IN FOCUS - 東芝機械株式会社 O˜cial magazine of Toshiba Machine (Chennai) Pvt. Ltd. | AUGUST 2012 CUSTOMER IN FOCUS BHAVYA CONTAINER & ESTATE COMPANY Desai …

Ed

itio

n-2

O�cial magazine of Toshiba Machine (Chennai) Pvt. Ltd. | AUGUST 2012

CUSTOMERIN FOCUSBHAVYA CONTAINER& ESTATE COMPANYDesai Group of Companies

Ronak V RawalManaging Director

Leading edge

The origin of Desai Group of Companies dates back to more than 3 decades ago. Started as a trading and distribution housein Ahmedabad, gradually it forayed into the business of off-set printing. Further it ventured into warehousing and renting of Godown Spaces. This group later expanded as a distributor encompassing varied businesses such as Paper, Chemicals including Organic chemicals, Petroleum Products, Poly Propylene and Poly Ethylene Granules. Late Shri.Natvarlal P.Desai was the visionary who started this business enterprise.

The list of principal companies in its fold as a distributor comprises of flag ship companies such as: Reliance Industries Limited, West Coast Paper Mills Limited, Shreyans Industries Limited, Shree Shyam Pulp & Board Mills Limited, Rama Newsprint & Papers Limited, Shree Bhawani Papers Mills Limited, Simplex Paper Mills Limited, Bharat Petroleum Corporation Limited, Pidilite Industries Limited, and Vinyl Chemicals Limited.

Being a family concern, its varied units are owned and managed by sons of Late Shri. Natvarlal P.Desai with support from other family members and professionals.

Not being content with trading activities, Desai Group made its entry into manufacturing sphere by forming a new company; BHAVYA CONTAINERS & ESTATE CO., for manufacture and selling of Paint pails and other packaging articles. At the helm of this company is Mr. Ronak V. Rawal son of Mr. Vashishtha I Rawal drafted into business even before he could complete his academic aspirations, this young and energetic business man who is still in his early thirties has very ambitious plans for this unit.

Bhavya Containers was started in a very small way with just one injection moulding machine in 2005. Quality of products that rolled out of Bhavya and the sustained efforts of Ronak Bhai complemented each other, triggering continues stream of orders from paint majors – Berger Paints, Shalimar Paints and Esdee paints. Besides paints industry, Bhavya Containers caters to packaging requirements in oil, adhesive, ink, pesticide and chemical industries.

Today with 10 nos of injection moulding machines from Toshiba Machine, erstwhile unit of L&T Company Bhavya Container has attained number one position in Gujarat in the realm of Paint Pails business. Ronak Bhai fondly recollects the supportive role, our company has played in the growth path of his company.

During my tete-a tete with Ronak Bhai, he was all praise for the technology level of our machines. His confidence in our machines is of high order for its sheer performance. As per him, business relationship cannot be nurtured only with good product. He values our friendly and highly responsive relationship that makesit very conducive to discuss and resolve any business issues.

Bhavya containers houses major range of models of machines from our company starting from 60T and up to 550T. Every year there is an addition of capacity with new machines getting added. Ronak Bhai had special mention about the excellent support received by his company from the local sales and service team of Toshiba Machine at Ahmedabad.

Looking forward, Ronak Bhai, has plans to eye areas other than paint pails. One of the options he is weighing is automotive. We signed off wishing him the very best in his new project, at the same time assuring of our best support and services in his expansion plans.

BHAVYA CONTAINER& ESTATE COMPANYDesai Group of Companies

V.Padmanaba Bhat

DMC- Dough Moulding Compound comprises of Glass fiber, Polyester Resin, Fillers, Catalyst, Additives, etc. Its excellent electrical and mechanical properties, heat resistance, chemical corrosion resistance, and adaptability to various molding processes make it a preferred choice especially in electrical applications. Some of the popular applications of DMC are electrical components like switches, distribution boards, meter casing, insulators etc. In addition its presence is felt in auto accessories, home appliances like microwave dishes.

