plant Solutions) Schneider Automation, Schneider Electric India says, “IT has an extremely important role to play right from the design, manufacture, and use of a product to satisfy customer needs and to meet environmental requirements. IT has enabled a new trend towards ‘Smart manufacturing’ or IIoT, which is driving a huge transformation. Networking and intuitive collaboration with the customer are tied to the concept of smart manufacturing ensuring efficiency and safety.” Dembi explains, “With the use of IT, equipment and stations within factories, entire manufacturing enterprises, and networks of suppliers, partners and customers located throughout the world can be more effectively connected and integrated. He also added, “Therefore the entire manufacturing floor – including packing, picking, sorting and conveying systems – must evolve to accommodate, efficiency, productivity, predictive planning, remote connectivity and more flexible business needs.” The rise of ‘Intelligent’, connected machines Sameer Gandhi, MD, Omron Automation India says, “One of the most significant trends in manufacturing IT segment is the advent of connected shopfloors with more intelligent machines. These machines not only communicate with each other but also with the people working with them in their environment via a well-knitted and intricate network of products, systems, platforms and applications. An advanced IIoT based automation platform based on varied smart sensors and PLCs connected to MES or ERP layer is the backbone of this network.” The connectivity and the synergy leads to smart optimisation of the industrial processes so as to enable real-time information exchange leading to several benefits such as failure prediction, reducing frequency of unscheduled downtimes, analysis of long term data - which are very helpful in enhancing productivity and quality. It ushers in productivity enhancement benefitting not only the manufacturers but also the end users. Industry 4.0: New levels of human machine interaction Anand Bhade, President of Asia-Pacific Sales & Global Head for Corporate Marketing, Tata Technologies Ltd says, “Manufacturing is changing; some call it the emergence of the next-generation of manufacturing which is leading to a new industrial revolution, also known as Industry 4.0. that will in turn lead to new levels of human machine interactions.” Industry 4.0 hype centres on the digitalisation of everything i.e. new embedded technology, real-time collaboration, mobility, on-the-fly advanced analytics, intelligence, connectivity (IoT, cloud-based solutions) and visualisation to create a seamless and agile manufacturing eco-system. Bhade observes that Industry 4.0 is expected to bring fully flexible and highly integrated manufacturing based on cyber-physical production systems. He further explains that the big idea is that it will allow companies to involve their customers more in the production process and to react faster on changing market requirements. “Architected well Industry 4.0 will enable integration and complexity management, creating an underlying framework for modern manufacturing,” Bhade concludes. -------------------------------------------------------------- EOS presents new periphery module for material handling EOS, global technology supplier in the field of industrial 3D printing of metals and polymers, introduces the material handling solution IPCM M pro for its EOS M 290 system. For this purpose, the EOS M 290 – a highly productive system for the Additive Manufacturing (AM) of metal components–is equipped with a special process chamber door with coupling points to connect with the IPCM M pro and material containers. The combination of system and periphery enables users to convey material easy, fast and safe out of the system, sieve it and refill it into the system – thus, simplifying industrial 3D printing as an established manufacturing method overall. In AM, a laser beam fuses powdered material at points defined by computer-generated component design data. With the IPCM M pro, material not fused during the building process can be directly conveyed out of the AM system – without opening the process chamber door and therefore without the operator coming into direct contact with the material. “A vacuum pump conveys the powder out of the system and into the IPCM M pro, where it is sieved under inert gas within the module at a throughput of 120 kilograms of material in 30 minutes – 50 per cent faster than previous solutions,” EOS claims. Powder treated in this way can be used for a new building process, the powder cycle starts anew. For the user, this semi-automated, dust-free material handling within the process chamber of the AM system has clear advantages in terms of health and safety as well as operability, as the risk of powder contact is minimised. This makes a more comfortable protective equipment possible for the operator without compromising safety in any way. At the same time, even large volumes of material can be sieved and conveyed more quickly and the manual tasks are both fewer and simpler. Moreover, the IPCM M pro module is mobile, which means it can be efficiently used for several systems. All of these points contribute towards additionally improving user-friendliness and productivity of AM. For more information, visit www.eos.info ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 26-30 Material Handling Made Easy Highlighting new developments in the field of material handling for industrial manufacturing. Material handling equipment (MHE) industry is all set to grow. The manufacturing industry has seen numerous developments in recent years which have spurred a continuous stream of innovations at every level of the value chain. Everybody wants to ride the wave of these developments by leveraging technology to accelerate productivity and profit. “The ongoing industrial revolution is reshaping businesses and because of these advancements, there is a steady rise in the degree by which these businesses are automating. Industrial robots which were once perceived as dumb machines merely used for reducing drudgery that human operator goes through while performing monotonous activities are now turning smarter every day,” says Kunal Pruthi, Consultant – Solutions & Business Development, The Hi-Tech Robotic Systemz Ltd. MHE which are very critical for any supply chain have also been influenced remarkably by this continuous progress in the field of robotics and rapid digitalisation of factories. Earlier diesel operated MHE made way for battery operated equipment and then came Automated Guided Vehicles (AGVs) which were able to substitute conventional MHE partially. Because of the dependency of AGVs over some additional infrastructure like magnetic tapes, colour tapes, QR codes, RFID tags etc for the purpose of navigation and localisation, the utility of these vehicles was very limited. Because of these constraints, there are many applications which are still carried out in an old-school way. But with the onset of Industry 4.0, we have started witnessing a shift towards adoption of systems which are more “Autonomous” in nature rather than being just “Automated” and this shift is quite evident in MHE segment also. Growing MHE demands Material handling industry is ever growing industry, as the demand of MHE is increasing day by day. It is evident from the fact that Pioneer’s cranes are working in 26 states of India and 13 countries across the globe. The MHE help the industry to increase the production with same manpower keeping the vital aspect safety enhanced for operator or user working with MHE. Keeping in view the safety of the operator and quality of the product Pioneer is always looking towards the constant improvement. “We are adding a state-of-the-art machine shop with latest machinery to provide the best of products to the esteemed customer,” claims Arshdeep Singh, Director, Pioneer Cranes & Elevators Pvt Ltd. Automotive sector plays a crucial role in MHE “A big shift is unfolding in terms, where customers invest in MHE to improve productivity and quality in their manufacturing processes. Automotive sector has always been investing in material handling equipment,” says Nilesh Karandikar, Managing Director, Fine Handling & Automation. New developments in material handling for industrial manufacturing MHE demand increased manifold Material handling for industrial manufacturing is changing at an unprecedented pace in the Indian market. Long gone are the days when they were considered in isolation by each location. With supply chains getting