Industrial Visit Report by Ajay

8/4/2019 Industrial Visit Report by Ajay

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14th February 2011

Eveready Industries India Ltd

Company Profile

Kolkata, West Bengal, India

Power Products - Manufacturer, Export / Import,

Public. Ltd. Firm Since 1905

Eveready Industries India Ltd. Is heralded as the market leader of India

when it comes to dry cell batteries and flashlights.

Today the brand Eveready is synonymous with power, with a durable

franchise that has spanned over a century. Its a name that has progressed

with the country, be it lighting up a slushy monsoon path or keeping beat

with a nation young with achievers. In this new millennium, sales of

Eveready Industries India Ltd. Have reached over US $200 million. The

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flagship of the Williamson Magor Group, Eveready has expertise in the areas

of manufacturing, cultivating, marketing and distributing a diverse range of

products. The portfolio ranges from carbon zinc batteries, rechargeable

batteries, alkaline batteries and flashlights to packet tea and bulk tea.

In fact the group has over 130 years of experience, growing the worlds

finest teas in the most challenging of terrains. Some of the best tea brands

in the world have a blend with the produce of Williamson Magor gardens.

Thus from the first flush of tea in the gardens to the first invigorating sip in

the morning, Eveready is always there to revitalise your day.

ProductsManufacturers and marketing and distributing and Exporters of products as

covering Batteries. Batteries: Carbon Zinc, Rechargeables, Alkalines.

Premium Gold, Jaago and Classic. Exports: Heavy-Duty series, the Super

Heavy - Duty series and even the Alkaline series.

Raw Materials

This section, as well as the following section, will focus on alkaline batteries.In an alkaline battery, the cylinder that contains the cells is made of nickel-plated steel. It is lined with a separator that divides the cathode from theanode and is made of either layered paper or a porous synthetic material.The canister is sealed at one end with an asphalt or epoxy sealant thatunderlies a steel plate, and at the other with a brass nail driven through thecylinder. This nail is welded to a metal end cap and passed through anexterior plastic seal. Inside the cylinder, the cathode consists of a mixture ofmanganese dioxide, graphite, and a potassium hydroxide solution; theanode comprises zinc powder and a potassium hydroxide electrolyte.

The Manufacturing Process

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The cathode

1 In an alkaline battery, the cathode actually doubles as part of thecontainer. Huge loads of the constituent ingredientsmanganesedioxide, carbon black (graphite), and an electrolyte (potassium

hydroxide in solution)are

Mixing the constituent ingredients is the first step in batterymanufacture. After granulation, the mixture is then pressed orcompacted into preformshollow cylinders. The principle involved incompaction is simple: a steel punch descends into a cavity andcompacts the mixture. As it retracts, a punch from below rises to eject

the compacted preform.

delivered by train and mixed in very large batches at the productionsite. The mixture is then granulated and pressed or compacted intohollow cylinders calledpreforms. Depending on the size of the batterybeing made, several preforms may be stacked one on top of anotherin a battery. Alternatively, the series of preforms can be replaced byan extruded ring of the same material.

2 The preforms are next inserted into a nickel-plated steel can; thecombination of the preforms and the steel can make up the cathode of

the battery. In a large operation, the cans are made at the batteryfactory using standard cutting and forming techniques. An indentationis made near the top of the can, and an asphalt or epoxy sealant isplaced above the indentation to protect against leakage.

The separator

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3 A paper separator soaked in the electrolyte solution is then insertedinside the can against the preforms; the separator is made fromseveral pieces of paper laid at crossgrains to each other (likeplywood). Looking down at an open can, one would see what looks likea paper cup inserted into the can. The separator keeps the cathode

material from coming into contact with the anode material. As analternative, a manufacturer might use a porous synthetic fiber for thesame purpose.

The anode

4 The anode goes into the battery can next. It is a gel composedprimarily of zinc powder, along with other materials including apotassium hydroxide electrolyte. This gel has the consistency of a verythick paste. Rather than a solution, it is chemically a suspension, inwhich particles do not settle (though an appropriate filter couldseparate them). The gel does not fill the can to the top so as to allowspace for the chemical reactions that will occur once the battery is putinto use.

