Prism group's new corporate Presentation

Germany – India

MISSION

TO SUPPLY PAINTING LINES & POWDER COATING LINES TO ANY PRODUCT MANUFACTURED OUT OF METAL, WOOD & PLASTICS.

SUPPLYING CUSTOM DESIGNED PAINTING/ POWDER COATING LINES.

SUPPLYING PRE-DESIGNED, PACKAGED PAINTING AND POWDER COATING LINES, PAINT BOOTHS.

Germany / India

TURNKEY SOLUTION PROVIDERS

Engineering (Germany, India)

Project Management

( India & Germany )

Design(Germany )

Manufacturing(India or

Germany)

Installation & Commissioning

(Germany & India )

Service Support (World Wide)

Concept &Consultancy (Germany )

OMT DESIGN TEAM – STUTTGART, GERMANY

LEADERSHIP TEAM IN INDIA

THE PRISM GROUP’S COMPETITIVE EDGE

•OVER 450 PAINTING AND POWDER COATING PLANTS INSTALLED WORLD WIDE

•PROVEN DESIGNS FROM 50 YEARS OLD OMT – GERMANY

•CATERING TO WIDE RANGE OF APPLICATIONS WORLD WIDE

•GERMAN ENGINEERING, INDIAN MANUFACTURING – VALUE FOR MONEY, PROJECTS TO CUSTOMERS.

PRISM FACTORY & HEAD QUARTERS IN BANGALORE

NEW MANUFACTURING FACILITY OF OMT INDIA NEAR BANGALORE, INDIA

PAINTING LINES

BLAST ROOMS &

PAINT BOOTHS

E – COAT LINES

POWDER COATING

PRISM OFFERS TURNKEY PLANTS

Europe

South East Asia & China

The Middle East

Eqypt & Turkey

North America & South America

Number of Installations in Various Geographical RegionsNumber Of Installations

1015202530354045

Number of Installations

Number of Plants Installed

Valves Bus Body, Truck &

Rail Coaches/Wagons painting

Drums/ Barrels

Bicycles and Two Wheelers

Lighting Aerospace0123456789

10Number of Installations

Number of Plants Installed

MAJOR PLANT PHOTOS

SOME OF THE MARQUEE CUSTOMERS

Sales Network

• Chicago • Bangkok • Singapore • Ho Chi Minh City • Shanghai • Moscow• Chennai • Pune • Delhi • Baroda • Dubai • Cairo • Dammam • Stuttgart

OUR BUSINESS SEGMENTS

1 •Painting Lines

2 • Powder Coating Lines

3 • Blast Rooms & Paint Booths

PAINTING LINES

PLASTIC BUMPER PAINTING LINE

E – COAT LINES

PAINTING LINES FOR WHEELS

ROBOTIC ENGINE PAINTING LINE FOR VOLVO JAPAN & VOLVO FRANCE

ADVANCED ELECTRONIC CONTROLS FOR AUTOMATION AT VOLVO JAPAN AND FRANCE

PAINTING LINE OF BICYCLE FRAMES

PAINTING LINE FOR HHP ENGINES AT CUMMINS

PLASTIC PAINTING LINE FOR IJL

VALVE PAINTING LINE FOR FISHER SANMAR

Painting line for assembled machine – Volvo Bangalore

CONTROL SYSTEM FOR PAINT SHOP

INDUSTRIAL PC

HMI OPEN SCREEN

REAL TIME MONITORING AND MODIFICATION IN PID VALUES TO MAKE BOOTHS MORE COMFORTABLE AND OVEN AT PROPER TEMPERATURE

CENTRAL MASTER CONTROLS

DISTRIBUTED CONTROLS ON PROFIBUS AND INTERFACE TO PRODUCTION PLANNING SERVER

ROBOT INTEGRATED WITH CONVEYOR LINE.

•Painting as per the bar code values read from Engines

•Uniform painting which gives uniform thickness all over the engine

•Emergency controls to pause and restart the painting.

•Communication through Profibus

•Paint reaches all the points in the engines

ONLINE PAINT COAGULATION AND SEPARATION SYSTEM

CONVENTIONAL SLUDGE PIT

ust BOOTH

P.1VP1P.3AG.2

AUTOMATIC SLUDGE REMOVAL SYSTEM

WATER TANK (PIT TANK)

CHEMICAL DOSING GROUPPUMP

ADVANTAGES OF ONLINE PAINT COAGULATION SYSTEM• The change of water in the spray booth must be carried

out only every 12 months maximum.• The automatically extracted sludge has a very low

volume.• By continuous mud extraction ,the booth water volume

will be reduced of 70%• Spray booths maintenance coasts will be reduced of more than 90%• Our plants are completely automatic and the operation is

very easy to operate.• The size of the pit required is negligible while comparing

to the conventional type systems.• The percentage of paint in the circulating water will be

maintained at a level of < 0.2% at any time.

