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O�cial magazine of L&T Plastics Machinery Limited | AUG 2012
Mr. Jadavjibhai L ShahChairman
2681 2003
Editorial Team: V. Padmanaba Bhat, Benny Mathew, C Somas Kandhan, S. Narayanaswamy, R. S Moorthy, A. Muthuraman
Greatwhite Electricals Pvt. Ltd.Greatwhite Electricals Pvt. Ltd.
26810777
One cannot stop uttering the word Electrifying when looking at the feat accomplished by Mr. Jadavjibhai L Shah in the domain of electrical switches. The same word also signifies the emotional bond that has been struck between L&T Plastics Machinery Limited (LTPML) and the companies held by Mr.Shah, both in the past and in the present. This strong acquaintance between the two companies is built and nurtured on an edifice of mutual trust and transparent operations.
Mr. Shah has been a towering personality in the electrical space during the past almost half a century of years. Along with his brother Mr.Damjibhai L. Shah, he started Anchor group of companies for manufacturing electrical switches way back in 1963. Those days, along with other like minded entrepreneurs, he had pioneered the concept of modern day piano type of sleek switches which eventually displaced completely the prosaic toggle type Bakelite switches.
Pursuit of excellence in any field is beset with many challenges. Switches are made of Polycarbonate which is an engineering thermoplastics material. It calls for sophistication in technology to mould this material. During mid-nineteen nineties, to source indigenous injection moulding machine and auxiliary equipment that could produce quality polycarbonate switches was a daunting task. That was the time, L&T’s Plastics Machinery Division had introduced its range of cost-effective DL series of machines, which had European stamp of quality and prices matching to the aspirations of Indian moulders.
It did not take much time for Mr. Sagar R Jetly, GM-Technical, who has been spearheading engineering and technical functions of the Anchor group for many years, to spot L&T’s range of machines to churn out quality polycarbonate switches for them. L&T’s range of high quality dehumidified air driers further enriched the quality of mouldings with its enhanced pre drying capabilities.
From then on, it has been the proverbial ‘no looking back’ for both the companies. Till now, L&T has supplied more than 225 machines - 139 Nos to Anchor Electricals Pvt Ltd and 88 Nos to GreatWhite Electricals Pvt Ltd. Each of these machines is supplied with a set of standalone dehumidified air drier, loader and Temperature controllers. Mr. Sagar strongly vouches for high performance and high uptime of these moulding systems.
The growth saga of Anchor group makes an interesting reading. Within a short span of just 4 years the fledgling company shot to the position of numerouno in the domestic market and retained this coveted position thereafter without any respite. Mr. Shah’s passion for electrical switches goes beyond normal tenets of business management. A survey proclaimed “Anchor is available in places where even bread isn’t…” Such is the reach this brand of switches had and the strong and wide dealer network meticulously established and nurtured by Mr. Shah made it possible.
In 2007, Mr. Shah sold electrical business of Anchor group to Panasonic as he could strike a good deal with them. However his fervor for electrical business would not remain dormant for a long time. Immediately on completion of non-compete agreement period, he launched GreatWhite brand of switches. This move by him received accolades from the media, with ‘The Economic Times’ carrying a story that proclaimed “The Shahs just can’t switch off….”. The outlook projected for this business looks impressive with revenue estimation of Rs.150 Crores for the current year.
GreatWhite does not want to confine itself to electrical switches business alone. It has forayed into writing instruments space by launching Italia brand of pens targeting the mass volume market. With dealership network of 1000 merchants who distribute it to about 200,000 retail outlets, ‘Italia’ is poised to reach nook and
Mr. Sagar R Jetly, GM – Technical
Greatwhite Electricals Pvt. Ltd.
speed go together
Whereprecision &
Chennai 600 123, INDIA. | Phone: +91 44 2681 2000 | E-mail: [email protected]| www.larsentoubro.com |
Mr. Jadavjibhai L Shah, Chairman
The Injection unit is specially designed to deliver optimum size to performance ratio. High speed heavy duty twin ball screws ensure durability, rigidity and accuracy. LM guides provided for both injection and nozzle movement ensures minimum frictional losses keeping energy consumption to a bare minimum value. The injection forces are monitored through a high accuracy load cell to ensure precise switch over.
Nozzle touch mechanismEquipped with VFD control and proximity sensor to ensure the nozzle touch force this mechanism makes the machine
truely All electric. Disc springs used in this mechanism ensures high response and accuracy and the highly durable roller ball screw gives the desired reliability.
High speed high power rating of the timing belts gives high load capacity and low noise. It also ensures zero backlash and is easy for maintenance.