The seals

5 Though the battery is able to produce electricity at this point, anopen cell is not practical and would exhaust its potential rapidly. Thebattery needs to be sealed with three connected components. Thefirst, a brass "nail" or long spike, is inserted into the middle of the can,

through the gel material and serves as a "current collector." Thesecond is a plastic seal and the third a metal end cap. The nail, whichextends about two-thirds

The container of a typical alkaline battery, consisting of preforminserted into a steel can, also doubles as the cathode. The anode in

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the middle is a gel composed primarily of zinc powder. The separatorbetween the anode and cathode is either paper or synthetic fiber thathas been soaked in an electrolyte solution.In the finished battery, a plastic seal, a steel nail, and a metal top andbottom have been added. The nail is welded to the metal bottom and

extends about two-thirds of the way into the can, through the anode.

of the way into the can, is welded to the metal end cap and thenpassed through the plastic seal.

6 This seal is significantly thinner in some places than in others, sothat if too much gas builds up in the can, the seal will rupture ratherthan the entire battery. Some battery designs make use of a wax-filledhole in the plastic; excess gas pushes through the wax rather thanrupturing the battery. The seal assembly meets the indentation madein the can at the beginning of the process and is crimped in place.

7 The opposite end of the can (the positive end of the battery) is thenclosed with a steel plate that is either welded in place or glued with anepoxy-type cement.

The label

8 Before the battery leaves the factory, a label is added identifying thetype of battery, its size, and other information. The label is oftenpaper that is simply glued to the battery. One large manufacturer hasits label design printed on plastic shrink wrap: a loose fitting piece of

heat-sensitive plastic is wrapped around the battery can and thenexposed to a blast of heat that makes the plastic shrink down to fittightly around the can.

Quality Control

Because battery technology is not especially new or exotic, quality controland its results are especially important as the basis for brand competition.The ability of a battery to resist corrosion, to operate well under a variety ofconditions, to maintain a good shelf and usage life, and other factors, are

the direct results of quality control. Batteries and ingredients are inspectedand tested at almost all stages of the production process, and the completedbatches are subjected to stringent tests.

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11th February 2011

Holoflex Limited

Company profileHoloflex Limited is one of the leading manufacturers of Holograms andallied products in India. An ISO 9001:2000 & ISO 14001:2004Certified Company, their state-of-the-art manufacturing facility in SaltLake, Sector V, Kolkata houses some of the most sophisticatedmachinery required for secure and high quality Holographicapplications. Besides thry have our branch offices in Delhi, Mumbai,Chennai & Guwahati. As one of the pioneers of this technology inIndia, Holoflex Ltd. entered a nascent market, which needed extensive

education on the concept of holograms. Today Holoflex Ltd. provides avariety of customized holographic solutions to various governmentdepartments in India as well as numerous corporate houses in Indiaand across 25 countries all over the world. Their effort to achieve thehighest level of excellence in product quality has been recognised evenby the apex body of Hologram manufacturers across the globe.International Hologram Manufacturers Association (IHMA), Londonwho conferred upon Holoflex the highest level of award in the field ofCommercial Holography The IHMA Award for producing the BestHologram Label worldwide consecutively in 2003 & 2004.

ProductsManufacturer & exporter Holoflex product bouquet includes dot matrix

master, holograms in reels / sheets with variable information, holograms

with scratch coating, ready-to use stock image holograms, regular /

holographic shrink sleeves, wads and hot stamping foils.

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Raw Materials

Holograms made by individuals are usually exposed on very high resolutionphotographic film coated with a silver halide emulsion. Holograms made for

mass production are exposed on a glass plate pretreated with iron oxide andthen coated with photoresist. The photoresist material will chemically reactto the specific wavelength of light that will be used to create the hologram.Because of their availability at a relatively low cost, helium-neon lasers aremost commonly used by individuals who make their own holograms.Commercial hologram manufacturers use different laser types such as ruby,helium-cadmium, or krypton-argon ion.

After exposure, the film or photoresist plate is processed in chemicaldevelopers like those used in photography. Both nickel and silver are used to

make the production masters that will be used to stamp multiple copies ofthe holograms onto polyester or polypropylene film. Aluminum is used tocreate the reflective coating on the back of embossed holograms.