These molding compounds are available in dough form which requires force feeding to the machine feed throat during the material charging. This calls for a special mechanism to be interfaced with injection moulding machines to force feed the dough. TMIC has developed this feature, which forces the dough to the hopper feed throat, with a settable speed and force. The drive for this is taken from an additional servo power pack, which helps to retain the original capabilities of the machine. This feature added to our energy efficient servo machines makes it an attractive value proposition for the end users. This feature is now available for injection units ranging from 200 to 900 in TMIC machines.

- Benny Mathew

Stuffing unit forDMC moulding

CASE STUDY-Energy efficiencyof TMIC machines

Energy Cost is one of the major cost components in the molding industry, it is of paramount importance to have energy efficient machines to stay ahead in the chronic competitive business environment. The impact of energy efficient machines can go far beyond energy savings and acts as an important contributor for growth.

Toshiba machine offers range of innovative energy efficient Servo Hydraulics based machines which gives significant benefits like

• Reduced operating cost as specific energy consumption is less• Lower maintenance cost and extended equipment life due to

gear pumps which is having less movable mechanical elements,

• Enhanced molding environment quality & decreased pollution due to less noise & cooling water requirement

• Increased product sale & marketability, due to superior precision & control of molding process leads to good quality componentsat low cost.

In a recent energy study involving parts of writing instruments, it was found out that a Servo Pump based machine would offer approximately 22% energy savings. A comparative work out is shown below.

TMIC offers Servo Hydraulics based machines in the range 40Ton to 1000Ton and shot weight ranging 21gm to 6643gm.

- A. Muthuraman

HYDRAULICS SYDFEE SERVO

Product Zylo Section Zylo Section

No. of Cavities Nos. 20 20

Raw Material PP PP

Product Weight Gms 1.185 1.185

Runner Weight Gms 17.8 17.8

Shot Weight Gms 41.5 41.5

Cycle Time Sec 17.4 S

Energy kWh 5.40 4.28Consumption

Specific Energy kWh/Kg 0.619 0.484Consumption

Energy Savings % 21.80

Injection profile

The injection phase is critical in injection molding process as it not only produces a part, but also influences the properties of molded part. Various quality parameters of a part such as Surface finish, appearance, clarity, mechanical properties, dimensional & part weight requirements are determined in this critical phase.

By optimizing an injection phase, one can even influence the location of weld lines, their visibility, surface glossiness and control a critical dimension of the part.

Here are some guidelines for selecting optimum injection process parameters

To a greater extent, the absolute injection speed is determined by complexity of part, surface finish requirements , gating system and quality of mold being used to produce the part.

To produce a part with a simple contour and almost even wall thickness, a simple single stage injection speed is highly recommended. Multiple stage injection profile is preferred under the following scenario:

1. if there is a change in wall thickness in the part2. Pin point gating/ submarine gating in a mold for multi

cavity parts. 3. Considerably longer runner length in cold runner mold4. Longer flow path in article 5. Complex contour of molded part

To arrive at optimum injection process parameters, it is desirable to start the injection with slow speed and a close monitoring on actual injection pressure will help to optimize. The injection pressure is dependent on type of material processed, type of gating system adopted in mold, melt temperature of material & mold wall temperature.

During the process of optimizing, if the injection time is saturated even after a change in set speed, it may be an indication that the actual injection pressure has reached the set pressure and hence the velocity remains almost same in spite of increasing the injection speed.

Under such scenario, increasing the injection pressure would be a better option so that the injection process works on velocity mode and not dependent on pressure.

Based on the contour of part, selecting a higher injection pressure than actual pressure achieved during injection is desirable, so that the intended injection velocities are achieved.

While opting for multi stage injection, the following guide line would be more helpful.

At the end of an article, if there is a reduction in wall thickness, higher injection speed may be used till the melt enters the thinner wall section and then the speed can be reduced gradually.

If there is a pin point or submarine gate, reducing injection speed at the entry of melt through the gate would avoid many defects including jetting .

If the runner length is longer, keeping higher injection speed till the gate point in article would help to achieve required melt temperature in the cavity.

If the article contour is complex in nature, it is advised to opt for multi injection speed stage based on melt flow pattern in the cavity.

- C.Somaskandan

Parts where Stepinjection is employed

(To be continued in the next edition)

- [email protected]

UnlockingProfitability inInjection MoldingManufacturing companies today are under severe pressure to deliver growth and at the same time enhance profitability. As inter-departmental functions rally to respond to this challenge, they are at the risk of deteriorating the business as against an expected high growth. The keenness to drive growth can introduce a costly and unmanageable level of complexity, which muddles different arms of the business and creates a drag on the overall profitability.

