INDUSTRIAL VISITS REPORT

Submitted by

KAILAS SREE CHANDRAN

S8N, 28432

To

The University of Kerala

In partial fulfilment of the requirements for the award of the degree

Of

Bachelor of Technology in Mechanical Stream Industrial Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING, THIRUVANANTHAPURAM – 16

April 2010

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING

THIRUVANANTHAPURAM – 16

CERTIFICATE

This is to certify that the Industrial Visits Report submitted by “Kailas Sree Chandran, S8N,

28432” to the University of Kerala in partial fulfilment of the requirements for the award of

the Degree of Bachelor of Technology in Mechanical Stream Industrial Engineering, is a

bonafide record of the industrial visit conducted by him, under our guidance and supervision.

SRI. V. REGI KUMAR SRI. K. SUNIL KUMAR

Senior Lecturer Lecturer

Dept. of Mechanical Engg; Dept. of Mechanical Engg;

PROF. E. ABDUL RASHEED

Head of The Dept Of Mechanical Engineering

College of Engineering

Thiruvananthapuram

ACKNOWLEDGEMENT

I express my my sincere thanks to the management of Kerala Automobile Limited,

HLL Lifecare Limited, Intimate Machines Pvt Ltd, KSRTC Central Works

Thiruvananthapuram for grating me the opprtunity to visit their esteemed organizations.

I am also thankful to Prof. E. ABDUL RASHEED, Head of the Department of

Mechanical Engineering, Sri. V. Regi Kumar, Senior Lecturer, Department of Mechanical

Engineering, Sri. K. Sunil Kumar, Lecturer, Department of Mechanical Engineering,

College of Engineering, Thiruvananthapuram, for their direct and indirect helps for

undergoing individual visits.

KAILAS SREE CHANDRAN

SUMMARY

SL. NO. NAME OF COMPANY DATE OF VISIT

1 KSRTC Central Works 09-07-2009

2 Kerala Automobiles Limited 24-07-2009

3 HLL Lifecare Limited 23-01-2010

4 Intimate Machine Pvt Ltd 15-02-2010

1

KSRTC CENTRAL WORKS

INTRODUCTION

The Kerala Road Transport Corporation, Which has been providing quality transport

to the people of Kerala, is one of the lading organizations of its kind. It is presently

headed by the honorable minister Sri. Balakrishna Pilla.

The K.S.R.T.C has had a very glorious past. Begun in the late 60’s this organization

has been providing excellent service to the people both within the state and the

neighbouring states. The travel is comparatively cheap and the innovative mode of

having Ordinary, Limited stop, fast and Super fast buses, super deluxe, which caters

to the different sections of the society, has made it immensely popular.

The K.S.R.T.C workshop at Pappanamcode – Central Works, is the main one, which

deals to complaints at a large scale. Assembly of parts for the launch of new buses is

also done here. The campus is a huge one and has different sections, mainly the

overhauling and assembly sections which engage in the maintenance of machine

parts. A group of dedicated staff personnel together under the close supervision of

their superiors work in close co-ordination to provide quality work.

The dedicated work of the staff together with the management has thus made the

K.S.R.T.C one of leading organizations in the public sector.

MAIN DEPARTMENTS

WORKSHOP DEPARTMENT

1. Dismantling Section

2. Engine Overhauling & Assembly Section

3. Transmission Section

4. Fuel Injection Section

5. Suspension Section

6. Vehicle Overhauling Section

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BODY - BUILDING DEPARTMENT

1. Welding Section

2. Carpentry & Sheet metal Section

3. Painting Section

WORKSHOP DEPARTMENT

1. Dismantling Section

This section deals with the dismantling of the various parts of the vehicle. The vehicle

accessories are separated to provide for keen scrutiny of the defective parts. Generally

the overhauling is required in the following events:

1. Power loss due to poor engine compression.

2. Excessive consumption of lubricating oil.

3. Mechanical failures such as excessive noise due to defective ignition or

injection.