Design

A three-dimensional, physical object can be used to create a hologram. Theholographic image is normally the same size as the original

object. This may require construction of a detailed scale model of the actual

subject in a size suitable for the holographic image. Altematively, the

artwork that is to be reproduced as a hologram can be computer generated,

in which case software controls the laser exposure of the image file, one

pixel at a time. (Pixels are the individual dots that comprise a graphic image

on a computer screen or printout.)

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The Manufacturing Process

Various manuals are available that explain to amateur holographers how tomake holograms at home. The following steps describe the commercial mass

production of a holographic image of an actual, three-dimensional object.

Mastering

1 A laser is used to illuminate the physical object, with the reflectedlight falling on the photoresist plate. Simultaneously, a reference beamfrom the laser also falls directly on the photoresist plate. Theinterference patterns of these two light beams react with the photo-sensitive coating to record a holographic image of the object. Commonexposure times are between one to 60 seconds. In photography, slightmotion of the object or the film results in a blurred image. In

holography, however, the exposed plate will be blank (contain noimage at all) if during the exposure there is movement as small as onefourth the wavelength of the laser light (wavelengths of visible lightrange from 400 to 700 billionths of a meter).

A typical photoresist plate has a 6 in (15.24 cm) square working area;an extra half-inch (1.25 cm) of space on two edges allows the plate tobe clamped into position. Because many holograms are smaller thanthis, several different images can be "ganged" (clustered) onto oneplate, just as numerous individual photographs are exposed on one

roll of film.

2 The plate on which the original hologram is recorded is called themaster. After being exposed, the master is processed in a chemicalbath using standard photographic developers. Before proceeding withproduction, the master is inspected to confirm that the image hasbeen properly recorded. Because of the chemical reactions caused bythe laser and the developer on the photoresist, the developed plate'ssurface resembles the surface of a phonograph record; there areabout 15,000 grooves per inch (600 per cm), reaching a depth ofabout 0.3 microns (1 micron is a thousandth of a millimeter).

Electroforming

3 The master is mounted into a jig (frame) and sprayed with silverpaint to achieve good electrical conductivity. The jig is lowered into atank along with a supply of nickel. An electric current is introduced,

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and the master is electroplated with nickel. The jig is removed fromthe tank and washed with

deionized water. The thin, nickel coating, which is called the metal

master shim, is peeled off the master plate. It contains a negative

image of the master hologram (the negative is actually a mirror image

of the original hologram).

Using similar processes, several generations of shims are created.Those made from the metal master shim are known as"grandmothers," and they contain positive images of the originalhologram. At this stage, numerous copies of the original image are

"combined" (duplicated in rows) on one shim that can be used to printmultiple copies with a single impression. Successive generations ofshims are known as "mothers," "daughters," and "stamper shims."Because these generations alternate between negative and positiveimages of the original, the stamper shims are negative images thatwill be used during actual production runs to print the final productholograms.

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Embossing

4 Stamper shims are mounted in embossing machines. A roll ofpolyester film (or a similar material) that has been smoothed with anacrylic coating is run through the machine. Under intense heat and

pressure, the shim presses the holographic image onto the film, to adepth of 25 millionths of a millimeter. The embossed film is rewoundonto a roll.

Metallizing

5 The roll of embossed film is loaded into a chamber from which theair is removed to create a vacuum. The chamber also containsaluminum wire, which is vaporized by heating it to 2,000F (1,093C).

The sheet is exposed to the vaporized aluminum as it is rewound ontoanother roll, and in the process it becomes coated with aluminum.After being removed from the vacuum chamber, the film is treated torestore moisture lost under the hot vacuum condition. A top coating oflacquer is applied to the film to create a surface that can be imprintedwith ink. The roll of film, which may be as wide as 92 in (2.3 m), issliced into narrower rolls.

Converting

6 Depending on what type of film was used and what kind of product isbeing made, one or more finishing steps may be done. For instance, thefilm may be laminated to paper board to give it strength. The film is alsocut into shapes desired for the final product and may be printed withmessages. Heat-sensitive or pressure-sensitive adhesive is applied to theback of holograms that will be affixed to other objects or used as stickers.