MATERIAL HANDLING SYSTEM

FLOOR CONVEYOR SYSTEM

CONVEYOR

GROUND CONVEYOR

POWER AND FREE CONVEYOR SYSTEM

POWDER COATING LINES

WE CATER THE FOLLOWING INDUSTRIES

ELECTRICAL PANELS/ CUBICLES

TRANSFORMERS CONSTRUCTION MACHINERY

ALUMINIUM & ARCHITECTURAL COMPONENTS

Contd.

VALVES

AGRICULTURAL IMPLEMENTS

Contd.

STEEL FURNITURE

ELEVATORS

DISH ANTENNA

CONSUMER DURABLES

PALLET TRUCKS

ALUMINIUM & ARCHITECTURAL COMPONENTS

ELECTRIC & POWER COMPONENTS

TRANSFORMERS

CONSTRUCTION / EARTH MOVING MACHINERY

VALVES

ELEVATORS

STEEL FURNITURE INDUSTRY

CONSUMER DURABLES

PALLET TRUCKS

AGRICULTURAL IMPLEMENTS

DISH ANTENNA

HOLLOW CONE

FLAT JET

V - JET

NOZZLES AND ACCESSORIES

S P R A Y T U N N E L- - - - - - - - - - - - - - - - - - - - - - - -

TUNNEL

MAINTENANCE DOOR

FILTER

TANKVERTICAL PUMP

RISERNOZZLE

CONVEYOR SUPPORT

DRAINOVERFLOW TO SPARY

FOR NOZZLES CONN.

FOR NOZZLE

QUICK RELEASE COUPLINGS

END CLOSING

SPRAY PRETREATMENT

SPRAY PRETREATMENT TUNNEL

SPRAY PRETREATMENT – NOZZLES & RISERS ARRANGEMENT

SPRAY PRETREATMENT TANKS

DIP PRETREATMENT SYSTEM WITH HOIST

DIP PRETREATMENT SYSTEM WITH TRANSPORTER

PROCESS CONTROL USING SCADA

PROCESS MONITORING - SCADA CONTROLS

POWDER COATING BOOTH – STAINLESS STEEL CONSTRUCTION

POWDER COATING BOOTH FOR CONSTRUCTION MACHINERY

POWDER COATING BOOTH WITH RECOVERY SYSTEM

INSIDE VIEW OF POWDER COATING BOOTH

POWDER COATING BOOTH – PLASTIC CONSTRUCTION

POWDER COATING BOOTH WITH RECOVERY SYSTEM

POWDER COATING BOOTH FOR CONSTRUCTION MACHINERY

POWDER COATING BOOTH

POWDER COATING BOOTH WITH CARTRIDGE RECOVERY SYSTEM

POWDER COATING BOOTH WITH CYCLONE AND CARTRIDGE AFTER FILTER RECOVERY SYSTEM

MULTICYCLONE RECOVERY SYSTEM FOR POWDER COATING BOOTH

MULTICYCLONE WITH CARTRIDGE AFTER FILTER RECOVERY SYSTEM FOR POWDER COATING BOOTH

FLEXIBLE RECOVERY SYSTEM

POWDER CURING OVEN – VARIOUS TYPES

GROUND MOUNTED OVENS

GROUND MOUNTED OVEN

INSIDE VIEW OF POWDER CURING OVEN

GROUND MOUNTED OVEN

GROUND MOUNTED OVEN WITH POWER & FREE CONVEYOR

PRISM’S ELEVATED ‘A’-ZONE TYPE POWDER CURING OVEN

ELEVATED ‘A’-ZONE TYPE POWDER CURING OVEN

ELEVATED ‘OVEN – COMPONENT ENTRY AND EXIT

COMBINATION OF DRYING AND CURING OVENS

GAS CATALYTIC OVENS

CONTROL PANELS

LAMELLAR CLARIFIER FOR PHOSPHATE SLUDGE REMOVAL

FILTER PRESS FOR PHOSPHATE SLUDGE REMOVAL

WASTE WATER TREATMENT PLANTS

DEMINERALISED WATER RECYCLING PLANT

OVERHEAD CONVEYORS

POWER AND FREE CONVEYOR

OVERHEAD CONVEYORS

BLAST ROOMS & PAINT BOOTHS

SCOPE OF PRESENTATION

1.BLASTING SYSTEMS

2.PAINT BOOTHS

BLASTING SYSTEMS

Blasting is a process in surface preparation for cleaning metal objects free oil and rust and leaves the surface ready for painting or bonding.

