Know Your Supplier - Rubber & Tyre Machinery World June2016 Special

rubbermachineryworld

In this special edition of Know Your Supplier’s cover story, we feature Bharaj Machineries Pvt. Ltd., a company that has been steadily building up their repute with global approach and right technology.

ubbermachineryworld.com / tyremachineryworld.com

Know Your

Supplier

Rubber & Tyre Equipment - Accessories

Global Approach To

Rubber Machinery

Technology.

Rubber & Tyre

Machinery

World

Information On Equipment, Technology, Innovation & Suppliers

Special Edition

In Conversation With

AMARDEEP SINGH

DIRECTOR (SALES & PROJECTS)


Contents

Know Your

Supplier

8COVER STORY

Global Approach To

Rubber Machinery

Technology

Conversation with Amardeep Singh,

Director (Sales & Projects) on Bharaj

Machineries solutions for global rubber

and tyre industry.

Rubber & Tyre Equipment - Accessories

June 2016

29

INSIGHT

13 Things You Should Know

About Hydraulic Power Pack

36

TIPS

The Biggest Problem With Heat

Transfer Efficiency on Rubber

Machinery (And How You Can Fix It)

5

RUBBER&TYREMACHINERYWORLD

INFORMATIONONEQUIPMENT,TECHNOLOGY,INNOVATION&SUPPLIERS

KNOWLEDGE-ON-THE-GO

Through A Gadget Of Your Choice


INFORMATION PORTAL | E-MAGAZINES | INTERVIEWS | KNOWLEDGE PARTNERS | DOWNLOADS

........... And More


| Editor’s Note |

Global Approach

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, some 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 machineries for the rubber industry,

Bharaj has transformed into a giant machinery supplier.

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. Their aspirations to be leaders in their

various business segments is filled with passion and backed

with technology.

In addition, we have two other topics from our portal

titled ‘Insight’ and ‘Tips’ sections. Our last issue with a new

cover theme (standardized in line with our other editions)

along with these two additional sections were well-accepted

and read. I hope you find this issue equally knowledge

enriching.

Indian machinery

companies, like

Bharaj Machines

have been steadily

building their

repute with global

approach and right

technology.

rubbermachineri

rubbermachineryworld

7

As always, I welcome your feedback on

rubbermachineryworld@gmail.com.

Best Regards

Prasanth Warrier

+Rubbermachineryworld1

grp/home?gid=8252803

rubbermachineri

(Disclaimer: The pictures and statements in our special supplements are shared by the respective companies and/or sources mentioned.

Rubber & Tyre Machinery World does not verify/vouch for their genuineness, hence will not be liable for any misrepresented data)

Know Your Supplier | JUNE 2016


| BHARAJ | AT A GLANCE

1982

Privately Owned

Factory: 30,500 Sft.

Corp. Ofce: 2,400 Sft.

STATE-OF-THE-ART

Manufacturing.

CUSTOMER-ORIENTED

Technology & Service.

PERCENT

35 Exports

PERCENT

65 Repeat Buyers

PERCENT

50 Market Share*

DAYS DELIVERY

25 Of Selected Eqpt.

+ COUNTRIES

15 Eqpt. Installations

MARKED EQPT

Customized

+ GLOBAL BRANDS

10 of Satised Customers

8

Serving Global

Members of

Rubber Industry

from Tyre, Automotive,

Pharmaceutical, Footwear,

HQ

Mumbai

India

FEDERATION OF INDIAN

EXPORT ORGANISATIONS

Sports, Aerospace, to

Specialized Silicon.

KEY MILESTONES

- INDIA'S FIRST 4 ROLL Z-TYPE CALENDER WITH COMPLETE LINE FOR TYRE CORD.

- INDIA'S FIRST CE APPROVED SILICON RUBBER MILL - VARIABLE FRICTION RATIO.

- INDIA'S FIRST SPECIALIZED CLEAN ROOM SILICON MACHINERY.

- INDIA'S FIRST 25 MM SILICON EXTRUDER.

- INDIA'S FIRST DISPERSION KNEADER WITH INTERMESHING ROTORS.

By TUV, CRISIL, and

INDIAN EXPORT

HOUSE (By Ministry of

Commerce & Industry)

- Indian Leadership Award (2010-11)

- Bharatiya Udyog Ratan Award (2010-11)

- Export Merit Award (2010-11)

- Outstanding Performance in Exports (2014-15)

Know Your Supplier | JUNE 2016


| BHARAJ |

Bharaj Machineries Pvt. Ltd. based in Mumbai, India manufactures

and supply high-quality and advanced machineries for the rubber

industry. They specialise in rubber mould manufacturing, rubber

moulding, extrusion and mixing technology.

We gather from our conversation with Amardeep Singh,

Director (Sales & Projects) of Bharaj Machineries , that they

are the first choice for many rubber related industries

starting from Automotive, Sports, Tyre, Aerospace,

Pharmaceutical, Footwear, and Specialized Silicon

Rubber Industry. This interview captures their growth

and aspirations to be leaders in their various business

segments.

Bharaj manufactured machineries

are considered as a first choice for

many rubber related industries.

Bharaj has gradually and consistently built a strong

name in Rubber & Tyre Industry with sizeable exports.

What are the challenges that you face these days on

sustaining this momentum?

