Rubber & Tyre Machinery World

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Global Approach To Rubber Machinery Technology

Make in India is an initiative launched by the Government of India in 2014 to encourage multi-national and national companies to manufacture their products in India. While this initiative has garnered significant international attention and keenly watched, few Indian machinery companies have been steadily building up their repute with global approach and right technology.

In this special edition of Know Your Supplier’s cover story, we feature one such company Bharaj Machineries Pvt. Ltd., through an interactive conversation with Amardeep Singh, Director – Sales & Projects.

Established in 1982 with a vision, to always produce most advanced and quality machinery for the rubber industry, Bharaj has transformed into a giant machinery supplier. Read the full interview here of how Bharaj’s aspiration to be leaders in their various business segments’ is filled with passion and backed with technology.

KYS Cover-June-2016

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(This digital edition is available on Youblisher and Yumpu)

Based in Mumbai, India, Bharaj manufactures and supply high-quality and advanced machinery for the rubber industry. They specialise in rubber mould manufacturing, rubber moulding, extrusion and mixing technology.

They are a preferred choice for many rubber related industries starting from Tyre, Automotive, Sports, Footwear, Pharmaceutical, Aerospace and Specialized Silicon Rubber Industry with exports to USA, UK, France, Canada and many Asian Countries.

Here is a teaser from the interview.

Q) What products and services can a prospective equipment buyer expect when they approach you?

ASB: Yes, we offer complete solutions in rubber mould manufacturing, rubber moulding, extrusion and rubber mixing areas. Bharaj designs and manufactures latest technology rubber machinery that saves power, compact in size, has low maintenance, requires minimum labour through smart automation and are user-friendly. Our prospects can choose from a range of Cold Feed Extruders (Plain/Vent Types), Heavy duty Rubber Mixing Mills, Rubber Dispersion Kneaders, Hot Feed Extruders, Refiner Mills, Cracker Mills, Grinding Mills, Calenders with complete lines, Batch-Off Units, Vulcanizers, Bale Cutters, Conveyors, Stock Blenders, Vacuum Compression Type Rubber Moulding Machines, etc.

Bharaj Machineries

Q) How do you compete technologically on your product offerings? 

ASB: Starting as a small manufacturing unit, today Bharaj Machineries has evolved into a well-respected machinery supplier for the rubber industry in India as well as in the Global Market in the areas of rubber mould manufacturing, rubber moulding, extrusion and mixing technology. We focus on providing high quality machinery at a competitive price. The wide range of quality machinery made by Bharaj is well-accepted worldwide. Our competitively priced equipment performs consistently and we extend prompt back-up. We export to developed countries like USA, UK, France, Canada and many Asian countries. Hence, it is also apt to mention here that Bharaj manufactured machinery are considered as a first choice for many rubber related industries starting from Tyre, Automotive, Sports, Pharmaceutical, Footwear, Aerospace and Specialized Silicon Rubber Industry. Depending on the equipment, we offer quick delivery to our customers. Some of our equipment is delivered in as low as 25 days.

Download PDF of this special edition here

As they pursue global growth, Bharaj management respects and value every equipment buyers’ desire for optimum technology in their production floor. Emphasizes, Amardeep Singh Bharaj,

“We recommend the right machinery with right features that gives our customers the best return on his investment. This means we consult him on equipment selection to match his production process, share layout drawings and take great care to clarify his genuine queries in the most practical manner feasible. Depending on availability, we arrange equipment visits for our prospects either at our 30,500 Sft ultramodern and state-of-the-art manufacturing plant near Mumbai or at any of customer sites.”

I hope you find the contents on this leading rubber and tyre industry equipment supplier, and their global approach to rubber machinery technology, informative .

Below is the rubber machinery supplier info image-card of Bharaj Machineries and their contacts, if you would like to reach them quickly.

Bharaj Info Card

In addition, we have two other knowledge-enriching topics from our portal in the ‘Insight’ and ‘Tips’ sections of this special edition.

Let me know your thoughts.


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Know Your Supplier is an advertorial initiative of Rubber & Tyre Machinery World. 

If you would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at engage@rubbermachineryworld.com for your customized offering.