The hood of the engine compartment is first removed. All coolants hoses are

disconnected, the radiator mounting bolts are removed and the radiator is lifted from

the engine compartment. All wires, tubing and controls connecting the engine to the

automobile are removed and tagged. The alternator and fans are removed to avoid

damage during removal of engine. After that the driver shaft and exhaust pipes are

disconnected. The mounting bolts are at last removed and the hoist is operated to lift

the engine.

The dismantling procedure is then followed by:

Removal of:

1. Cylinder head.

2. Valves and valve mechanism.

3. Piston-connecting rod assembly.

4. Cylinder.

5. Crankshaft and main bearings.

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2. Engine overhauling and assembly section

Cylinder in the block is the place where power is generated. Hence after some use

they get worn out. The cylinder block form the dismantled engine is cleaned

thoroughly, then boring ands honing is done to remove wear. Cylinder head is cleaned

by removing carbon and rust from the head, valve and cylinder block. The valve is

grinded to proper finish and valve seat is lapped. The damaged piston is replaced by a

new one. The weared crankshaft is ground so that ovality and taper are within

permissible limits.

The thorough cleaning of engine parts follows overhauling, and then the crank shaft

is coated with recommended lubricant and carefully placed. Timing gears, sprockets,

chains etc. are aligned and installed. Piston-connecting rod assemblies are installed.

Cylinder head is assembled and then valve lifters and push rods are then placed

followed by rocker arms. Water pump and outlet neck are then fixed into the block.

3. Transmission Section

In this section the various transmission parts, which are the Clutch, Gearbox,

Propeller shaft and Differential are overhauled and assembled.

Overhauling Of Clutch Assembly

Clutch is a coupling fitted immediately after the engine in between the gear box to

disconnect engine power to gear box to change gear, to stop the vehicle as well as to

allow the engine to take up load gradually.

Visual inspection of friction flywheel surface is done for any scoring mark, heat crack

and the pilot bearing play is checked by inserting a finger in the bearing and feeling

the play. Clutch plate is checked for wear of the clutch lining wear. Cracks in the

clutch plate steel disc are also checked. The pressure plate is checked for heat

damages, cracks and flatness using a steel rule of feeler gauge. After cleaning all the

parts and checking for any undue play in the linkage, the parts are assembled.

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Overhauling Of Gear Box

Gearbox is fitted after clutch assembly and has a set of gears, which can be engaged

to increase driving torque to cope up road and load condition of vehicle. The teeth of

all gears are checked & the needle bearing if worn out is replaced. The dog clutch

and the sleeve are checked for pitted teeth and the splines are checked for wear. The

gear parts are then assembled, reverse gear first and then the second, third, fourth

gears in correct order with adequate provision for the washer and slide needle.

Overhauling Of Propeller Shaft

The propeller shaft is used to transmit power from the gear box to the rear axle.

Keeping the propeller shaft on the v-block and with a dial gauge check the propeller

shaft for bends, this should not exceed 2mm.

If more, it is straightened out using hydraulic press. The cross pin and bearing cap is

checked for any sign of wear placed with a new set if required. The propeller shaft is

then fixed back to the gear box flange and differential flange taking care that the

yokes of the propeller shaft are properly fitted.

Overhauling Of Differential

Differential is fitted in the rear axel housing and is a mechanism in which one wheel

is allowed to run faster or slower than the second rear wheel as and when required.

Each tooth is inspected minutely for any pitting or broken teeth on crown wheel

pinion, sun and star pinion and if worn out is replaced. The thrust washer and pinion

bearing are also checked for damages. Checking the back lash of the sun pinion with a

star pinion using dial gauge does assembly of the differential. The pinion is assembled

in oil seal with new oil seal in reverse order and after washing the differential casting

the pinion is inserted. The differential assembly is then fixed back in axle housing

with new gasket and nuts are all tight.

4. Fuel Injection Section

The injection system consists of fuel tank, fuel feed pump, fuel injection pump, fuel

filter, fuel injection nozzle and a governor. The injection pump pumps metered

quantity of fuel to all injectors and ands should build enough pressure so that diesel

gets sprayed in fine atomized form. To increase or decrease the quantity of the fuel a

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helix is cut on top of the plunger. The alignment of this helix determines the quantity

of fuel pumped.