more and more integrated, customers are looking at these systems end-to-end. GST scenario is a classic case. Requirement of MHE has increased manifold all of sudden. “We expect to see factory, plant and warehouse consolidation along with the development of larger warehouses with modern materials handling facilities. As a result goods will also need to travel longer distances between fewer locations. This combined with the revised plant networks, will necessitate the adoption of modern materials handling practices in order support the increased volume throughput. All this is to enable cost reductions and improve efficiencies,” says Matt Quinn, Country General Manager, CHEP India. He adds, “To make the shift to the modern materials handling practices the adoption of a number of supply chain standards (systems, racking, MHE, pallets, packaging materials and trucks) is required and is likely to accelerate. Standardisation, mechanisation, automation and innovation will be a theme in the post GST supply chain to address the growing complexities. Faster inventory turns mean less working capital; faster pick rates result in more efficient use of labour; and faster truck turnaround reduces dead time.” Racking crane enables multi-layered storage For increasing the storage capacity, Pioneer Cranes & Elevators has developed a racking crane enabling its customers to store material in multi-layered racks. These cranes are useful for warehouses and stores to store material vertically in racks, increasing the storage capacity of the warehouse within same floor area. “The size of storage space drastically reduces with this application of crane. If needed, full automation of crane can be done to provide uninterrupted operation without use of manpower,” the company’s Director Arshdeep Singh claims. Considering the growing demands of MHE, Pioneer Cranes & Elevators is enhancing the production capacity by adding a new, state-of-the-art manufacturing facility with 35,000 sq.m. of area in Ludhiana. The new unit will have an advanced manufacturing facility to keep the company’s initiative of keeping innovations in the products alive, informs Singh. Automation As manufacturers invest in expensive machines, the needs for highly reliable systems that deliver consistent quality, through-put while guaranteeing maximum up-time are critical to return on investment. “Today, manufacturers recognise the role and importance of reliable MHE to earn the best return on their investments,” says Karandikar. Karandikar further claims, “With respect to recent developments, there is a clear shift to integrated, large-scale systems with greater level of automation.” The need for flexible systems that can handle all the variants without change in configuration or gripping mechanism is also evident across sectors, from automotive to aerospace. There is a huge opportunity to make productivity gains in material handling with men and automation systems working together, in sync with each other. “The other emerging area is the Internet of Things or Industry 4.0 where manufacturers will deploy advanced data analytics techniques to get previously unavailable insights,” observes Karandikar. Emerging IoT protocols and real-time equipment monitoring MHE manufacturers are continuing to innovate and introduce features that enable higher throughputs; storage-and-retrieval of a larger variety of SKUs, improved labour productivity, and improved safety-and-ergonomics. “Automated Guided Vehicles (AGV), sensors which communicate directly with the internet using emerging IOT protocols and real-time equipment monitoring and diagnostics are 3 notable innovations. These innovations are spawning an era where MHE will communicate with and react to their surroundings without the use of operators,” says Mihir Contractor, Senior Vice President (Material Handling), Nilkamal Ltd. Intra-logistics applications Pruthi informs, “Most of the intra-logistics applications which were carried out by regular MHE are now possible using “Autonomous Mobile Industrial Robots” (AMIRs). Material in all shapes and sizes can be easily handled with these AMIRs. Whether it’s a tow truck for transporting WIP trolleys, a BOPT for moving pallets between in or outbound dock or even a high reach truck for put away applications in a distribution centre, there is an autonomous system for every application. This all is now possible due to the evolution of controllers with better computing capabilities, high-fidelity sensor models and intelligent autonomous navigation algorithms for running mobile robots in complex environments.” Innovative material handling solutions for industrial manufacturing CHEP India provides cost-effective engineering solutions With experience of more than 60 years, CHEP India has helped more companies move more goods, to more places, more efficiently and more sustainably than anyone else in the world. Company has always been known to be just a ‘Blue pallet’ company. CHEP India understands this comes from its product that is a highly integral part of their business and its customers. However, in line with the market requirements the company has grown their offering for the supply chain solutions. In India, CHEP India offers 6 categories of solutions i.e. platform, system wide, manufacturing and warehousing, transport, international and connected supply chain. These solutions are designed to make supply chains more agile and efficient. “Our solutions help optimise customers supply chain within their manufacturing and warehousing processes. We ensure that all distribution platforms integrate with their automated and non-automated equipment, regardless of the platform design or specification.” Further, Quinn informs, “We work with the equipment suppliers, systems integrators and contractors to build in tolerances ahead of time. Our application-engineering experts quickly identify areas of opportunity for cost savings.” Nilkamal’s storage and handling solutions Nilkamal’s material handling business offers warehouse and factory operations quick and direct access to a Pan-India team of sales professionals who can walk through the customer’s operations and propose solutions to protect the customer’s products, improve their storage, and increase their labour productivity, all while improving safety and hygiene. Contractor claims, “We offer India’s broadest range of storage and handling solutions including plastic crates-bins-pallets to unitise SKUs; manual-and-electric equipment like pallet trucks, stackers and lift-trucks to move the unitised load; and manual-and-automated storage solutions like shelving, mezzanines, selective pallet racks, shuttle racks, ASRS racks and mini-load systems.” Hi-Tech Robotics - Improving operational efficiency “At Hi-Tech Robotics, we are developing solutions for alleviating the challenges faced by our customers and improving their overall operational and supply chain efficiencies,” claims Pruthi. Hi-Tech Robotics is one of an industry leader in the field of self-driving technology with expertise in robotics, artificial intelligence and control technologies. The company has developed a suite of products called NOVUS SYSTEMS which can fulfil all MHE related requirements. From material handling or storage inside the plant to material delivery at customer doorsteps they are trying to increase the productivity at every stage of the supply chain. The core of all these products is Artificial Intelligence (AI) which gives self-driving as well as self-learning capabilities to robots so that they can have human-like thought process but are much more efficient in deriving the Small Data i.e. timely and meaningful insights from the Big Data generated in the surroundings. These insights are like a gold mine of solutions and give more visibility across the supply chain to the users. According to an industry report, the worldwide MHE market size was over US$ 110 billion in 2015 and with the increasing penetration of advanced technologies, this market is further expected to grow at over 8 per cent CAGR in coming years. With Omni-channel driving the need for more visibility across the supply chain, whether it’s an MHE, OEM or its end user, whosoever is willing to embrace these fast and frequent technology changes will have a winning edge over their competitors. Progressive leaders, who are able to foresee the utility of these new technologies and are quick in adopting, will definitely see transformative results. Innovative and customised solutions from Fine Handling In line with this need, Fine Handling provides innovative, customised