Servo Motors and DrivesHeavy duty, force cooled AC synchronous servo motors with its low inertia renders high response to suit the demands of fast cycling applications. This coupled with encoder and resolver ensures high resolution. Compact design with higher torque per Amp makes it a real power house.
Optimized drive configuration well matched with servo motors. High dynamic sampling (2ms) of the control terminals and the serial interface ensures fast current loop response(1ms).
This machine comes with the feature-rich iCon controls which makes the machine user friendly. A 12.1“ TFT touch screen display which conbines control, operation, visualisation and key board in a single unit. It has a built-in memory for storing more than 100 mould catalogues and is equipped with USB interface for data transfer. We can give the inputs in both metric and imperial units. Its wide viewing range gives a clear view of the screen from different angles.
In a Nut shell, the LTPML e-Tech series all-electric machine combines the ruggedness of the twin toggle clamping system and a powerfull injection unit using high end mechatronics that ultimately translates into an highly energy efficient fast cycling machine.
- Benny Mathew
e-TECH SERIES MACHINES Setting new scale in energy efficiency
Focus on energy efficiency assumes greater role than being a mere tool to boost profit margins. It is an imperative ingra-dient of the growth strategies of any responsible corporate citizen. The freightening rate of depletion of the natural resources, forces one to think and find ways and means
to conserve them for the future genera-tions. LTPML’s efforts are always chan-nelised in this direc-tion and it was amply demonstrated with the introduc-tion of energy saving solutions from time
to time. Be it the variable pump technology,DFEE pump technology and the servo pump technology, LTPML was one of the pioneers to quickly reach the advanatages of this technologies to the end customer. The latest entrant to this list is the fully all electric injection moulding machines. Developed in-house with a unique combination of sophisti-cated drive technology and robust mechanical engineering, LTPML all electric e-Tech series machine is poised to address the industry needs in an energy efficient way.
The clamping unit is based on the time tested 5 point twin toggle mechanism with special empha-sis to enhance value proposition. The system comes with:• Shockless mould open and
close using servo system• High speed ball screw for
durability with faster cycles• Wider platens to accommo-
date large size moulds• Anti friction roller bearings for
moving platen• Balanced grease lubrication
system to deliver required quantities of grease to the toggle bushes and ball screws.
Servo controlled belt driven twin ball screw arrangement delivers high speed ejection. This coupled with the facility for central and multi point ejection as per EUROMAP and JIS makes the ejection system suitable for all application require-ments.
corner of India. In the next 5 years, this business alone is expected to generate annual revenue of Rs.500 crores. Manufacturing is gearing up to this task by enhancing the capacity to levels of 20 Lakhs pens per day by end of this fiscal.
Keeping in tune with ambitious plan charted out by GreatWhite for the coming years, L&T Plastics Machinery Limited (LTPML) is equally geared up to deliver machines to them at short notice with moving line concept of assembly in place at its impressive manufacturing facility in Chennai . Days are not far off before quantity of machines sold by LTMPL to GreatWhite zips past the double century mark.
Mr. Shah went speechless when asked to comment on LTPML machines and auxiliary equipment. His body language made it abundantly clear beyond an iota of doubt that he was more than happy with the performance of LTPML products and services. He finally said, “You can write all good things a quality machine is supposed to deliver as LTPML machines go beyond these and perform exceeding all expectations”. He further went on to add that perfect harmony exists in the relationship between GreatWhite and LTPML.
For all of us at LTPML, it was a proud moment!
- V. Padmanaba Bhat
TPM Cladding:Machines with TPM Cladding will have transparent acrylic sheet mounted on metallic frames for the safety gates, electrical cabinet doors and hydraulic station guards instead of fully metal sheets. The advantage of TPM Cladding is better visibility of all important elements of the machine which are required by moulders in Automotive Segment to conform to TPM programme.
Special Screw Barrel:(a) Stellited Screw & Bi-metal Barrel: For processing Glass
Filled Material upto 60%(b) Bimetallic Barrel & Through Hardened Screw: For
Processing Glass Filled material upto 30%(c) Through Hardened Screw & Nitrided Barrel: For
Processing Glass Filled material upto 10%(d) PET Screw with 25:1 L/D ratio: For processing PET Resins(e) Special Screw Barrel for Processing UPVC & CPVC(f) Barrier Profile Screw: For better Melt Homogeneity and
Plasticizing(g) Also material specific screws are available for Nylon etc
TPM Programme:TPM Programme is a software feature which helps in monitoring periodical Safety & Maintenance Check points.
Good & Bad Part Selector:This feature helps in segregating the bad parts from good ones based on comparison of set values of certain critical parameters vis-a- vis actual values. Flexible chute beneath the platens gets signal to direct the mouldings in the appropriate directions.