The delivery valve keeps the injector pipe always filled up with diesel oil. This valve

sits back on its seat after the pumping operation and the space vacated by the piston

made on delivery valve is taken up by the diesel oil under pressure in the pipe. These

engines are equipped with governors to ensure that engine doesn’t pick up speed

when there is no load, as the engine speed is dependent on quantity of fuel supplied.

The diesel is fed into the injection pump in two ways namely gravity feed and forced

feed. The injection pump must give equal quantity of fuel to all cylinders and the

supply should commence and stop at fixed degree of crank angle both of which are

checked and adjusted on the injection pump test bench. Phasing of injection pump is

done by mounting the injection pump on the test bench and noting the angle of

delivery on its flywheel.

Fuel filter is necessary to supply clean fuel otherwise dust will wear the plunger and

barrel. Primary filter made of felt and secondary filter made of paper, which needs to

be replaced at regular intervals, are highly recommended.

Injectors are used to spray diesel in fine atomized state before the piston reaches TDC

in compression stroke. Injectors should commence and cut off fuel rapidly and at the

same time should not dribble. Facilities have been provided for suitable testing of the

injectors, which includes

Leak off test: The injector tester is worked up to build a pressure of 150 atms,

which is kept for 10 seconds (without spraying).In case there is a drop in

pressure the body seat and the needle is lapped.

Spray test: The injector is fixed up as done earlier and pressure gauge is

disconnected by closing the valve. The tester is worked up four times and a

second and the spray pattern is noted. If the spray pattern is in the form of a

stream or jet, the needle and the nozzle body seat requires grinding.

Nozzle and needle come in as one unit with the needle circular in shape having a taper

end while nozzle body has fine finish. Where the needle can slide there is a circular

groove called pressure chamber at the lower end connected to the oil gallery in the

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body though a drilled hole and it is from this hole diesel oil reaches the pressure

chamber and lifts the nozzle valve of its seat and gets sprayed in atomized form.

5. Suspension Section

The automobile chassis is mounted on the axles, not direct but through some for m of

springs. This is done to prevent road shocks form being transmitted to the vehicle

components, safe guard the occupants from road shocks and to preserve the stability

of vehicle in pitching or rolling while in motion. All the parts which perform the

function of isolating the automobile from the road shocks are collectively called

suspension systems. The buses here commonly use the semi-elliptic steel leaf spring

variety. These are selected for their excellent durability and elastic capability.

The spring consists of a number of leaves called blades. All t he blades are bound

together by means of steel straps. The spring is supported on the axle, front or rear by

means of a v-belt. One end of the spring is mounted on the frame with a simple pin

while on the other end connection is made with a shackle. When the vehicle comes

across a projection on the road surface, the wheel moves up deflecting the spring, this

changes the length between the spring eyes. If both the ends are fixed the spring will

not be able to accommodate this change of length. This is provided by means of a

shackle, which gives a flexible connection.

Repair and Maintenance of Suspension Systems

After prolonged us or over loading, spring assembly gets flattened or one or two of its

leaves get broken. The centre bolt is then removed ant the broken leaf is dismantled

and replaced with the new one. The rubber bushes, which are used to hinge the

suspension systems to the chassis, are greased and are replaced if these are worn out.

6. Vehicle overhauling Section

The Chassis frame supports the load of the vehicle and provides connecting link

between frame and rear axle to withstand stresses caused due to cornering, breaking,

sudden acceleration or bad road conditions.

Rough use of vehicle may cause the chassis to crack, bent and dislocate its welded

parts. The loose and distorted rivets are removed and new heated rivets are fixed. Red

7

oxide paint is s prayed on the chassis frame to prevent corrosion. If the chassis has

met with an accident, it should be straightened out and the alignment checked, failing

which, running the bent chassis will make the steering hard and eat away the tyre.

Defects in the external body of the bus, which is made of sheet metal, are checked and

the necessary corrective steps are taken. These include providing fresh coat of paint to

the rusted parts. Distorted portions of the sheet metal are then sharpened out. New

ones replace the worn out furniture if necessary or the existing ones are repaired.