solutions to step-change the productivity and quality of cutting processes through efficient handling. During the last decade, the company has provided more than 1,000 solutions to over 100 customers across 13 industrial segments. Fine Handling has been pivotal in bringing world-class handling solutions to the Indian market and gradually to its overseas clients. Each of their product, system and project is focused on realisation of a singular goal – to enhance safety and productivity by multi-fold. Company’s innovative automation solutions for pick and place tasks are well recognised in the industry. Some of their breakthrough solutions include high speed gantry systems for component transfer between machines or stations with world-class automation. They have also provided manipulators to handle components with weights up to 350 kgs and over 16 variants using a single customised gripper. Fine Handling’s range of products includes: • Industrial manipulators • Customised gripper • Gantry systems • Aluminium rail systems • Machine to machine conveyors • Specialised solutions like ElbowLIFT, AccelLOADER, VacuumLIFTER Lift n Move. --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 32-33 Capturing the benefits of IT Discussing the impact of IT on productivity and efficiency in industrial manufacturing. India’s manufacturing sector is on a high growth trajectory. Prime Minister Narendra Modi launched the ‘Make in India’ program to place India on the world map as a manufacturing hub and give global recognition to the Indian economy. The next generation of manufacturing will be driven by connectivity. It is happening today in modern plants: Industrial Internet of Things (IIoT) is enabling manufacturers to embed assets with the capacity to communicate with each other. This allows manufacturers to continually measure and improve optimal performance, opening up new possibilities for safety, productivity, reliability, organisational responsiveness and, ultimately, profitability. “IIoT is the industrial revolution of the 21st Century. In this industrial system, all processes such as product design, manufacturing, services, and refurbishment are completely integrated and will exchange information in real time. The keystone of the IIoT is productivity,” says Rahul Khare, Regional Business Leader (India & South Asia), Honeywell Connected Plant. “In the world of oil and gas, where plant owners have one eye on capital expenditures (CAPEX) and another on falling oil prices, the biggest driver of IIoT technology is the promise of greater output. This revolution will transform the manufacturing process by allowing manufacturers to adapt to changing customer needs in a short amount of time,” he adds. IIoT improves key operational processes Countries around the world are rapidly moving integrating digitisation. “The IIoT is not only driving advancements in distributed energy and grid communications, but it is also helps improving key operational processes, including remote monitoring, predictive maintenance, advanced control, and safety and security. This has facilitated in the development of a new concept- ‘smart manufacturing’. From smart pipelines to smart meters and the smart grid, every aspect of energy generation and transmission is being made safer, greener, more dependable and efficient through IIoT,” says Sudhir Dembi, General Manager (Plant Solutions) Schneider Automation, Schneider Electric India. Sustainability and efficiency Ensuring efficiency with sustainability is the key to development and advancement today. To address this, Schneider Electric has developed innovative technology such as EcoStruxure which involves innovation at every level including IT, buildings, grid, power, machines etc. It is an interoperable and open platform which is IoT enabled that improves operational profitability in a measurable, safe and sustainable way. Smart industrial automation Schneider Electric’s Ecostruxure can turn industrial automation into a profit engine of the business. Company’s technology and real-world IIoT expertise help in shifting from managing business, to controlling it. With an empowered workforce and optimised industrial assets, one can maximise not only process efficiency, but also safety, reliability and even profitability of the operations, in real time. The EcoStruxure Profit Advisor enables industry to control real-time profitability applying big data analytics and patented real-time accounting models to identify potential profitability improvements area. Also, the EcoStruxure Control Advisor Software diagnoses, prioritises and improves control-loop tuning and process optimisation which leads to energy savings and increases production capacity driving operational efficiency and profitability. Understanding the power and influence of technology The power and influence of technology will increase as much in the next 12-18 months as it has in the last three decades. Clearly technology cycles, and the pace of technology adoption, have begun to outpace business planning cycles. “Manufacturers today need to learn to manage not for stability, but for disruption. In a manufacturing context, change may come from many directions. Innovations in advanced manufacturing technologies are breaking the traditional paradigms of assembly and ‘subtractive’ manufacturing. Embedded Artificial Intelligence (AI) will allow collaborative business ecosystems not only to connect, but to learn and improve, creating the potential for outcomes we can’t even yet predict,” says Anand Bhade, President of Asia-Pacific Sales & Global Head for Corporate Marketing, Tata Technologies Ltd. It is important to understand how technology is changing a business. For that one needs to decide which technologies to use to gain business advantage and should build new business models and offerings that use technology to match the ways in which the customers are changing. Perhaps the most significant problem faced by manufacturers today is that of bandwidth; not data bandwidth but human-capital bandwidth. With disruptive innovation, and the pace of change constantly challenging competitive positive, how can any manufacturer maintain and evolve current product, and invest sufficient time on the next generation of products? Bhade feels it is unlikely that any business can sustain the incremental resource cost to manage both old and new technologies during the transition period. Instead, manufacturers must be disciplined about what is really “core” and what can be considered “non-core”. The answer will be uncomfortable for many, but it is relatively straight forward that manufacturers must partner with suitable external manufacturing sources, and engineering services partners alike, to release critical internal resources to develop the products that will ultimately sustain the future of their business. IIoT brings significant improvements in productivity According to Sameer Gandhi, MD, Omron Automation India says, “Some of the key outcomes of IT based solutions (IIoT) are reducing downtime, improvement in efficiency of product changeover and up time, predictive maintenance etc. These all are linked to each other and work in a collaborative manner to bring significant improvements in productivity which is one of the key objectives of any manufacturing operation.” Total Traceability: The key concept in identification technologies One can look at one such IT based technology or solution such as Total Traceability - to exemplify the kind of benefits IT has on the manufacturing industries. Gandhi informs, “Total Traceability is the ability to trace and verify the history, location or application of an item by means of documented recorded identification. Considering one defective product can bring loss and setbacks to the credibility of a brand, the solution holds a lot of importance to ensure zero-defects manufacturing system. It also enables big data management – images collated together with process parameters. This data (together with images) can be used for statistical analysis, quality control, quick identification of faulty parts, managing and tracing loss of components while processing from one plant to another.” Gandhi opines, “Companies adopting traceability can not only actively participate in developing a sustainable and safe production process but also witness significant growth in their profitability while delivering higher customer satisfaction.” -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 34-35 A Real World Approach to the IIoT This article explains how adapting the IIoT helps to operate a plant