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21th April 2011

TATA TINPLATE COMPANY OF INDIA Ltd

Company profile

TCIL has a history of pioneering several industry initiatives since itsinception in 1920. The latest in this line of firsts is the setting up of theSolution Centre last December. It is the first step in TCILs efforts tograduate from being a mere downstream steel business towards its vision ofbecoming a total metal packaging solution provider the hallmark of aglobal major in the packaging business.

TCIL is today the largest indigenous producer of tin coated and tin free steelsheets in India, enjoying 35-40% market share and undoubtedly theindustry leader for 85 years. The company exports about 20-25% of itsproduction directly to end-users (can-makers) and its products are wellaccepted in the markets of SE Asia, Middle East and some developedcountries in Europe.

Headquartered in Kolkata, the Companys Works is located at Jamshedpur,Jharkhand. There are presently 12 offices in India and a distribution network

with 17 stocking points.

TCIL Works, situated at Golmuri, Jamshedpur has presently two dualprocessing line for ETP/TFS and Cold Rolling Mill (CRM).The company hascommenced CRM-2 set-up as a backward integration in feeding the secondtinning line with TMBP coils.

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Manufacturing Facilities - Stages ofProduction

All tinplate originates as in the steel-making furnace (Tata Steel), where theproper chemistry for steel is obtained to meet the specific needs of the enduser. All tin mill products start their production process in a Basic OxygenFurnace (Tata Steel).

Hot Rolled Coil Manufacture

Once the steel is produced, the continuous casting process transformsmolten steel into slabs in one continuous operation. Continuous casting is ahighly energy- and cost-efficient process that produces a slab of excellentquality and consistency. Continuous casting methods are now used invirtually all carbon steel production facilities to produce products ofconsistent, high quality. Next, the slab goes into the Hot Strip Mill (HSM) ofTata Steel where its thickness is reduced and it is wound in a down coilerinto coil form. This is where the Hot Rolled Coil (HRC) is procured as thebasic raw material by TCIL from Tata Steel.

Pickling Process

To remove the scales adhering to the hot rolled coils Tinplate Company usesits Push-Pull shallow bath Hydrochloric Acid Pickling Line. The line has 3pickling tanks and 5 rinse tanks. The Pinch Roll # 1 in the entry sectionpushes the strip that is "paid off" and the Pinch Roll # 3 in the deliverysection pulls it thro the process section of the line. The line has a cascadingsystem for rinse water and online trimming facility.

6 Hi Cold Rolling Mill

Tinplate, as a packaging material, continues to be most preferred, both inpackaging food products like processed food, vanaspati, ghee, etc., and alsowhere criticality of application is important, as in the case of battery jacketsand pesticide cans, to name a few select areas.

Understanding the need of increased indigenisation, TCIL commissioned itsstate-of-the-art 120,000 tonnes per annum Cold Rolling Mill having the

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benefit of synergy with TATA STEEL, from where raw material is available inthe form of Hot Rolled Coils for the manufacture of TMBP coils.

The mother mill of the complex is a 6 High, continuous variable crown-reversing mill. The pickled strip is "paid off" from a Pay-Off Reel and fed into

the cold rolling mill. Depending on the input thickness, desired output gaugeand pass schedule designed by the mill operator, the hydraulic system setsthe draught. After the first pass that has run between the POR andReversing Reel # 2, the tail end is fed into the Reversing Reel # 1. The stripis run reverse and forward between RR1 and RR2, thro the CR mill, with thethickness being reduced in each pass. The thickness gauges at the entry andthe exit side of the mill gives real time feed back thro the automationsystem to the mill's hydraulic system for online correction of roll force andhence the thickness.

Electrolytic CleaningDuring the process of cold rolling cooling oil is used to keep the temperatureof the roll and the strip within limits. This cooling oil mixed with water in anemulsion has to be removed for further processing. This is achieved in theElectrolytic Cleaning Line. The line uses alkaline dunk and ortho-silicateelectrolytic cleaning to remove the emulsion oil coating. The strip is thenscrubbed, rinsed, dried and rewound on a reel into coils. These coils arethen tilted 90o and taken for annealing.