BODY BUILDING DEPARTMENT

The chassis coming from the factories is brought to this section and the body is built

through a continuous process of welding, carpentry, sheet metal and painting. This

department essentially deals with the assembly of the interior and the exterior parts of

the bus with the engine, gear parts etc. being bought from other automobile

companies like TATA and ASHOK LEYLAND.

In the welding section the steel structure is welded to the chassis. To this frame work

wooden attachments consisting of the platform, the foot board and the wooden parts

by the window sill are fixed. The skeleton frame work is then covered using the sheet

metal section. Care is taken to ensure a clean and stable fit. Nuts, bolts along with

additional fixtures are provided wherever necessary to provide compactness to the

structure. Painting glass fixing, seating arrangements and other finishing touches are

done to ready out the interior and exterior portions.

8

KERALA AUTOMOBILES LIMITED

INTRODUCTION

KAL incorporated in1978 as a government of Kerala undertaking, is setup in the picturesque

backdrop, 16Km south of Thiruvananthapuram in a tiny village called Aralumoodu, in

Neyyatingara taluk. The company manufactures three wheelers suitable for passengers and

goods traffic in th e brand name KAL and are considered as most ecofriendly vehicles. The

strong highly motivated workforce in the technical and management cadres are working hard

in hand for the progress of the company.

The ancillary units developed by the company around the factory complex livelihood for

hundreds of persons.

Since the commencement of production in 1984 the company has manufactured and

marketed more than 43,200 three wheelers, KAL distinguished itself as a force worth

reckoning the automobile industry in India. The company has also exported a number of

three wheelers to Srilanka, Nepal, Sudan, Botswana, Bangladesh, Guatemala, and Nigeria

& South Africa. The company could achieve record turnover and could turn the corner for

the first time in 1993-94, and generated profit since then. the company could maintain the

trend of profit making till date. The acceptability of KAL three wheelers in the third world

countries speaks for its utility & quality.

KAL is also manufacturing & supplying sophisticated components to be used in space

program of VSSC which calls for stringent quality standards. This it is a testimony of the

high level of quality consciousness of KAL.

MACHINE SHOP

The bulk of operations for converting the metal parts into useful components to be used in the

three wheeler are done at the machine shop. This section is the biggest section at KAL having

the largest share of qualified work force. This section ensures the quality standards at the

organization. The section has a large number of sophisticated machinery both automatic as

well as semiautomatic to produce the components at fast pace and satisfying stringent quality

standards. At each level of operation inspections are done to take appropriate action.

9

The raw materials used here at the machine shop includes those fabricated at the fabrication

shop and also castings and forgings imported from other factories. The machine shop also

does jobs for the space program of the VSSC.

Overview of Machines

Fine boring machine (FBM734)

Vertical machining centre (VMC800)

Vertical tool centre (VTC)

Vertical machining and boring (VM8)

CNC Lathe (ECONO CNC)

Radial arm drilling machine (RD32)

Gear shaping machine

Thread roller

Horizontal hobber

Broaching machine

Tapping machine

Honing machine

Chuck mate

Vertical milling machine (FN2V1)

Horizontal milling machine (FN2EH2)

External grinding machine (K130U,)

Internal grinding machine (GIF80)

Copying lathe

Turret lathe

Centre lathe (2D,2D1, 4D)

FABRICATION SECTION

This section mainly deals with cutting and sizing of sheets to produce various kinds of

channels used in the chassis construction, production of brackets and clamps for fixing of

various components on the frame like the air filter bracket, horn bracket etc. Here the rear

axle housings are cut to size and welded with the differential cover, the half axles cut to

length. The various chassis components like the main beam, cross members, and the side

members are also cut to size and these are welded by arc welding to get the final rigid frame

of the three wheeler.

Overview of Machines

Arc welding unit

Spot welding machine

Vertical band saw

14T Pneumatic press

80T Press brake

80T Shearing machine

16T Press

Enterprise Lathe

Horizontal band saw

MIG Welding unit

Centre lathe

Tube Bending Machine

Nibbling Machine

Abrasive cutter

10

ASSEMBLY SHOP

STAGES OF ASSEMBLY

Wheels & Tyres

KAL vehicles use pressed steel disc wheels of divided type. The two halves are securely

fastened to form a rim having two fixed flanges. The tyre with tube is then fixed onto the

wheel. KAL uses MRF-savari brand of tyres for its vehicles.