with optimal efficiency. Process plants today are faced with meeting increasing performance demands, which starts with the plants running at maximum efficiency. But, the path to achieve maximum efficiency is filled with many road blocks, such as unplanned equipment breakdown. To address the untimely breakdowns, a facility needs to predict undesired process conditions and equipment failure before they take place. Currently, most facilities have a run-to-fail approach to address untimely malfunctions. Unplanned downtime at a mid-sized refinery can cost up to $40 million a year. To ensure uptime, companies send field technicians to perform routine diagnostic inspections and maintenance as per fixed schedules. This is a costly, labour intensive process with minimal assurance that failure will not occur between inspections. Companies have also adapted other methods like Advanced Process Control (APC), defined operating boundaries with their alarm systems and creating Key Performance Indicators (KPIs). Apart from this, companies have also sought help from local experts to resolve operating problems but these measures are difficult to sustain as they are dependent on dedicated on-site personnel. Therefore, a need arises to address these staggering loss-making numbers in a process industry. In a highly competitive global market, industrial organisations seek “Digital Intelligence” to manage and operate thousands of assets from a single site or across an enterprise to address critical operating demands. Manufacturers today are looking for solutions that can interpret a vast quantity of data to analyse impact on performance. To support the multiple monitoring and support applications necessary for manufacturing facilities, data needs to be churned into information and delivered with context so it can be understood and used in numerous ways by various people. A growing number of players in the global market are adapting the Industrial Internet of Things (IIoT) to optimise their business performance. Manufacturing plant operators are being enabled by IIoT to improve the operational efficiency and reliability. They are doing this by capturing and analysing data to identify and predict the adjustment and maintenance of process equipment and proactively servicing installed assets before problems arises. IIoT allows companies to do more with their current systems and extend their business processes to enhance monitoring and reduce time-to-action. An IIoT environment, or a connected plant as we know it, offers companies the ability to aggregate data from existing sources, create additional data sources and bring these together in a cost-effective way to identify breakdown patterns and derive insight through analytics that were not previously possible. It can transform work process from manual and reactive to automatic and proactive, helping users to avoid unplanned downtime, and improve performance and safety. An IIoT-enabled plant uses a combination of advanced sensors, automation systems, and cloud technologies integrated with current systems and data analytics to become smarter. This provides the ability to locate data in a cloud environment where it can be accessed and analysed with analytical tools. For example, an equipment vibration reading would be sent to the plant’s Distributed Control System (DCS) as a single value, whereas rich dynamic data stored in the cloud would allow engineers to study the harmonic signature of a bearing or shaft to determine the root cause of a pending asset failure. Currently, in most cases, dynamic data is only employed by specialists in custom applications – limiting its accessibility by other users in the plant. It is important that IIoT not be just about capturing sensor data. Information needs to be put into asset context structure. Merely operating on tag-based data will not ensure a repeatable and scalable solution. Processes are instrumented for control rather than reliability or optimisation, and as a result, much of the ‘derived data’ important for prediction and decision –making is in locked spreadsheets and other standalone tools. It is essential to calculate this data on an on-going basis and bring it into the IIoT environment where continuous runtime analytics can examine historical performance for use in machine learning algorithms. Furthermore, IIoT solutions should not solely rely on statistical models to detect deviations from normal. Having a fundamental, physics-based model creates a digital twin, with a virtual representation of the process or asset located in the cloud. This allows users to model and compare expected process performance against actual results, and then view these deviations as early indicators of health degradation. Adoption of IIoT has created economies of scale for smart sensors, connectivity, analytics and robust software platforms. This change is driving the adoption of enterprise-level performance management, process monitoring, predictive maintenance programs, and business transformation with the goal of eliminating unplanned downtime and reducing operating costs – all while maintaining product quality and compliance. Though one may ask, what does IIoT mean in numbers? IIoT has multiple benefits in terms of customer value: • Increased asset utilisation up to 10 per cent: Plants can reduce unplanned downtime by predicting and providing proactive responses • Increased operating efficiency up to 10 per cent: Industrial organisations can manage performance, including yields, energy and raw material usage to achieve up to 10 per cent reduction in costs • Sustained APC benefits up to 25 per cent longer: Proactively maintain the effectiveness of control loops, controllers and models • Reduced maintenance costs up to 10 per cent: Operations teams can take proactive measures to minimise equipment damage and emergencies while optimising maintenance based on real asset conditions. Industrial facilities need combined production and maintenance strategies to minimise unscheduled shutdowns and optimise product quality while cost-effectively using the operations, maintenance and engineering resources they have on hand. The true value of IIoT can only be fully realised with a holistic view of asset management. Authored by: Rahul Khare, Regional Business Leader (India & South Asia), Honeywell Connected Plant --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 36 Top 7 benefits of using biometrics in healthcare centre Biometrics in hospitals has become an essential tool to enhance the patient safety. The potential of biometrics is enormous as physical security of any building or establishment is becoming increasingly important. It has emerged as a critical tool for the safety and security of hospitals and health centres as it contributes to improved patient safety. Further, biometrics assists in properly identifying patients that enables providing right treatment to the right person while maintaining relevant medical records. The major benefits of using biometrics in hospitals and healthcare centres are as follows: Increase patient safety Secure identification through biometric devices brings patient safety to a higher level. Errors are eradicated in the identification of the patient thus avoiding the appearance of adverse events of all types for this cause. Biometric identification through fingerprint scanner can also save lives, as it allows finding out the ailments or allergies of certain patients in cases of emergency. More comfort for the patient The patient can access health services in a much more comfortable way than before since he does not need to carry anything physical with him or memories the data that is necessary for his identification. In turn, the patient does not have to permanently wear uncomfortable bracelets that can cause skin irritations or other inconveniences. Greater satisfaction with the service Improved care processes (for example, reducing the time of all processes requiring patient identification) and more efficient and error-free information management, the quality of service provided to the patient is improved, and patients who perceive favourable change increase their degree of service satisfaction. More confidence and peace of mind Patients welcome the use of the biometric system as a way to protect themselves against fraud and safeguard their identity. The new identification system guarantees the total privacy of access to the patient’s confidential information, respects his rights and complies with current legislation that supports the patient. The patient gains in tranquillity