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Practical Modern Solutions For Tyre And Rubber Industry

Change is inevitable. Changes in the business environment happen all the time. The economy fluctuates up or down on a daily basis, frequently causing businesses to alter the way they operate. New competitors enter the marketplace while others leave. Advancements in technologies, products and innovation lead to change in a business environment.

Sustaining and innovating amidst changes is the hallmark of exemplary leadership. Pelmar Group has been displaying dynamic leadership for the last 50 years! Hence, in this special edition of Know Your Supplier’s cover story, we showcase for you Pelmar Engineering Ltd., the Practical Modern Solution Providers For Tyre And Rubber Industry.

We understand from our conversation with Jacob Peled, Founder and Executive Chairman, that Pelmar had three consecutive record years. And is now planning expansion of both its commercial and technical activities in Israel and worldwide.

It’s not easy to achieve three record years consecutively handling a range of activities that include pre-owned machinery, new equipment, complete engineering services, raw materials, military technical rubber production, technology transfer, M&A activity and more. Because, this requires efficiency and focus.

Don’t miss our main interview to know how Pelmar has been consistently outperforming customer expectations year-on-year.

Know-Your-Supplier-Pelmar-May-2016

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(You may read this digital edition either on Youblisher and/or Yumpu platform.)

An anecdote shared by Peled in his own words that I choose to mention here.

“I was asked a question yesterday evening by one of the persons I admire most in the industry, Michael Labbe the Managing Director of Rema TipTop, how could I and Pelmar cope with handling so many various subjects efficiently at the same time. He referred mainly to Pelmar handling pre-owned machinery, new equipment, complete engineering services, raw materials, military technical rubber production, technology transfer, M&A activity and more. I did not have a proper answer.

This morning I had breakfast with the technical director of one of the major Tier 1 tyre companies, who asked me how could I with the size of our Group, with the international spread, with the diversity of functions handle only one industry, the tire and rubber industry. I tried to explain that tire and the technical rubber industry are separate, but found myself mumbling.

The worst thing about the above is that both questions are absolutely correct and in place. The only answer that I can think of is that because we are handling “just one industry” we can and should be involved in as many aspects of this industry as possible.”

Pelmar Engineering Ltd.

Identifying and capitalizing on the opportunities swiftly along with thirst for growth has helped Pelmar diversify their expertise, spread reach globally and offer single-stop shop total solutions for rubber and tyre industry.

Additionally, on this digital edition, we have two knowledge-enriching topics from our portal aptly titled ‘Insight’ and ‘Tips’ sections.

Download PDF of this special edition here

I hope you find the contents informative to learn more about this leader in rubber and tyre industry.


If you found this supplier details informative, please do share with your colleagues, customers and friends who could benefit. And if you would like to be informed of our articles regularly, please register with us for free updates today.


Know Your Supplier is an advertorial initiative of Rubber & Tyre Machinery World. 

If you would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at engage@rubbermachineryworld.com for your customized offering.


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Why We Love Gear Coupling (And You Should, Too!)

First things first! You choose a coupling to connect two shafts together at their ends to transmit power. The primary purpose of coupling is to join two pieces of rotating equipment while permitting some degree of misalignment or end movement or both.

Normally, couplings do not allow shafts to disconnect during operation, however there are torque limiting couplings which can slip or disconnect when some torque limit is exceeded. Hence, you should carefully select, install and maintain couplings; as this could give you substantial savings in the form of reduced maintenance costs and downtime.

Gear Coupling

A gear coupling is a mechanical device to join two rotating shafts (that are not collinear) for efficient transmission of mechanical power. These are crucial because although you may align the shafts (for example, between the gearbox and the mixing mill roll) at the time of installation, it is likely that during the operation there may be disruption to this alignment.

Disruptions could occur due to setting of foundation, thermal expansion, shaft deflection, wearing out of other parts, improper maintenance and many more reasons. At these times, where the misalignment occurring during the operation is unavoidable, a gear coupling compensate or minimize the effect of misalignment thus providing a good solution to prevent your rubber machinery, bearings, seals and shafts from being subjected to the additional forces.

Gear couplings are power intensive and considered as the king of the coupling types. You would see the gear couplings being adopted for wide range of application in drive technologies. Hence, we love love gear coupling (and I think, you would too!).

Gear Couplings and Universal Joints

Gear couplings and universal joints are used in similar applications. Gear couplings have higher torque densities than universal joints designed to fit a given space, while universal joints induce lower vibrations. The limit on torque density in universal joints is due to the limited cross sections of the cross and yoke.