Back plate Assembly

The drum brake system used consists of two brake shoes with friction material actuated by a

wheel cylinder. The parking brake is actuated by a cam. Retractor springs used for release of

brakes. Tension springs are placed beneath the brake shoes.

Differential Assembly

Matching planet and sun gears are selected and fixed on the seats provided in the differential

cage. Then the cross pin is inserted .the meshing of the gears are checked to see if there is any

backlash.

Propeller Shaft Assembly

The propeller shaft consists of two universal joints and sliding joint. Bevel pinion is attached

to one end via the universal joint .flexible ring type universal joint is used.

Handle Bar Assembly

Handle bar consists of mechanisms for actuating clutch, accelerator and front brake .it also

houses the switch assy. for light and other accessories.

Assembly Line

The welded frame is lifted on to the trolley of the assembly line by the tradesmen. Then the

assembled rear axle is fixed to the frame via the leaf spring. Now the brake pedal is fitted and

master cylinder fitted. The master cylinder is filled with brake fluid. Brake lines are fixed.

After completion the hydraulic brake assembly the parking brake is fixed. The vehicle is

shifted to the dome assembly section for fixing the dome and checking the brake assembly.

Here the steering column and front wheel assembled along with the handle bar. The vehicle is

shifted to the engine assembly section where the engine –gear box assembly is fitted to the

chassis frame using rubber seats. Now the vehicle undergoes detailed testing.

11

HLL LIFECARE LIMITED

INTRODUCTION

HLL Lifecare Limited (formerly Hindustan Latex Limited) (HLL) is a large manufacturing

company in Thiruvananthapuram, Kerala, India. They produce health care products, including

condoms, blood bags, and contraceptive pills. HLL has today five state of the art manufacturing

facilities. HLL commenced its commercial operations on April 5, 1969 at Peroorkada in

Thiruvananthapuram. All these units have ISO 9001, ISO 14001- quality and environmental

management system certifications. HLL’s Peroorkada, Akkulam and Kanagala Plants have

OHSAS 18001 Certification for efficient occupational health and safety management system.

The testing laboratory for finished products at Peroorkada factory has NABL accreditation under

ISO/EC 17025.

DESCRIPTION

Peroorkada Facility, Thiruvananthapuram is equipped with modern machines and equipment for

production, inspection and quality testing, conforming to GMP and meets international

standards. The unit produces many variants of condoms with different flavours and textures.

Condoms manufactured in this facility have product certifications such as, CE, KITE, SABS, NF

Mark, and meet a range of international quality specifications and standards such as: WHO 2003,

ISO 4074:2002, SANS ISO 4074, ASTM D 3492, and GOST- 4645-81.

The facility includes the condom production area and the support facilities. In the condom

production facility specific areas for condom mould dipping, condom washing, treatment for

vulcanization, electronic testing for defects, testing laboratories and packing are provided.

The supporting facilities include two steam boilers of 8Tph capacity and one steam boiler of

10Tph capacity for heating the latex for 30 min at 85oC. There is an all parallel connection of

two 60TR and two 30TR refrigeration systems for cooling latex after heating to 18oC. Also the

facility has four 90TR capacity air conditioners for cooling the whole plant. A semi automated

manufacturing facility was visited. How the supporting facilities like steam plants and

refrigeration plants helped in the smooth running of the plant was understood. Also how different

departments work in coordination was also seen.