Marketing and R&D staff are driven by their appetite to bring in more clients, enter new markets, innovate in search of revenue, growth and market share. They add new product lines; create newer channels and customers at a go without considering the cumulative impact on existing business. Manufacturing that aims to utilize existing production facilities fill plant capacities in a way that strains the manufacturing and distribution systems. Executive with their individual skills can lead the management to believe that one or other of their actions or business plan would benefit the company.

This gradual spread and resulting complexity introduce new costs across the business in ways that are not easily traced to their origin. This obscures the profit contribution and leaves a lot to defend for. However the important question to ask is whether this something that we can do without?

This situation is increasingly a problem for both established small end plastics manufacturers and systems integrators. For most plastic component producers pricing power has deteriorated over the past decade, availability of capital, technology, skilled manpower and maturity of the market place is adding to the pressure to deliver revenue growth on the base business that much more intense. India has reached a stage where even big businesses tend to sell large scale capital assets and real estate for enhancing quarterly cash flow as the business gets tougher. By sorting certain product lines, customers, considering an adaptive pricing model and rationalizing manufacturing, distribution capacity would greatly help simplifying the cost model and pave a way forward towards a more healthy existence. This is nothing but revisiting the basics of what to offer, when to offer, whom to offer and How to offer. This simple exercise helps … always.

Toshiba Machine toLaunch Indian-made InjectionMolding Machines to North Americaon a scale of 700 units per yearby 2015-16

Toshiba Machine will launch the North American sales of the injection molding machines manufactured in India this autumn. It will release the product made at the ex-L&T plastics machinery, the Indian major company that was purchased in the year 2012. Toshiba Machine had the aim of developing the Indian market by the purchase of this company, looking at the business enquiry for the low price hydraulic type machine in the United States, Toshiba Machine would like to seize the momentum and expand the North American sales to 700 units/year by the fiscal year ending March, 2016.

Toshiba Machine established a plan to sell 5200 units globally by the fiscal year ending March, 2016. It will promote the Indian made machines to Central and South America and plans to sell 300 units there. The global market scale at the same period is assumed to be 71,000 units. It is expected that the hydraulic type machine with the mold clamping force of ≤350 tons will be focused for starting the North America sales of the Indian made injection molding machine. But at the outset the 100 ton machines will be sold. The sales promotion would be focused mainly at the plastic molding trader of small parts including miscellaneous goods.

It is expected that the hydraulic type machine will account for half of the entire market in the United States though the high-value-added fully electrically operated type machine, in which this company is skillful, is popular in developed countries. It will counter the Chinese and South Korean manufacturers with strong price competitiveness in the small parts field by adopting for the North America specifications.

Toshiba Machine acquired all the stocks of the ex-L&T Plastic Machinery, manufacturer of the hydraulic type injection molding machine in the year 2012. It made the company as its subsidiary company as Toshiba machine Chennai. In India Toshiba Machine is selling injection molding machines imported from Japan and China and is now focused at sales expansion by the on-site production.

Press Release: Nikkan Kogyo Shimbun ltd.(business & technology daily news)Article Translated in English

2681 2003

Editorial Team: Girish R Hindigol, V. P. Bhat, Benny Mathew, C Somas Kandhan, S. Narayanaswamy, R. S. Moorthy, A. Muthuraman,

• SALES & CUSTOMER SUPPORT CENTRES:

» ChennaiMobile: +91 98410 01914e-mail: [email protected]

» KolkataMobile: +91 98300 25608e-mail: [email protected]

» MumbaiMobile: +91 93231 51850e-mail: [email protected]

» New DelhiMobile: +91 98990 20315e-mail:[email protected]

Marketing Division:Toshiba Machine (Chennai) Pvt LtdChembarambakkam,Off-Chennai-Bangalore HighwayP.O.Box No.5, Chennai – 600 123Tel :+91 44 - 2681 2000/2023 Fax :+91 44 - 2681 1088/2681 0777e-mail: [email protected]

For automatic conveying solutions contact bikram.beura @toshiba-machine.co.in