The gear teeth in a gear coupling have high backlash to allow for angular misalignment. The excess backlash can contribute to vibration.

Structure of a Gear Coupling

Gear couplings are torsionally rigid and consist of hubs with multi crowned teeth at flank, tip and chamfering on teeth, gaskets, sleeve and O-rings. The hubs attach to the machinery shafts, and sleeves span the gap from one hub to the next. They are available in two designs – completely flexible and flexible/rigid.

The hub is the heart of any gear coupling. Hence manufacturers take great care to impart a superior design and mostly manufacture the hub on CNC machine for precision. Together with the tooth profile of the hub, these aspects enable the gear coupling to function well under all operating conditions with increased reliability and long life.

The tooth flanks and outer diameter of the external gear are crowned to allow for angular displacement between the two gears. The multi crowned teeth reduce the alignment adjustment and improve the load carrying capacity of the teeth. The backlash between the teeth is minimal due to multi-crown tooth design.

A completely flexible coupling comprises two hubs with an external gear and two outer sleeves with an internal gear. It’s a universal coupling for all sorts of applications and accommodates all possible misalignment (angular, radial and combined) as well as large axial moments.

Structure of a Gear Coupling

A flexible/rigid coupling comprises one flexible geared half and one rigid half. It does not accommodate parallel displacement of shafts but does accommodate angular misalignment.

Information to order Gear Coupling

When you are buying rubber machinery, your machinery supplier or OEM would take care of this. However, you need to understand that there is a check list of information that needs to be provided to a gear coupling supplier that includes,

  1. Specify quantity required and delivery expectations.
  2. Specify shaft or bore sizes and key-way dimensions. You need to give exact dimensions with tolerances.
  3. Specify load – HP and/or torque at a specific RPM. State the normal and maximum conditions of use.
  4. Specify Speed of operation – Minimum, Normal and Maximum.
  5. Specify Application. Most Rubber & Tyre Machinery (Mixers, Kneaders, Mills, Calenders, Extruders, etc) conforms to a service factor classification where heavy shock conditions or frequent reversing peak loads that do not exceed 150 per cent average horse power is observed. Uneven load is usually present during operation. Service factor ranges from 1.25 to 1.50.
  6. Specify Coupling Series, Type and Size.
  7. Specify Space limitations – envelope dimensions, shaft extensions and shaft spacing.
  8. Specify unusual misalignment conditions if any.
  9. Specify Modifications – tapered bores, special keys, hub cut off, counter bores or others
  10. Specify unusual operating conditions ambient temperatures and atmospheres, if any.

Maintenance of Gear Coupling

Gear Coupling maintenance is mostly simple – requiring a regularly scheduled inspection of each coupling. Your schedule should consist of:

  • Performing visual inspections – checking for signs of wear or fatigue, and cleaning couplings regularly.
  • Checking and changing lubricant Each coupling half is provided with grease nipple/plug on the housing from where grease can be filled directly. The coupling is supplied with some quality of grease to facilitate assembly. It is recommended to fill the required quality and quantity of grease before putting the coupling in operation. This maintenance is required annually for most couplings and more frequently for couplings in adverse environments or in demanding operating conditions.
  • Documenting the maintenance performed on each coupling, along with the date.

Here’s a 1:17 min video of dismantling of a gear coupling so you could appreciate the components that make-up this coupling much better.

Video of Dismantling of A Gear Coupling

Video

Failure of Gear Coupling

Caution! Even with proper maintenance, your gear couplings can fail. The other causes of failure include:

  • Improper installation
  • Poor coupling selection
  • Operation beyond design capabilities

The only way to improve your coupling life is to understand what caused the failure and to correct it prior to installing a new coupling. You could check for some external signs that indicate potential coupling failure like,

  • Abnormal noise, such as screeching, squealing or chattering
  • Excessive vibration or wobble
  • Failed seals indicated by lubricant leakage or contamination

Summarizing, gear coupling is a mechanical device to join two rotating shafts for efficient transmission of mechanical power, are power intensive and is the king amongst the coupling types. They offer the highest load capacity and stiffness, yet easy to maintain. These are some of our reasons to love this gear coupling on the rubber machinery. 