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PRODUCTS MANUFACTURED IN PEROORKADA FACTORY

MOODS:

Ultra Thin

Supreme Dotted

All Night

Extra Long

Scented (Rose, Musk, Jasmine)

Chocolate Flavored

Banana Flavored

Strawberry Flavored

Ribbed

Coloured

Glow

RAKSHAK

Sifpsa

Telugu

SHARE 3s

NYMPH 3s

USTAD 5s

CREZENDO

NIRODH

Deluxe

Super Deluxe

Lubricated

13

INTIMATE MACHINES PVT LTD

INTRODUCTION

Intimate Machines Pvt Ltd is the first branch of Welbound established in 1989 in Monvila

Industrial Estate, Thiruvananthapuram. It is small scale manufacturing industry. The firm

consists of Research & Development department, Manufacturing department and Assembly

department. The products of Intimate Machines are Post-Printing equipments like Perfect

Binder, Gathering Machine, Folding Machine, Trimmer etc. Intimate Machines (P) Ltd won

the Award for Quality Products (State Level) from the President of India (for the year 1993).

The firm got ISO 9002 certification in 1999.

ORIGIN AND HISTORY

The idea of this product was conceived by two enterprising individuals Sanjeev and Kumar.

They started the manufacturing small binding machine in the beginning as a small scale unit.

The product was an innovative one during that period and was widely accepted in the market.

The unit grew and was registered as a private limited company – “Intimate Machines” In the

beginning, the company was mainly the assembling unit in which the main components are

manufactured in Coimbatore. Afterwards the company started manufacturing its components

by themselves. In 1989, “Impel Machines” was registered at Sasthamangalam,

Thiruvananthapuram. In the early stages, Impel Machines got managerial, technical advices

from Intimate Machines. Since 1999 the company has been functioning as an independent

unit registered as independent company to meet the following.

• Service centers regional wise to meet service requirement all over India and abroad.

• Procurement centre to procure items from established suppliers and quality

assurance system in place.

DESCRIPTION

Different types of machines are manufactured depending upon the number of books binded.

The Company has adequate infrastructure for fabrication, assembling, and surface treatment.

This includes mechanical, electronic devices system and assembling unit. The trained and

experienced man power is the strength of the company. The factory is set up in approx. 8000

sqft with crucial plant & machinery which includes 25 CNC machines. The R&D section

involves 3D modeling and analysis of components using SolidWorks. Using various

14

softwares, the designers prepare part and assembly drawing and also Bill of Materials,

alteration proposals etc. Manufacturing department consists of most modern production

machines which includes 25 CNCs. The assembly section is divided in the basis of product.

The strength of the company lies in the research and development centre, which brings new

products and utilities and continuous improvement on existing product profiles based on

market feedback.

PRODUCTS MANUFACTURED

1. WELBOUND CREAM

Single Clamp Perfect Binder with Automatic Jogging and Clamping of the

Signatures/Formes.

Facility for Binding 2 identical books of size upto 1/8th Demy in a Single Binding

Cycle.

Easy Job Change over - Clamping of different jobs are automatic;

Sliding Type Milling Front plate, Self Adjusting Cover Nipping Plates.

Can handle a wide Range of jobs of thickness from 2mm to 70mm.

Milling Cutter with Notching Tools for exposing maximum fibre possible.

Grinding Wheel Attachment for Pad Making.

Separate, Powerful Suction Device for Milling Waste Extraction.

Excellent Control over Gluing with Roller and Scraper Mechanism.

Cover Nipping Station with Facility to control the nipping and cover breaking

pressure; Facility to vary the duration of Nipping.

Safety Control Mechanisms - Book, Cover and Delivery Sensing.

2. WELBOUND BLUE

Single clamp Perfect Binder with easily adjustable book clamp

Milling station with cutter, notching teeth and a powerful dust extractor

Optional grinding wheel attachment for pad making

Gluing station with Single Roller and Scraper mechanism. Doctor blades provided for

increasing or decreasing adhesive layers

Cover nipping station with facility to control the nipping pressure

Timers for adjusting feed-in-time, cover nipping duration and delivery.

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3. WELBOUND GREEN

Automatic jogging & clamping of signatures

Facility for binding 2 books of size up to 1/8th Demy, in a single cycle

Easy job change over. Wide range of jobs can be done and changed over fast

Milling cutter with notching teeth and powerful dust extractor. Optional strip type

milling cutter which removes paper from book spine in strip form

Optional grinding wheel attachment for pad making.

Trident Three roller gluing system (with reverse spinner). The first roller penetrates

adhesive into the notches, the second roller builds up adhesive layer and the reverse

spinner removes the excess adhesive as well as levels the coating.