Types of blasting

1.Centrifugal Blasting

2.Wheel type Blasting

AIR ASSSISTED BLASTING

ENT BLASTING

MACHINE Our business associate CLEMCO INTERNATIONAL GMBH is the European headquartered Clemco Industries, the world's largest manufacturer of air-powered blast equipment used to remove Mill scale of rolled steel, De scale the forgings, Clean sand castings, Deburring of Gear components, remove coatings, to prepare the surface for further Coating process

BIG CLEMNo Job too big, even for the biggest jobs CLEMCO designed a wide range of Bulk Blasters. Customers can choose between 1.500 and 10.000 Liter capacity, either stationary or portable design. On request we offer mobile units Highway towable. The additional choice on outlet quantities makes any BIG CLEM to fit your needs.

GFROM SMALLEST

TO LARGEST BLASTING ROOMS

CABINET TYPE BLASTING ROOM

ENT PROTECTIVE

CLOTHING & HELMET

Abrasive Blast cleaning requires specially designed protective clothing and an air-fed respirator. CLEMCO´s Apollo helmets, blast suits, filters and related equipment deliver the highest level of protection you can buy. Wearing CLEMCO Operator Safety Equipment lets you concentrate on the job of abrasive blasting. Inside your comfortable Apollo helmet, you breathe clean, filtered air, while the CLEMCO blast suit and gloves protect you from rebounding abrasive.

G BLAST HOSEInner tube of wear-resistant rubber or super wear-resistant rubber quality

Intermediate layers for higher pressures or high flexibility Working pressure: 12 bar

G BLAST NOZZLESpecial Nozzles: Angle nozzles with single or multiple orifices Flange mount nozzles fit quick coupling nozzles holders Jacketing Materials: Aluminum, Urethane Rubber Liner Materials: Silicon Carbide, Tungsten Carbide, Boron Carbide.

G REMOTE VALVES

The RMS 2000 is a consequent further development of the prior model RMS-100. Offering highest operating comfort, minimized pressure loss, quick reaction time as trouble free working, she sets new standards and has highest reputation in the market within the pneumatic Control Valve.With the following accessories you make the RMS 2000 a complete package of highest reliable pneumatic or electro-pneumatic remote control system

G METERING VALVES

Metering and valve actuation are separate functions

Accurately meter all common blast media

Fail-to-Safe design stops media flow instantly if air or electric power is interrupted

Works with pneumatic or electric remote controls

Installs in minutes on most blast machines.

LE AREA OF COVERAGE

FOR SA – 2 ½ FINISH

1. 6 mm Nozzle - 10 Sq Mt / Hr

3. 9.5 mm Nozzle - 22 Sq Mt / Hr

COMPRESSOR (AIR

REQUIRMENT)

Pressure at the Nozzle (psi) Nozzle Orifice 50 60 70 80 90 100 125 140

Air (In cfm) Abrasive

& HP requirements

No. 2 (1/8")

11 .57 67 2.5

13 .77 77 3

15 .88 88 3.5

17 1.01 101 4

18.5 1.12 112 4.5

20 1.23 123 5

25 1.52 152 5.5

28 1.70 170 6.2

Air (cfm) Abrasive (cu.ft./hr

& Lbs/hr) Compressor hp

No. 3 (3/16")

26 1.5 150 6

30 1.71 171

33 1.96 196 8

38 2.16 216 9

41 2.38 238 10

45 2.64 264 10

55 3.19 319 12

62 3.57 357 13

No. 4 (1/4")

47 2.68 268 11

54 3.12 312 12

61 3.54 354 14

68 4.08 408 16

74 4.48 448 17

81 4.94 494 18

98 6.08 608 22

110 6.81 681 25

No. 5 (5/16")

77 4.68 468 18

89 5.34 534 20

101 6.04 604 23

113 6.72 672 26

126 7.40 740 28

137 8.12 812 31

168 9.82 982 37

188 11.0 1100 41

No. 6 (3/8")

108 6.68 668 24

126 7.64 764 28

143 8.64 864 32

161 9.60 960 36

173 10.52 1052

196 11.52 1152 44

237 13.93 1393 52

265 15.60 1560 58

No. 7 (7/16")

147 8.96 896 33

170 10.32 1032

194 11.76 1176 44

217 13.12 1312 49

240 14.48 1448

254 15.84 1584 57

314 19.31 1931 69

352 21.63 2163 77

No. 8 (1/2")

195 11.60 1160 44

224 13.36 1336

252 15.12 1512 56

280 16.80 1680 63

309 18.56 1856

338 20.24 2024 75

409 24.59 2459 90

458 27.54 2754 101

S Abrasive Characteristics Comparison Material Mesh

Size Shape Density

lbs/ft3 Mohs Friability Init.