PC Connectivity:This optional feature is to facilitate storing and accessing of mould catalogues in excess of 60 Nos.
Switch Off Programme:Machine will stop automatically based on date and time set after purging sequence for a Set Cycle
Process Start - up:Process Start-up helps in getting an idea for setting process parameters such as Clamping Force, Dosing Stop, Injection Pressure and Temperature based on inputs like Component Dimension details, Material and Shot Weight.
Switch On Programme:The pump, heater and Oil Pre-Warming will be switched on automatically exactly at the time and date set on the machine.
Process Capability Study and Statistical Process Control:This feature helps in understanding the machine’s capability on repeating the various processing parameters like Shot Weight, Melt Cushion, Injection Time, etc within the set control limits
Programmable Inputs &Outputs:This electrical cum software feature helps in interfacing external additional units like Blending Units, Mould Temperature Control etc..up to 6 Nos. in our Control
- A.Muthuraman
Some more to follow in the next edition
Process Data Statistics:This software feature helps in analyzing the process data of eight important parameters for the last 256 shots on a continuous real time basis (1024 would be available in a short time) which can be downloaded in Excel Sheet
that makes LTPML injection mouding machines more versatileWIDE ARRAY OF FEATURES
Plastics processing is influenced by many factors viz., raw materials that come in different grades & varieties, varying levels of sophistication in mould technology and most importantly the capability of machine to monitor & control process parameters.
This necessitates configuring of machine with relevant optional feature to address specific needs of an application. With wide range of standard & optional features supporting LTPML injection moulding machines the above task is easily met.
Thermosetting polymer is a pre-polymer in a soft solid or viscous state that changes irreversibly into an infusible, insoluble polymer network by curing. Curing can be induced by the action of heat or suitable radiation or by both means. A cured thermosetting polymer is called a Thermoset.
Injection moulding of thermoset material imparts itself to automating the process which can result in lower piece costs.
In thermoset Injection moulding process, the granular or powdered plastic is fed into the barrel of the machine, and no external auxiliary performing or preheating equipment is required as far as thermoset is concerned. Despite this, the temperature of the material entering the mould is higher and more uniform than that in other thermoset moulding processes or techniques which is because of the homogenizing effect of the screw upon the plastic.
Most barrels are covered with a metal jacket or integrated fluid passage lines constructed to permit heated water to flow across the barrel. The water or temperature controlled fluid not only assists in heating the thermoset material as it moves along the screw flight, but also helps prevent over-heating, as the fluid will withdraw excessive internal heat should it occur owing to the excessive screw speed or back pressure.
Non-return valves or ring plungers, which are standard for thermoplastics (exception being Rigid PVC, as it is heat sensitive thermoplastic material) are not used with thermosets. They provide restrictions to even flow of high viscous materials, and eventually cause the material to set up in the NRV or ring plungers. Some amount of material slippage (back flow) does occur when the injection pressure approaches maximum set point. Because of this slippage, the full slug of semi-plasticized material does not reach the cavities. Therefore one should not attempt to use the maximum rated shot capacity of the machine. A rule of thumb for most material is to use up to 80% of rated capacity. Nozzles at the barrel end usually are temperature controlled to maintain a proper balance between a hot mould (175 to 210degC) and a relatively cool barrel (75 to 100degC. However, BMC requires much lower temperature, approx. at 20deg.C)
Thermoset moulding materials developed specifically for injection moulding have a longer shelf life in the barrel at moderate temp (approx. at 100degC) and react very rapidly when the temperature is brought up to 175degC to 210degC as the material is forced through sprue, runners, gates and further fills the cavities. This unique development in materials helped to gain acceptance of injection moulding as a reliable production process.
In most injection moulding of thermosets, the material in granular or powder form is fed by gravity from hopper into the feed throat of the barrel. Further it is conveyed inside by the action of flights of the screw. As it passes through the barrel, the plastic picks up conductive heat from the heating medium (circulated externally to the barrel core) and the frictional heat from the screw rotation.
For thermoset materials, the depth of flights of the screw at the feed-zone end is normally the same as the depth of flight at the nozzle end; in other words a 1:1 compression ratio screw. As the material moves forward in the barrel, it changes from a granular (or powder form) to a semi-viscous consistency and it forces the screw backward in the barrel against a preset hydraulic Pressure. This back pressure is an important processing variable. The screw stops turning when pre-determined amount of material has reached the nozzle end of the barrel, as sensed by linear stroke measurement system controlled by machine software. This material at the nozzle end is the exact volume of material required to fill the sprue, runners and cavities of the mould. The heated and semi-plasticized slug of material at the front (nozzle end) of the barrel is moderately stable for perhaps a minute or more. i.e, enough retention time for the mould to complete closing and the machine to be in high pressure clamp mode. The screw is then moved forward at rapid speeds by hydraulic pressure on the plastic (up to 1400 bar).