and increases his level of confidence in the security of his personal data and the treatment of the same by the institution and the staff. Improve your quality of life By receiving better medical care free of medical errors and inconsistencies in the Electronic Medical History, the patient receives more successful treatments and, consequently, improves his quality of life. Increased safety for health personnel All health personnel benefit from greater security in the processes that require their unequivocal identification, both in the control of physical access to the facilities and in the logical access to the implanted information systems. Biometric machine eliminates the possibility of theft or fraudulent use of your passwords, as well as the possible loss of your identification cards. More comfort in identification for health personnel Healthcare personnel do not need to memorise their passwords or carry identification cards to access hospital facilities or hospital management systems and patient information. Whenever you need to identify a patient, you can do it with great convenience, speed and agility through fingerprint scanner. Administrative staff can more quickly process such as filiation, admission or discharge of the patient. Authored by: Vipin Yadav, Managing Director, Star Link Communication Pvt Ltd Email: www.starlinkindia.com ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 37 Nearly half of Asia-Pacific manufacturers to have smart factories by 2022: Study Zebra Technologies unveils high-performance industrial printers as manufacturers seek to increase operational visibility and productivity. Nearly half of Asia-Pacific manufacturers to have smart factories by 2022, revealed Zebra’s 2017 Asia Pacific Manufacturing Vision Study. The regional study discovered that the number of manufacturers supporting a fully connected factory would nearly triple by 2022. This means 46 per cent anticipate having the capability in five years’ time. The study reveals that workers will use a combination of radio frequency identification (RFID), wearable technologies, automated systems and other emerging technologies to monitor the physical processes of the plant and enable companies to make decentralised decisions. APAC manufacturers will lead the way globally, with 77 per cent of respondents expecting to collect data from production, supply chain, and workers in a holistic manner by 2020, compared to 46 per cent doing so today. Executives across APAC cited achieving quality assurance as their top priority over the next five years. Forward-looking manufacturers are embracing a quality-minded philosophy to drive growth, throughput and profitability. In a sign that improvements made by both suppliers and manufacturers will ultimately boost the quality of finished goods, fewer respondents say quality-related issues will be a top concern in the future. Today, 55 per cent of manufacturers see quality as a top concern, but this falls to 35 per cent in 2022. Manufacturers expect to expand the level of technology use between now and 2022, specifically mobile technology (27 per cent vs 72 per cent), wearable technology (33 per cent vs 65 per cent), location tracking (38 per cent vs 51 per cent), and voice technology (45 per cent vs 51 per cent). 42 per cent of the manufacturers expect investments in visibility technology to spur growth. Fifty-five per cent will implement real-time location systems (RTLS) and 48 per cent plan to use RFID by 2022, providing the much-needed transparency across their operations. By 2022, 44 per cent of manufacturers expect to enable Just-In-Time (JIT) notifications for their customers. The request will increasingly come from the high-tech (48 per cent), pharmaceutical (40 per cent), automotive (35 per cent), and food & beverage (36 per cent) industries. Deep Agarwal, Regional Sales Director – India, Zebra Technologies APAC said, “Manufacturers are entering a new era where there are increasing expectations of faster and higher quality production along with highly competitive margins. India is at the forefront of a digital revolution, with the potential to become the digital factory of the world. The Zebra APAC Manufacturing Vision Study shows savvy manufacturers have already started to invest in smart factory technologies to reap benefits such as enhanced productivity, increased visibility, and the ability to predict demands. As we move toward Industry 4.0, this trend will continue to expand and shape the industry in the coming years.” Jason Low, APAC Lead for Specialty Printing Group, Zebra Technologies, Asia Pacific added, “Industrial printers play an essential role in a highly efficient supply chain, allowing enterprises to track every single component or asset from assembly to delivery and after-sales service.” ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 38-40 Pumps for Pharma An analysis on importance of pumps and compressors in pharma industry. Role of Compressor in pharma sector In order to ensure optimum supply of products, the pharmaceutical industry is required to follow a strict mandate on the processing conditions of the manufacturing plant. “It is essential to ensure that the variables such as temperature and humidity are accurately monitored to ensure that the qualities of the products are not affected. Compressors play an important role in this regard as they are the core unit to enable precision cooling. A minor lapse in these areas will critically affect the performance of the product, and thereby make it unfit for distribution in the market leading to large amounts of material and monetary losses.” informs Ravichandran Purushothaman, President, Danfoss India. Compressed air applications Compressed air is one of the most critical utility in the pharmaceutical industry as many of its applications involve direct product contact some examples of compressed air applications are de-dusting and spray coating of tablets, pressurising mixing and holding tanks, pressurising liquid product through filters and fill lines, operating control valves and pneumatic cylinders in automated production lines, packaging of capsules, tablets, vials, ampoules, tubes and bottles, nitrogen generation. According to Jatinder Kaul, National Sales Leader- Sales, Compression Technologies and Services, Ingersoll Rand, India, “The compressed air system must be properly designed and built from the outset, the initial validation testing and ongoing monitoring of compressed air is also vital to assuring both the quality and safety of the pharmaceutical product.” The quality standards for a pharmaceutical facility are best defined as a composite set of specifications that are site-specific based upon the point-of-use requirements. (US FDA or GMP guidance and ISO air quality standards). “Ingersoll Rand class 0 oil-free compressed air technologies help pharmaceutical manufacturers adhere to this regulation by ensuring production processes remain 100 per cent free of compressor-created contaminants and aligns with GMP and USFDA standards. Our innovative intellisurvey assessment tool allows us to also monitor and analyse current air system performance in order to determine solutions that will maximise system reliability and efficiency,” said Jatinder about compressed air technologies. Reducing contaminant risk in compressors “It is recognised that there are two main sources of contamination in compressed air systems. The main contaminant source being atmospheric air, which is drawn in to the system and the second major source being the compressor, which traditionally uses oil for lubrication and cooling and can carry over downstream. If not treated, this oil will pass freely through the system to the critical control point. Most pharma companies are switching to oil free compressor technologies which allow the users to remove fully, one of these major sources of contamination,” said Pankaj Kumar, Business Line Manager and Industrial Products Group, Gardner Denver Engineered Products India Pvt Ltd. “Some pharma companies may select 100 per cent oil free air compressors. These compressors do not contain oil at all, whereas some oil free compressors contain oils within gearboxes and other non-air side areas of the compressor. In terms of risk analysis, pharma producers should consider the potential impact of this should there be any failure of internal sealing arrangements or even leakage of these lubricants and oils,” claims Pankaj. Requirement of pumps in pharma industry In pharmaceutical industry, pumps are required at all stages like processing, unloading, dosing, mixing