Do you have more? Let us know your thoughts.


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Industrie 4.0 And Why You Should Be Excited About It?

If you are even remotely following the advancements in manufacturing and automation, then you have already heard this term – Industrie 4.0. A German branded initiative, this is a term coined for the next stage of manufacturing that describes the main future development tasks required to achieve a ‘Smart Factory‘.

To quickly understand, you may visualize smart factories as ‘social networks’ where humans, machines and materials communicate and interact in real time.

Considered the 4th industrial revolution in manufacturing (watch a video), Industrie 4.0 is a dynamic process of evolution. It refers to the technological evolution from embedded systems to Cyber-Physical Systems (CPS).

Too much of jargons? Let me make an effort to explain…..

Relevance of CPS

In your manufacturing environment, these Cyber-Physical Systems comprise of smart machines, storage systems and production facilities capable of autonomously exchanging information, triggering actions and controlling each other independently.

This means all your machines, processes, control systems, logistics and even end-products are closely interconnected via internet-based, data-handling technologies and devices.

CPS makes your next level of decentralization realistic. It improves your resource productivity and efficiency, enables more flexible models of your work organization.

Says, Ashutosh Chincholikar, Business Head, Smart Controls India Ltd, “With Industrie 4.0, rubber and tyre machinery will no longer simply ‘processes’ the product, but your product would communicate with the machinery to tell it exactly what to do.”

Industrie-4.0-Rubber-Tyre-Machinery

Benefits of Industrie 4.0

Your benefits include flexibility in specification and volume, fine-tuning to your customer needs, and improving efficiency as a way to reduce your cost.

Your product development-to-market and order-to-shipment lead times become shorter. Expensive downtime for your machinery and plant gets reduced through remote monitoring and predictive maintenance.

Digitization, connected-ness and virtual tool planning opens your door to customized mass-production. This means you can produce very small batch sizes and yet sell at a profit.  Flexible manufacturing may mean that more of your parts and production materials have to be detected, inspected and identified. Transparency and reproducibility of your processes will enhance your product quality.

Experiences shared by Smart Controls India Ltd, include significant benefits like

  • 5% increase in productivity on 20 machines was equal to an extra machine.
  • 25% saving on a plant in Auto industry
  • 11% efficiency improvements in first 3 months at a Tire Company.
  • 68% gain in production by just fine tuning setup processes (up from 410 to 690 parts/week)
  • A large equipment manufacturer’s OEE shot up from 24% to 62% on machines

It is these benefits of speed, flexibility, quality amongst others that should keep you excited and upbeat about the prospects of Industrie 4.0. Further when you use CPS, you will have a clear advantage to attract the best employee talent since you can offer a better work-life balance.

| It is these benefits of speed, flexibility, quality amongst others that should keep you excited and upbeat about the prospects of Industrie 4.0. |

Need for a balanced approach

Interestingly, Industrie 4.0 goes by a variety of names: ‘Advanced Manufacturing’ in the USA and the UK, ‘les usines du futur’ (The Factories of the Future) in France, ‘Made Different – Factories of the Future’ in Belgium, and “Smart Industries” in the Netherlands.

As a manufacturer, you definitely need to procure equipment with right level of futuristic automation. Because Industrie 4.0 is bringing fundamental change to your business competition in today’s ‘VUCA’ (Volatile, Uncertain, Complex and Ambiguous) world.  If you continue using today’s automation systems you will fail due to excess cost in automation.

| If you continue using today’s automation systems you will fail due to excess cost in automation. |

However, it is also necessary to find the balance between full automation and manual work. It doesn’t make sense to automate all your manufacturing processes completely as the cost of that will be too high.

For example, tire production is high-volume customization. The tire industry seeks to consistently improve quality while cutting waste, thus reduce the cost of each tire. Experts and Leaders will tell you that the steps you need to do this in China or India are different than they are in Japan or in Europe or in the U.S.

Every application must be evaluated with regards to the breakeven point. And that is where you will benefit with the assistance of a systems integrator.

balanced-approach

Adopt a Balanced Approach. (Image Source: Web)

| Every application must be evaluated with regards to the break-even point.|

Adds Ashutosh, “In order to implement automation solutions in the tyre industry someone who understands the intricacies of tyre manufacturing processes – from mixing, tyre building, curing to inspection – is needed. This is where Smart Controls plays a big role. With over 15 years of experience in serving the tyre industry, Smart Controls has full knowledge and experience of using the Siemens Technological Platform to implement automation solutions for almost all processes of tyre making.”