AnnealingAnnealing is done to relieve the stresses that are built into it during theprocess of cold rolling which makes the steel strip hard and brittle.Annealing is done using the batch annealing process.

Degreased coils are stacked four high on a base. An annealing cover isplaced over this stack and pure hydrogen is pumped in. Then the heatinghood is placed and programmed to heat the coils to predesignedtemperatures. This follows a heating - soaking - cooling cycle with cut offtemperatures and times depending on the hardness required by the

customer. After the process that takes 32 - 38 hours, the coils aredischarged from the base.

Temper Mill

The mill is a four high two-stand tandem mill with a facility to give a furtherreduction of upto 30%. After the process of annealing the strip becomes

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soft. To put it to further use the surface has to be given the proper finishand hardness. For this purpose the strip is passed thro the temper mill.Normally a skin pass is given (80% of product). This is dry temper rolling;where the hardness and shape is controlled in the first stand and the surfacefinish in the second stand. In the rest (20%) of cases a post annealing

secondary cold reduction of upto 30% is given by controlling the draught inthe first stand. This process is known as Double Cold Reduction. This processalso uses a cooling emulsion for roll and strip cooling. This imparts higherhardness and strength to the strip enabling thinner sections to be put to usein place of thicker plates

Coil Preparation Line (CPL)

Full hard and / or tempered coil before being tin plated has to be trimmed tothe required width as per the customer's order. For this purpose the coil is

passed thro' the CPL with edge trimming facility. The coil is "paid off" andpassed thro' the trimmer to cut off both sides to the ordered width of theend product and then rewound. While rewinding the edge guide system throa continuous feedback process ensures that the two sides of the coil windingis without any projected edges. This is done to facilitate handling of thecoils. The full hard cold rolled coils are packed and shipped out of this mill tocustomers.

Electrolytic Tinplating Line

The unique properties of tin provide a coating on the steel that protects thecontents, while providing the steel with an attractive appearance, corrosionresistance and ease in bonding, welding and painting. Tin is applied to bothsides of the black plate coil through an electrolytic process. The thickness ofthe tin coating (called coating weight) is dependent upon the end-useapplication. Typical applications for electrolytic tinplate include food andbeverage containers, paint trays, battery tops and paint, varnish and aerosolcans.

The Tinplate Company of India Limited pioneered the Indian Industry whenthey put up the country's first tinning line in 1922. The growth of TCIL has

been a continuous process of development and modernization to keepIndian Tinplate at par with international standards.

The technological advances had led to the introduction of ElectrolyticTinplate (ETP), while the spiraling and prohibitive cost of tin resulted in themanufacture of a suitable substitute, namely Tin Free Steel (TFS) orElectrolytically Chromium coated steel(ECCS). To keep pace with these

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developments, TCIL was the first to set up a combination line capable ofproducing both ETP and TFS. The plant was commissioned in 1978 and hasan installed capacity of 90,000 tonnes per annum. The line can be run uptoa speed of 247 m/min and is capable of processing coils ranging from 0.17mm to 0.60 mm in thickness and 600 mm to 965 mm in width.

The Electrolytic Tinplating line is the only one of its kind in India. It has afacility to coat the line with tin or with chromium / chromium oxide (Tin FreeSteel). The ETP uses the FEROSTAN process, where in an acidic bath ofStannous Sulphate is the electrolyte. The strip is "paid off" and passed throthe looping tower - which stores material to enable the line to runcontinuously, even while the entry is stopped for welding the tail end of onecoil to the head of the next. The strip then passes into the cleaner solutionto remove any remnant traces of oil or emulsion. Then it goes thro thepickling bath where the Sulphuric acid removes any oxide that may haveformed in the CRM complex. This acid also etches the plate, to prepare it forthe electro-deposition of tin. After the surface is fully prepared for plating itpasses into the plating section. Here the strip enters the bath with pure tinbeing used as anode and the strip itself as the cathode. By passing therequired direct current - this is dependant on the coating weight required bythe customer - in the bath the plate is coated. Thereafter it passes into themelting furnace where the deposited tin is melted to give it a brighter finishand also make it adhere to the base material better. After this the strip ischemically treated to reduce the action of atmosphere on tin and then

coated with oil to facilitate handling.