or transferring individual ingredients or the final product. As a full-line supplier Grundfos offer thoroughly tried and tested sanitary solutions for every conceivable pump application including upstream processes, downstream processes, CIP or SIP-systems, clean utility systems. “Common to all Grundfos solutions is highly reliable performance that guarantees peace of mind in even the most delicate and critical processes. The electropolished interiors of our unique sanitary pumps are free from edges, seams and screw heads to prevent bacteria particles from accumulating, which in turn safeguards your product quality and brand reputation,” asserts Shankar Rajaram, Vice President - Business Development, Sales, Grundfos Pumps India Pvt. Ltd. As shear-sensitive liquid biopharmaceutical products have proliferated; the industry has paid more attention to pump technology, from filtration and fluid transfer, to formulation, dispensing and fill or finish. “While traditional pumps of the centrifugal or piston variety, for example have all shown steady improvement in design, materials and finishes, more sensitive and easy-to-clean peristaltic, lobe pumps have captured significant market share as well,” says Jayashree Ananthan, Director Technical Service Viking and WFT India & Middle East, Idex Fluid and Metering Technologies. Solutions for pharma industry Digital Dosing solution from Grundfos Grundfos offers a wide range of dosing pumps representing state-of-the-art technology. Digital Dosing solutions (SMART Digital) set new standards in liquid chemical handling and accuracy. The operator can easily install and set up the pump to discharge exactly the quantity of dosing liquid required for the process in a unique drive- and flow-control management concept. The setting of the pump is displayed in ml/h, l/h or gph and the operation mode is easily identified by means of icons. Sterilobe pump from Idex Fluid and Metering Talking about the offering for pharma industries Jayashree said, “The basic design of the pump has been made keeping in mind of pharma industry requirements. Wright Flow Technologies offers several such pumping solutions and of them all, the Sterilobe pump design has been the most appropriate with special features demanded by pharmaceutical liquids.” Features of Sterilobe pump • This pump is EHEDG certified for CIP and SIP which certifies the pump for bacteria tightness. • The casing ID has one side of the port with special 45 degcut to enable easy drain. When the pump is mounted vertically with this flat face at the bottom, this allows easy drainability with zero hold up liquid. • There is big access to the stuffing box from the back side of the casing. This enables easy external cleanability and easy removal of seals reducing downtime to max 10 min, and further without having to disturb/dismantle piping or mounting. • The front cover joint has a profile that follows the id of the casing, thereby minimising the exposed crevice between the casing and the cover plate. More Hygienic design. • Minimum surface finish of 0.6um which is better than the normal finish of 0.8um, again providing the best hygienic feature. • Carbon Vs Sic Standard seal faces with EPDM FDA approved elastomer as standard in pump • Four lobe rotor designs offers better efficiency due to larger contact surface area with casing at the same time low shear effect on product. • Foot on Bearing Housing making it easier for pump to be mounted vertically or horizontally by just changing foot position. • A rotor retainer is cross haired and is flush thereby ensuring no liquid retention when pump is stopped at any angle. Stating the precise controlling of the system parameters that suit the unique requirements of the pharmacy processing sector for a clean room application, Ravichandran said as follow: • Pressure Independent Balancing and Control Valves (PIBCVs) The PIBCVs help in providing the perfect control and automatic hydronic balance which maximises the effective functioning of the processing plant. The versatility of the Danfoss AC drives lies in the fact that it is independent of motor manufacturers which contributes to its ability to adapt to any motor technology. • Variable Frequency Drives (VFDs) The Danfoss VFDs help in controlling the chilled water and the hot water valves of the machinery and the fan speed to ensure that the requisite conditions are met accurately. • Turbocor Turbocor (oil free compressor) compressor is used in oil free chillers and with inbuilt variable speed control which helps precise temperature can be achieved in labs with excellent efficiency. • Variable Speed Condensing Unit Variable Speed Condensing Units have unique feature of controlling precise temperature and load requirement of pharma cold rooms. Ravichandran opines, “As an industry leader in energy efficient solutions, we also focus on ensuring that our products and solution require minimum energy input without compromising on its performance, thereby contributing to the growth of the sector by reducing the incurred monetary and environmental costs.” Oil free air compressors from Ingersoll Rand “Ingersoll Rand has a complete range of premium efficiency class 0 Oil free air compressors and accessories to meet the stringent air quality requirement of the pharmaceutical industry. We have also launched the best in class efficiency in the small centrifugal compressors range starting from 500 CFM capacity with the lowest power consumption in the industry. We have also launched the entire range of desiccant dryers which can meet the stringent constant -40C PDP requirement of the pharmaceutical industry,” said Jatinder. He further adds, “With our philosophy of one stop solution and service provider, we not only provide energy efficient air compressor systems but a whole range of accessories like air dryer, filters, piping, control systems which can make a significant difference in energy consumption. Overall we believe in providing a total solution to customer’s compressed air needs which helps to conserve energy instead of supplying equipment.” CompAir from Gardner Denver Taking about the offering for pharma industries Pankaj said, “CompAir are committed to quality and innovation and understanding the customers’ operational and business needs. Nowhere is this more apparent than in the development of DH range. 100 per cent oil-less water injected compressors are helping industries across the globe to meet and exceed quality and production objectives in pharmaceutical, food and beverages, electronic, healthcare and power generation applications to name but a few.” Expressing his view on ‘No oil - no risks’ Pankaj said as follow: • Single-stage, direct-driven compression element maximises efficiency and minimises maintenance. • High quality water injection lubricates, cools and seals the compression process, maximising efficiency. • No gearbox means no need for associated oil lubrication. ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 41 Vashi Electricals sees huge response in e-commerce biz Our e-commerce team has been working round-the-clock to cater to the huge influx of enquiries and orders. We are receiving orders from places that I never even knew existed! Vashi Electricals has recently launched an ecommerce portal for selling motors, wires and cables, switchgears, gearboxes, motors and allied electrical products online. After witnessing its initial success, the company is gearing up for the next move! Excerpts from an interview with Vijay Nichani, Vice President – Purchase, Vashi Electricals: VEPL claims to be the preferred channel partner of major electrical MNCs. What makes you different from other channel partners? A key element of our success is that we know what our customers want. We are backed by solid hard work and experience of 40 years of service in the trade. Besides this passion for service, we have superb infrastructure in terms of state-of-the-art systems and processes and inventory holding capacities. We also have an enviable active customer base. These qualities are acknowledged and appreciated by the electrical MNCs as it gives them a ready market to further their brand. How do you bring the best experience for your customers? We invest a lot in technology which enables us to achieve speed and scale in operations. We have dedicated CRMs that handle about 75 customers each and literally provide customised service to each customer. We deal in over 40,000 SKUs and continuously check which items are more fast-moving than others, and keep adequate stocks based on anticipated