The hot plastic melt is forced inside the mould. The temperature of the material rises from the barrel temp (75 to 100 degC) to mould temperature (175 to 210degC) and thus fast cross-linking of polymers takes place, curing the part in few seconds or minutes depending on the mass of the material and cross sectional thickness of the article. When the screw has delivered 95% of the required charged material, the injection pressure (of up to 1400 bar specific pressure) is generally reduced automatically to about half that value for completion of the cavity fill and holding during cure. Following cure, the mould opens, parts are ejected, and the cycle continues.
ThermosetInjection moulding (Part 1 of 2)
Thermoset barrel
LTPML offers complete package for thermoset moulding which comprises of the following:
a) special software (Injection-compression sequence, Breathing sequence for degassing & temperature
profiles),b) Heating circuit Interface for the mould ,c) Insulation medium for the platens ,d) Complete screw barrel assembly which can be
retro-fitted in place of standard thermoplastics screw barrel assembly &
e) TCU ( Temperature Controller Unit)
- G.R.Rejith to be concluded in the next issue
For Bookings:
TRAININGCALENDAR 2012-13
Schedule-3March 5th to 8th 2013
Schedule-1September 5th to 8th 2012
Schedule-2December 5th to 8th 2012
Program Topics• Injection moulding machine - an overview of
major components & functions• Injection moulding process - machine setup -
process optimization• Explanation of set-up screens• Electrical & hydraulic circuits• Machine troubleshooting• Preventive maintenance techniques• Auxiliary equipment for injection moulding• Safe moulding practices
Target Group
For Operators & Set-up Technicians who require basic understanding of the injection moulding process, Trouble Shooting & maintenance.
We charge a nominal fee of Rs.6,500/- Perhead(includes Service Tax).
Prabhat Associates, New Delhi [email protected] 011-28031610/11
Mr. Arun Kumar Dubey, 9818195555
Sanavi Tools, Nashik [email protected] 0253-3048484
Mr. Vinod P Mahajan 9922518484
Deejco Industrial Tools, Pune [email protected]
Mr. Promod. P. Mahajan 9922538484
Newel Biz Link, Ahmedabad [email protected] 079 40033800
Mr. Naveen Bhardwaj 9898067241
Spectrum Petromac Pvt Ltd, Kolkata [email protected] 033 - 40089581, 40089582, 40089584
Mr. Soumitro Banarjee 9831273823
Narendra Enterprises, Pune [email protected] 020 27654414
Mr. R.R.Chandane 9371160187
Indane Solutions, Bangalore [email protected]
Mr. Girish 8892502788
Plastic Links, Chennai [email protected] 044-42652125
Mr. A. Deena Dayal 9840293338
Spares Sourcing Made Easy ThroughWide Network of Stockists
OUR STOCKISTS OUR STOCKISTS
LTPML signs MOU with Semyug of KoreaLTPML signed an MOU with Semyug India Enterprises, for cooperation in selling of robots, quick mould change systems and auxiliary equipment other than what is produced by LTPML. The agreement came into effect on the 9th of May 2012 at Chennai and was inked by Mr P. Kailas, Chief executive of LTPML and Mr Jun Hyung Jin, MD at Semyug India in the presence of senior executives of the company.
With this, the product line at LTPML would be substantially enhanced with the offerings of Pick & Place Robots from HY Robotics Co Ltd., Industrial Robots from Hyundai Heavy Industries Co Ltd., Quick Mould Change systems from MICO Myoungin Co. & a range of complimentary auxiliary equipment from Hankook system Co.,
The application coverage from LTPML would enhance further with the new agreement that would include high-end automation thus providing complete solution in plastics processing.
-S.Narayanaswamy
Standing (L to R) M. Kumar,V.R.J. Prem Kumar, Kumaravel Jothi, S. Murugan, V. Padmanaba Bhat & A. Muthuraman
Sitting (L to R) P. Kailas, Chief Executive LTPML & Jun Hyung Jin, Managing Director SIE
“The editorial team thanks all readers for their overwhelmingresponse and support in making this magazine a great success”(L to R - A.Muthuraman, C. Somaskandhan, Girish R. Handigol, V. Padmanaba Bhat, Benny Mathew,S.Narayanaswamy, R. Srinivasa moorthy (not in picture))