In case the order is for tin free steel, the strip is passed directly from thepickling bath to the chrome plating section. Here by using chromic acid bathand inert anodes a layer each of chromium and chromium oxide is depositedon the strip. Since this coated steel does not have any tin plating on itssurface it is called tin free steel.

The strip is then passed thro the online inspection to segregate any sheetthat falls outside the acceptable range of thickness, sheets with pinholes inthem and then cut up as per order and piled into packets of about 1500KGs. This is then shipped out to customers in trucks or containers, the lattermainly for overseas customers.

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Tin-free Steel/Electrolytic Chrome Coated Steels (ECCS)

Unlike the multiplicity of coating weights with tin, only one standardizedchromium-coated product is manufactured. The chromium coating processwas developed in the 1960s as an alternative to tin coatings for packaging

products cost-effectively, with desirable material properties. Chromiumoffers excellent lacquer adhesion, storage properties and strong resistanceto food corrosion with proper applications of lacquer. Chromium-coatedsteels are most frequently used for can tops, screw and lug caps, snap andpress-on closures and shallow-drawn food cans. Packaging steels are coatedwith different protective and decorative.

Research & Development

Assurance is sign of commitment and TCIL's commitment to quality is

byword in the Indian packaging industry. With the accreditation of ISO9001, TCIL has joined the league of international players in supplyingsuperior quality Tinplate/TFS in terms of their mechanical properties,dimensional accuracy, shape parameters, corrosion resistance values andrigid packaging. The quality Assurance team at TCIL is equipped withqualified and experienced engineers and chemists trained in all aspects ofthe Tinplate manufacturing technology from abroad. The process controlsand the product inspection standards during Tinplate/TFS production arevery stringent to ensure that every sheet undergoes minute scrutiny thusproviding 100% customer satisfaction.

Quality Grades

Single /Double Reduced Electrolytic Tinplate ,Open Top Sanitary Can, NonOil Can Tinplate and Tin Free Steel (Chrome Plated ) are available inStandard, Seconds and Waste/Waste quality.

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14th February 2011

Emami Limited is in the business of manufacturing personal, beauty andhealth care products. The company manufactures herbal and Ayurvedicproducts through the use of modern scientific laboratory practices. Thisblend enables the company to manufacture products that are mild, safe andeffective. The company's product basket comprises over 20 products, the

major being Boroplus Antiseptic Cream, Navratna Oil, Bororplus Prickly HeatPowder, Sona Chandi Chyawanprash and Amritprash, Mentho Plus PainBalm, Fast Relief, Golden Beauty Talc, Madhuri Range of Products andothers. The products are sold across all states in India and in countries likeNepal, Sri Lanka, the Gulf countries, Europe, Africa and the Middle East,among others.

ManufacturingEmami's products are manufactured in Kolkata, Pondicherry, Guwahati andMumbai. The company commenced operations at its fully automatedmanufacturing unit in Amingaon, Guwahati in 2003-04.

They are an ISO 9001:2000 company.

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HOT AIR Inner Heat Mechanics:

Hot air system adapts an uniform applicationto able different hot air temperatures to beadjusted without the need for parts

changeovers, as well as a choice betweenplastic or laminated tubes.Special tube end clip molds and exhaustsystem ensure that filling quality is not affectedwhen heat is being applied to inner tube ends.Accuracy is maintained at high productionspeed while tube end modes have options tochoose from.

OPERATING PROCEDURES::The operator places empty tubes onto inclinedchute (whole box of tubes are arranged ontothe tube cassette feeder, tubes are discharged

automatically; this mechanic is optional), andfed into individual tube holders tube centeringsensor adjust tube position, progressivebottom up filling (MAX. 130mm), end sealing,end trimming (Plain) and auto tube ejection.

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END TRIMMING:Trimming by a (horizontal) cutter is done after the tube sealing station to trim off excesstube ends.

Material Supply:Available selection of options, custom made requirements forcoding on single or double sides of tube ends also available

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Industrial Visit Report by Ajay

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