Cover nipping station with facility to control the nipping and cover breaking pressure.

Facility to vary the duration of nipping.

Safety control mechanisms- book, cover & delivery sensors

4. WELBOUND GREEN 750C

Automatic clamping of signatures

Easy job change over. Wide range of jobs can be done and changed over fast

Milling cutter with notching teeth and powerful dust extractor. Optional strip type

milling cutter which removes paper from book, spine in strips form

Three roller gluing system (with reverse spinner.) The first roller penetrates adhesive

into the notches, the second roller builds up adhesive layer and the reverse spinner

removes the excess adhesive as well as levels the coating. Separate Side Gluing

Station with Disc Type Applicators

Cover nipping station with facility to control the nipping and cover breaking pressure,

Facility to vary the duration of nipping.

Automatic Cover feeding with Online Creasing Attachment.

(Optional) Stack Delivery System.

Safety control mechanisms - book, cover & delivery sensors.

5. WELBOUND 2000

6 book clamps traveling in an oval shaped path, where th book back is in line th

crucial binding stations.

Calibrated book clamps, with single knob adjustments - Easy job change over

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Variable speed of operation

Continuous flow of clamps to the feed-in station with "No book - No cover" system

Special type milling cutter which removes paper in "strips" from (which has

commercial value) and avoids generation of paper dust

Three roller gluing system with reverse spinner; Head & Tail end cut-off to avoid

adhesive squeeze out

Separate side gluing station with tank and gluing discs. A thin & even layer of glue is

spread along the side adding value to the book finish

Automatic, pile type cover feeder with on-line creasing attachment. (Optional feeer

tray for manual feeding of gatefold covers)

Pre-setting station and moving type cover nipping station which can handle high

speed with accurate cover registration

Chute delivery system

Safety covers; built in safety systems with emergency stops; indicators for

temperature, speeds

6. PICKWEL GATHERING MACHINE

Pickwel is a modular (offline) signature gatherer. It can be expanded from 8 to 24 stations.

Sturdy design incorporating safety features

PLC controlled system; operations through Touch Screen Panel

Offline gathering - Base model of 8 Stations with delivery unit, expandable up to 24

stations.

Manual feed station

Suction - gripper Type of separation and pulling of forms from the feed stations.

Error Detection protocols :

o Missing signature detection (optical sensing)

o Multiple signature detection (operator adjustable through electro mechanical

Caliper)

o Low Level detection (Optical Sensing)

If and error is detected the corresponding signatures are rejected into a Rejection

Tray, without stopping the machine

Optional crisscross stacker delivery unit.

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7. TRIDENT THREE KNIFE TRIMMER

A Three Knife Trimmer that is Versatile , User friendly and provides superior Trim

Quality. The machine is designed keeping in view, the stringent safety mechanisms for

Guillotines and Three Knife Trimmers. High Grade Cast Iron structures, engineered for

maximum Rigidity and Durability are used for the main frames.

Controls of the various Modes of Operation of the Machines and Safety systems are

through a PLC based System.

8. MICROBINDER

Document Binder using hot melt adhesives

Economic, user friendly, versatile and compact

An ideal offline perfect binder for Digital Printing Units

Automatic Clamping of loose sheets / signatures

Milling cutter with notching teeth; Suction device for extraction of dust

Optional pad making attachment

Roller type adhesive applicator

Cover nipping can be controlled to match the cover & book thickness

Automatic control mechanisms Book, Cover Sensing

9. DIPLOMA FOLDING MACHINE

Machine has the latest safety systems and is PLC Controlled

Capable of folding in 4 parallel and 3 cross folds.

Sheet to sheet gap variable

Built in double sheet detectors provided.

Creasing attachments after buckles folds and after the first knife

Perforating Or Slitting attachments after buckles and after first knife.

Knife Setting automatic based on Sensors. (no mechanical setting need be done for

Knife timing when the paper size changes).

3rd knife (or final fold) Mobile Type Unit and have the choice of either left hand or

right hand folding.

Speed Indicators provided

Totalizers (up to max 6 digits) provided