Cost No. of Cycles

Per use Cost

Source Typical Applications

Sil. Sand 6-270 100 5.0-6.0 high low 1 med. nat. Outdoor blast cleaning

Min. Slag 8-80 85-112 7.0-7.5 high med. 1 - 2 med. b-p Outdoor blast cleaning

Steel Grit 10-325 230 8.0 low high 200+ med. mfg. Removing heavy scale

Steel Shot 8-200 280 8.0 low high 200+ low mfg. Cleaning, peening

Al. Oxide 12-325 125 8.0-9.0+ med. high 6 - 8 med. mfg. Cleaning, finishing, deburring, etching

Glass Bead 10-400 85-90 5.5 med. med. 8 - 10 low mfg. Cleaning, finishing

Plastic 12-80 45-60 3.0-4.0 low/med. high 8 - 10 med. mfg. Paint stripping, deburring, cleaning

Wheat Starch 12-50 90 2.8-3.0 high high 1 high b-p Paint stripping, cleaning

Corn Cob 8-40 35-45 2.0-4.5 med. low 4 - 5 low b-p Removing paint from delicate surfaces

= Angular = Spherical nat = Natural b-p = By-product mfg. = Manufactured

ABRASIVE RECOVERY SYSTEMS

Screw Conveyor system for recovering and Loading onto the Bucket

Elevator or Vacuum Suction system.

SCREW CONVEYOR SYSTEM

Belt Conveyor system can be offered as an alternative for recovering

the grits/shots and Loading onto the Bucket Elevator or Vacuum

Suction system.

BELT CONVEYOR SYSTEM

Scrapper floor system is a simple

mechanism to recover the

shots/grits inside the chamber.

Rugged steel vanes are suspended

on a pneumatically powered frame.

This pushes the media forward. As

the frame moves back, the vanes

ride up over the mounds of media,

and then falls back into position for

the forward push. ABRA

SCRAPPER FLOOR SYSTEM

Conveying distance up to 10

meters

High efficiency of filter

cartridge

Noise level below 72dB @ 1

meter distance

MANUAL SUCTION SYSTEM

A bucket elevator - for recovering

grits/shots for re-cycling.

Compact, easy to operate and maintain

automatic systems with wide

configurations offered

BUCKET ELEVATOR SYSTEM

The suction unit is of strong construction with sturdy maintenance access

doors and contains the cyclone/filter section fitted with safety relief valve

and automatically sequenced reverse pulse cleaning system, an acoustic

lined motor compartment housing an el drive motor and vacuum pump

complete with exhaust silencer fitted with a vacuum gauge.

VACCUM SUCTION SYSTEM

LIQUID PAINT BOOTHS

Side draft Down draft Cross draft Semi down draft

Dry paint Arrestor Filter type Booths

Water wash Booths

MARQUEE CUSTOMERS

Scope of Supply: Pressurised Down Draft Dry Booth Dimension: 12 x 8 x 6 meters.Component Painted: Dumper Bodies.Year of Commissioning: 2010

Pressurised Down Draft Booth dimension of 20mX6mX6m was supplied in the year 1999 to Al-Shirawi, Dubai to paint Mercedes Benz

Commercial vehicles Vehi

1613 Tippers

3116 Truck

Scope of Supply: Down Draft Dry Booth Dimension: 10 x 5 x 5 meters.Component Painted: Cabs.Year of Commissioning: 2003Ve

A Conveyorised line comprising of Robotic Flaming, 3 Pressurised Water Wash Paint Booths, 3 Flash Off Zones, and Baking oven along with Temperature and

Humidity Controller was supplied to Plastic Omium Varroc Ltd, Pune for painting automobile Bumpers- Supplied in the year 2009.