demand. These steps help us to improve our customer service ratio. Currently, we close 85 per cent of our orders within 4 days and we aspire to constantly better that ratio. There is a lot more that we have planned to enhance customer experience. Bad debts continue to remain the biggest concern for traders especially in the B2B industry. Has the situation deteriorated post demonetisation and GST? Bad debts and delayed payments are a roadblock and reduce our margins. Fortunately we have a dedicated credit control team that ensures collection through systematic and organised follow-up. However, there is scope for improvement in the process and result. How are you dealing with this? We have assigned credit limits to our customers based on their business of last few years and payment capacity, and we try to keep our exposure limited to that extent for each customer. Of course we have more detailed financial analysis for new customers before we extend credit. But as I said earlier, there is a lot more scope for improvement. How far are you from reaching out to every industrial town in India? We currently have a huge presence in major cities and towns in India. And now with GST, the whole country is one single market without any boundaries. Moreover, we have recently launched our e-commerce portal and that has enabled us to literally enter into people’s offices and homes, not just industrial towns. Of late, you have announced your e-commerce platform. How is the response? The response has been stupendous! Our e-commerce team has been working round-the-clock to cater to the huge influx of enquiries and orders. We are receiving orders from places that I never even knew existed! It’s been a great eye-opener for us and we are overwhelmed by the potential! It’s huge. ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 42-43 Polysoude demonstrates latest developments at Schweißen & Schneiden Polysoude demonstrated its latest developments in both the orbital welding and automated cladding industry at the Schweißen & Schneiden trade fair held in Düsseldorf, Germany. According to Polysoude, these developments have been driven by the need to satisfy the specificity of the customers’ need. “With the recent economic difficulties, it has been seen that a significant investment in technology requires a significant improvement in productivity, ease of use and most importantly, product quality. Schweißen & Schneiden is a great opportunity for Polysoude to showcase these advances,” the company said. The Schweißen & Schneiden trade fair provides the members of the welding industry with the opportunity to present their latest innovations in the market. Expansion of the welding head range In order to meet this demand, Polysoude has expanded its range of closed chamber welding heads with the MW 34 (Fig. 1), with an application range of 6 mm to 34 mm. Just like all the other welding heads from this series, the MW is in high demand, due to its ease of use with the controls placed directly on the handle of the head and a high duty cycle which meets growing market demand. The MW welding head is the ideal product regarding size capability, meeting not only the reduced radial space requirements of the micro-fittings industry but also the quality requirements of pharmacology and food industries. Another considerable advantage of this welding head: the casing (TCI), used for all closed chamber welding heads by Polysoude, is made of titanium, this allows response to variations in temperature on the outer diameter of tubes. By using titanium, Polysoude is in a position to provide both a lifetime casing warranty and also the possibility to avoid all performance loss over time in comparison with aluminium casing. The new tube-plate welding head At the fair, Polysoude will also reveal the TS 8/75-2, the latest in the series of tube-plate welding heads. Several welding heads can be used simultaneously thanks to the more the more compact and ergonomic design of the double handle, with integrated welding and clamping controls. (Fig. 2) This welding head has an impressive level of automation with its integrated AVC. With this new series, even tubes with a lower value can be welded in assembly with the new clamping/centering system. New development: Mastering the quality and productivity with data acquisition The close collaboration between field staff and Research & Development has resulted in the creation of the new DAQbox (Fig. 3): a brand new concept combining data acquisition with functions enabling the optimisation of productivity while ensuring a reproducible weld of indisputable quality. The core function of DAQbox is data acquisition, an essential tool for the production monitoring as part of the quality process. However Polysoude has added features that provide the welder and Quality Department with enhanced monitoring of the welding process. As seen in figure 4, the welder can now simultaneously monitor the smooth functioning of the welding process and respect the operating procedure while closely following the deposit rate and the welding energy utilised. In a single click the operator can choose the type of setting to be displayed and at all times return to the original settings. The installation is done very simply with the use of a USB2 stick with a free software licence and there is no need for an Ethernet network. This way the data saved during the complete welding cycle can be read on any PC in order to validate production. In comparison with data acquisition systems currently available on the market which consist of only six measurements (current, voltage, rotation speed, wire speed, hot wire current and gas flow) the DAQbox proposes the following additional data acquisition: temperature measurement, welding energy, wire deposition rate, linear and analog channels are increased to 15 (previously 5) and are customisable by the user according to the process requirements. Regarding the usability of the software, Polysoude exports more than 85 per cent of its equipment abroad, non-Latin languages such as languages such as Russian and Chinese are also available. Automated welding: tailor-made by catalogue A major concern for manufacturers is the length of time it takes between the decisions to install the equipment, up until the moment the equipment is ready to start production. This is considered as too long in many cases. Having engaged in years of development and feedback, Polysoude has widened its approach to meet shorter deadlines. This therefore allows the proposal of standard elements of installation, even for the more complex of configurations. The new Polysoude catalogues (Fig.5) contain the majority of solutions in the field of automated welding and cladding. They have become essential tools to respond to customer specifications, providing advice and enable the implementation of their projects. For some customers, the standard solutions may not meet all of the requirements. However, starting with the catalogue solutions, the Polysoude R&D team will focus entirely on a bespoke and unique solution. This installation will be perfectly compliant to with the product specification and delivered in an acceptable timeframe. Contact Polysoude India Anil B. Kulkarni (Head of Representations) Plot No. X-17 & X-1, MIDC, Bhosari, Pune-411026 Mobile: +91-9890529923 Tele: +91-20-27127678 Fax: +91-20-27137679 Email: ab.kulkarani@polysoude.in ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 44 Learned from the bees – Honeycomb system as a strain relief for cables igus introduces another world first: Universal strain relief saves engineering and assembly time Cable tiewraps play a predominant role in strain relief today. Every individual cable is fixed to an e-chain, which is often a job consuming a lot of time and space. Cable tiewraps are used quickly and can often only be used once. The company igus revolutionises the strain relief in the e-chain with the bionically inspired honeycomb system. This saves the designer’s engineering and assembly time. The motion plastics specialist igus has now developed a unique strain relief system with a honeycomb structure for its energy supply systems. Cables and hoses can simply and gently be pressed into the honeycomb. It is then closed, whereby the outer walls of the honeycomb cavities are pushed gently but extremely tightly around the cables. In this way, the structure simply adapts to the cable diameters. The honeycomb can be mounted in seconds; in comparison to the often used cable tiewraps or other strain relief solutions, the user saves about 80 percent