(You may wish to hear more on the ‘role of a system integrator in your smart factory’, when Ashutosh Chincholikar speaks at the International Rubber Conference in Chennai on March 1-3, 2016.) 

Summarizing, Industrie 4.0 is more than just a buzzword today and hence important that you take notice. Because it ensures that your resources are used more efficiently while people and machinery work far more productively.

Let us know your thoughts on Smart Factory and and plans for Industrie 4.0.


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Dispersion Kneader – Your Friend in ‘Knead’

For many years, open mill mixing has been the preferred form of mixing rubber. But then technology has been evolving.

Thus came mixers and the major considerations had always been cost. Since last twenty-five years, the Kneaders have become the most commonly used type of ‘mixer‘ in the rubber industry.

Kneader-Special-Supplement

Click on the Image to Flip Through The Digital Book

Download PDF of this digital edition.

This popularity, prompted us to showcase Dispersion Kneaders specifically in this Knowledge On-The-Go Special Supplement. Though developed initially for mixing thermoplastics, Dispersion Kneaders have a unique place in the elastomer mixing industry. Users love the ease of cleanliness on this machine especially when they have to change the color of their compounds frequently.

Dispersion Kneader is energy-efficient, maintenance-friendly, labor and time-saving machinery that offers consistent quality of rubber mix compound at higher output as compared to an open mixing mill – thus making it truly Your Friend in ‘Knead’ for your rubber processing plant.

I hope you agree and find this special supplement informative.

(Disclaimer: Any pictures and quoted statements in our special supplements including Know Your Supplier editions are shared with us by the respective companies and/or sources are mentioned appropriately. Rubber Machinery World does not independently verify them nor will vouch for their actions, hence will not be liable for any misrepresented data)


If you liked this article, please do share with your colleagues, customers and friends. And If you would like to be informed of our articles regularly, please register with us for free updates today.

If you are an equipment supplier and would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at rubbermachineryworld@gmail.com for your customized offering.


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Tire Production Simplified In A Flow Chart

My earlier post on Tyre Building Machine – 5 Amazing Videos You Must See was well received by the readers and they found it informative.

I have in earlier posts covered rubber machinery like Bale Cutter, Mixer, Mixing Mill, Batch-Off, Extruder, Tire Buffer, etc. However, its intriguing to see where all these equipment (along with the other machinery) goes into tire production.

This flow chart simplifies tire production overview and helps you visualize the various equipment that we discuss on this portal Rubber Machinery World in the right perspective.

Tire-Production-Flow-Chart

The source of above flow chart is from Nell Achieve Website.

And just in case, you thought even for a microsecond ‘Is this all to tyre manufacturing?’, I correct you here.

The tire production process is a very meticulous and complex  affair. Click here to download the infographic from Giti that explains their tire production concisely.

I hope you found this post informative. Let me know.


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How To Select Your Rubber And Tyre Machinery? Insightful Advices From 6 CEO’s

“How To Select Your Rubber And Tyre Machinery?”

This subject question could have volumes written in theory. But today we focus on what the CEO’s advise, distilled down from their experience, expertise, and wisdom.

Your equipment supplier ecosystem includes New Manufacturers, Rebuilders, OEM Suppliers, Pre-Owned Machinery Suppliers and Agent representatives.

So I asked all the CEO’s the same question to give you a true perspective.

“What would you advice on machinery selection to buyers and users of rubber and tire equipment?”

The different views they offered here are not only insightful, they are pertinent, prudent and practical.

Read on in our Special Supplement here….

This special supplement is one of our efforts to give you useful knowledge on-the-go in a concise and timely manner. This topic based micro-editions is in addition to our other initiatives like ‘Know Your Supplier’ that provides you information on the machinery supplier ecosystem.

Watch Video Version of this supplement on YouTube or Download Full PDF Here.


If you liked this post, please share with your customers, colleagues and friends. And If you would like to be informed of our posts regularly, please register with us for free updates today.

If you are an equipment supplier and would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at rubbermachineryworld@gmail.com for your customized offering.