Pressurised Side Draft Water Wash Booth Installed at M/S. India Japan Lighting Ltd, an OE supplier to

Maruti Suzuki Ltd and Telco for painting their Headlights. This plant was supplied in the year 2004

Scope of Supply: Shot Blasting Room & Down Draft Dry Booth Dimension: 15 x 8 x 9 meters.Component Painted: Heat Exchanger, Pressure Vessels & TurbinesYear of Commissioning: 2009

Steam Turbine

Pressure Vessel

Scope of Supply: Non-Pressurized Down Draft Dry Booth. Booth Dimensions: 24m x 8m x 6mComponent Painted: Defence Equipments & Missile Launchers.Year of Commissioning: June 2009

Non-Pressurised Down Draft Paint Booth measuring 8mX6mX5m of 5 nos. was supplied to M/S. Disa India Ltd, Bangalore between the year

2002-2009. Disa are manufacturers of Wheel Blasting Machines

Process Performance Cast Iron Motors

Modular Induction Motors

Scope of Supply: Down Draft Dry Booth Dimension: 7 x 5 x 5 meters.Component Painted: Induction & Process Motors.Year of Commissioning: 2009Mac

Tobacco Processing Machine

Scope of Supply: Pressurised Down Draft Dry Booth Dimension: 10 x 5 x 5 meters.Component Painted: Tobacco Processing Machine.Year of Commissioning: 2008M

Injection Moulding Machine

Scope of Supply: Down Draft Dry Booth Dimension: 10 x 6 x 5 meters.Component Painted: Plastic Processing Machine.Year of Commissioning: 2005Mac

Safety Equipments for Airbus

Lightings for Airbus & Boeing

Scope of Supply: Pressurised Cross Draft Dry Booth Dimension: 9 x 6 x 4 meters.Component Painted: Lightings & Safety Equipments.Year of Commissioning: 2009Aero

Scope of Supply: Pressurised Preparation Booth, Pressurised Side Draft Dry Booth with Wet Scrubbing Unit and Drying OvenDimension: 9 x 5 x 5 meters.Component Painted: Air Craft Equipments.Year of Commissioning: 2012Aero

Scope of Supply: Pressurized Down Draft Water Wash Booth & OvenBooth Dimensions: 11m x 7m x 7mComponent Painted: Soil Compactors & Pneumatic DrillsYear of Commissioning- June 2006Infr

Scope of Supply: Non-Pressurized Down Draft Dry BoothBooth Dimensions: 8mX6mX5mComponent Painted: Concrete Mixers & Batching PlantsYear of Commissioning- June 2007Infr

Scope of Supply: Pressurized Down Draft Dry Booth with Wet ASU-2 Nos.Booth Dimensions: 18mX7mX7mComponent Painted: ExcavatorsYear of Commissioning: June 2010

Scope of Supply: Non-Pressurized Down Draft Dry Booth with Insulated Panels. Booth Dimensions: 18mX9mX9mComponent Painted: Pneumatic DrillsYear of Commissioning- June 2008

Scope of Supply: Non-Pressurized Down Draft Dry Booth. Booth Dimensions: 10m x 5m x 5mComponent Painted: Backhoe Loaders.Year of Commissioning: June 2009Infr

Scope of Supply: Non-Pressurised Down Draft Booth & Thermo Reactive OvenBooth Dimensions: 14m x 5m x 5mComponent Painted: Railway wagon.Year of Commissioning- 2011Infr

Scope of Supply: Non-Pressurised Down Draft Booth & Thermo Reactive OvenBooth Dimensions: 31m x 5m x 5mComponent Painted: Railway wagon.Year of Commissioning- 2012Infr

New Development in Oven Technology

“Flameless Gas Catalytic Radiation Oven”

What is Infra-Red Radiation ?

• Long wave radiation.• Flameless catalytic reaction.• Temperature of 3700C generated at the catalytic

surface.• Used LPG or Natural Gas.• Pad consists of ceramic fiber blanket impregnated

with special catalyst, reaction promoters and stabilizers.

How does it work ?

OxidationGas + Oxygen + Catalyst Infra Red energy + CO2 +

Water Vapor + traces of CO and Nitrogen Oxide

Benefits• Substantial fuel and energy(electricity) saving.• Plant space saving.• Fast curing of paint on components which have low thermal

stability (opens up whole area of new application).• Quick heat up time for powder coated objects resulting in

better finish.• Easy to design the oven with several benefits for large and

heavy components.• Reduced WIP.

Limitations• Test trials are required for designing the oven in the absence

of technical information.

SHOWER TESTING LINE FOR TOYOTA KIRLOSKAR

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