assembly time. The new system saves space and protects the cables in the e-chain. It is also much more flexible, as the system is easy to open, to insert new cables or to replace them. The universal strain relief system is available in two versions. The horizontal strain relief CFU.H can be installed in layers. It allows the insertion of different cables in one layer. It is screwed from above in front of the mounting bracket and can also be used for long travels at the fixed end. The vertical version CFU.V can be simply hooked on in front of the mounting bracket. Different cables are simply inserted into the vertical rows. The system is tightly closed with a clip lock and thus protects the cables reliably against mechanical stress. The two versions of the new strain relief are available for the e-chain series E4.1L from summer this year. New strain relief and separators make the E4.1L the fastest harnessed e-chain The new honeycomb system is part of an innovation campaign for an even faster and simpler harnessing of e-chains. With the E4.1L, igus offers the most easy-to-fill e-chain on the market. Thanks to the innovative separator system, which was also presented by igus at the 2017 Hannover Messe, a custom interior separation of the energy chain is made still easier for the customer. Furthermore, the new strain relief gives the designer the freedom to insert the cables into the E4.1L precisely as and when he wants it in his own design process – and also the possibility to change this filling again without complication. ----------------------------------------------------------------- Level Indicators Visual level indicators combine up to three functions in one instrument: Level indicator, level switch and level transmitter. The display that can be read even over large distances works without energy and automatically as a result of the physical law of liquids in communicating vessels. The WEKA visual level indicators are characterised by their compact design and the wide range of applications. Application range Operating pressures can range from a vacuum up to 500 bar as well as calculation pressures for the float standpipe up to the nominal pressure PN 630. Liquid densities above 0.27 g/cm3 as well as a temperature range from 77 K to 673 K (-196 C to 400 C) allow use in applications for cryogenic liquid gases as well as in water hydraulics and steam boilers. Hermetically sealed floats for condensing media are available up to a maximum operating pressure of 320 bar. Flexibility through choice of suitable materials • Standard materials: 316/316L 1.4435/1.4404, group A4 stainless austenitic steel. • Other possible stainless austenitic steels: 304/304L 1.4301/1.4306, 1.4571, 321, 1.4541. Energy-free, automatic operation The WEKA visual level indicator is ideal for the commissioning of systems. The display works without energy and automatically as a result of the physical law of liquids in communicating vessels. Independent of a controller - and thus also independent in the event of a power supply failure - visual level indication on site is ensured. Excellent readability The wide, red- and silver-colour flag indicator system is easily and clearly readable, even from over large distances. The fully transparent flag indicator system made of polycarbonate (PC) also ensures readability from the side. The liquids, which are not always unproblematic and sometimes also hazardous, are safely enclosed in the dense and pressure-tight float standpipe and separated from the indicator. Applications Explosion-proof plants, mechanical and plant engineering, water management, ship building, energy, space and research. Contact Toshniwal Hyvac Pvt Ltd 267, Kilpauk Garden Road, Chennai - 600010 Tele: +91-44-26445626/8983 Email: sales@toshniwal.net www.toshniwal.net -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 45 Damping vibrations, shocks and noises Elesa+Ganter vibration-damping elements represent an easy and effective solution to damp unfavourable vibrations produced by moving bodies or non-balanced vibrating masses which can also affect adjacent equipment improving operator safety and comfort. They are ideal for use with compressors, fans, vibrating feeders, rotary pumps or electric motors. Manufactured with natural rubber NR, hardness 40, 55, 60 or 70, combined with zinc-plated steel or AISI 304 stainless steel threaded inserts, Elesa+Ganter damping elements are from now available in a wide range of dimensions and shapes. In addition to the already well-known series with cylindrical (DVA.1, DVA.2, DVA.3 – DVA.4, DVA.5) or parabolic shape (DVA.6, DVA.7), Elesa+Ganter has recently introduced on the market new solutions. DVB.6 and DVB.7 rubber bushes with conical shape, which are generally used as bumpers or limit stops for the absorption of vibrations. Standard executions are available with Ø from 20 to 60 mm and stiffness from 49 N/mm to 975 N/mm. New DVC.1, DVC.2, DVC.3 vibration-damping elements with bobbin shape. Under pressure, they allow more lateral movement as well as vertical dampening. Available with Ø from 10 to 95 mm, they provide stiffness from 15 N/mm to 903 N/mm. Also, DVE series bell-shaped mounts, composed of two metallic elements joined together by a rubber anti-vibration body. A round element with a boss and a threaded pass-through hole constitutes the base for fixing to the vibrating machine. Another element, oval or square shaped, constitutes the flange for fastening to the floor. Suitable for applications with rotary machines that do not present big dynamic imbalances, where elasticity is required both vertically and transversely. These damping elements provide stiffness from 13 N/mm to 448 N/mm. Elesa+Ganter buffers GN 454 are used as end-stop buffers, e.g. conveyor trolleys. They can be fixed on the damping side with socket head cap screws DIN 912. They absorb most of the kinetic energy development on impact. They act as dampers and prevent damaging shock and rebound. They also act as sound dampers. These buffers are also used as levelling feet. Finally, LW.A vibration-damping levelling elements, composed of base, plate, stem and washer in zinc-plated steel, NR rubber damping element with NBR synthetic rubber packing ring. Their maximum limit static load is up to 40,000 N and contributes to the stability of the machinery even in the presence of strong vibrations. For more info, visit www.elesa-ganter.in -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- pg no 46 Nilkamal promotes Aisle Master & Combilift Forklifts Nilkamal Material Handling Division has some advanced technology tie-ups with international partners Aisle Master & Combilift. Nilkamal Material Handling believes in protecting customers’ products, increasing their storage efficiency and improving their labour productivity. Aisle Master articulated forklift and Combilft multi-directional forklift fits the bill. Aisle Master is an articulated forklift designed to work in very narrow aisles of 2.1 metres. It has lift options of up to 12.4 metres so one can make maximum use of the available height. Electric AC motor drive and LPG options with lift capacities up to 2.5 tonnes are available in this and one can carry out normal counter balance forklift and reach truck operations with this unique machine easily. Some of the distinctive features and benefits of Aisle Master are: • Operator comfort and safety integral part of the machine • Ergonomically designed to reduce fatigue and maximise visibility • Full view of both the forks and the load • Reduced load cycle times and product damage • Large super elastic tyres, can take product from the rack in the warehouse to outdoors • Robust chassis construction • Integral side shift fitted as standard • Two motors only - traction and hydraulic • Low maintenance • Indoor and outdoor. Combilift is all wheel-drive multidirectional forklift. It is a unique combination of forklift, side loader and reach truck. It is the most safe and cost effective solution to handle long and heavy awkward loads. Combilift is available in electric, diesel and LPG variants. Combilift benefits its customers in: • Safe product handling • Space saving • Long load handling • Indoor and outdoor • Increasing productivity • Less product damage • Easy operation and maintenance. Nilkamal designs and provides an optimised cantilever storage system through its India based sales and manufacturing JV with BitoLagertechnik, Germany. Contact Nilkamal Limited Email: marketing@nilkamal.com Toll free: 1800 1219 115 www.nilkamal.com -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------