Since our founder and chairman, Balraj Singh Bharaj,

started Bharaj Machineries Company Pvt. Ltd in 1984, our

core vision has always been to produce high quality and

advanced machineries for the rubber industry. We today

have expertise in rubber mould manufacturing, rubber

moulding, extrusion and mixing technology, thus evolving

ourselves into a formidable machinery supplier or repute

for the rubber industry in India and abroad. Bharaj

manufactured machineries are considered as a first choice

for many rubber related industries starting from

Automotive, Sports, Pharmaceutical, Footwear, Aerospace,

Tyre, and Specialized Silicon Rubber Industry; who are

quality-oriented and seek precision and performance in

their products. We a well known brand in various

developed countries to like USA, UK, France, Canada and

many Asian Countries. When we operate at such a scale, it

9

Know Your Supplier | JUNE 2016


| BHARAJ |

10

is quite natural to face price competition

from machineries of Chinese and SE

countries, where the domestic market has

slumped. This is because there are

customers who still make buying-decisions

only on initial price. Educating them is a

challenge.

What are the major strengths of

Bharaj? How do you add value

to equipment buyers?

The rubber industry has always

considered Bharaj as a reputed

name in Quality & Technology.

This is because our continuous

R&D has always kept us ahead of

competitors. We introduce new models and

upgrade existing technology regularly. We

offer complete solution in rubber mould

manufacturing, rubber moulding, extrusion

and rubber mixing areas. Depending on the

equipment, we offer quick delivery to

our customers. Some of our

equipment is delivered in as

low as 25 days. Our response

time to support service

requests is less than 48 hours.

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.

@Bharaj

@Bharaj

Image: Bharaj Make BMK-75 Liter Heavy Duty Dispersion Kneader

(Back Feeding and Front Discharge Type)

Know Your Supplier | JUNE 2016


| BHARAJ |

@Bharaj

@Bharaj

Image: Bharaj Make CE Approved Rubber Mixing Mill

With Variable Friction And Variable Ratio, Digital Nip

Gap Indication and Peripherally Drilled Rolls.

12

Buyers would need technical inputs and

customization. What level of pre-sales

support does Bharaj offer?

We deeply respect and value every

equipment buyers' desire for optimum

technology in his production floor. Hence,

basis our long-standing experience in

rubber mould manufacturing, rubber

moulding, extrusion and mixing technology,

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.

We recommend the right

machinery and features to

give our customers the best RoI.

What products and services can a

prospective equipment buyer expect

when they approach you?

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.

Know Your Supplier | JUNE 2016


| BHARAJ |

@Bharaj

@Bharaj

Image: Bharaj Make

50 Tons Lab Press.

Do you invest in R&D? Where are your

R&D investments and efforts directed?

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. R&D is the crucial for our new

launches and product refinement. Our

accomplishments and new launches

include,

- India's first silicon rubber mill.

- India's first 4 roll calender with complete

line for tyre cord.

- India's first 25 mm silicon extruder.

Image: Bharaj Make

6" x 13" Lab Mill.

R&D is the crucial for our

new launches and product

refinement.

- India's first dispersion kneader with

intermeshing rotors.

- India's first tyre tread cooling line rubber

batch off units.

Today, our R&D investments are

directed in areas of high-end software,

precise process engineering and

overall equipment improvements basis

our customer's feedback.

13

Image: Bharaj Make 4-Roll Open Z-Calender.

@Bharaj

@Bharaj

Know Your Supplier | JUNE 2016


| BHARAJ |

Which are your fast moving products? Which

machinery of yours have larger exports?

The wide range of quality machinery made by Bharaj

is well-accepted worldwide. Our competitivelypriced

equipment performs consistently and we

extend prompt back-up. We export to developed

countries like USA, France, UK, Canada and many

Asian countries. And we offer complete solutions

in rubber mould manufacturing, rubber

moulding, extrusion and rubber mixing areas. I

would say that our Mills, Calenders, Presses and

Extruders are high in demand.

Image: Bharaj Make 120MM CFE

with Tube Head.

@Bharaj

14

@Bharaj

@Bharaj

Image: Bharaj Make 90MM Cold Feed Extruder

Pin Barrel Type.

Know Your Supplier | JUNE 2016


IKATAN TEKUN SDN. BHD.

Your Partner in MALAYSIA for Rubber & Processing Machinery

“Complete your Plant

with your desired

technology to your

complete satisfaction

on-time through us.”

For your green-field and brown-field expansion

or research projects in raw rubber and other

technical rubber goods, we can source for you

the right machinery to meet your technology

requirements, and be your single-window

support for after-sales service communication

and training in Malaysia.

For crucial projects, we train our personnel on

the machinery we supply, to give you quick

support.

In addition, we are established and licenced

contractors in Mechanical, Telecommunications,

Electrical and Civil Works. Hence, we offer you

on turnkey basis - from equipment supply,

material handling at site, equipment relocation,

erection and installation, services and utilities

to equipment commissioning.

Contact me today to know more on our

team, the equipment brands we partner

with, our esteemed clients and full range

of services for your rubber related projects.

IKATAN TEKUN SDN. BHD.

1st, Floor, Bangunan Sapura,Lot 2,

Jalan Enggang, Kawasan Perindustrian PKNS,

Hulu Kelang, 54200, Kuala Lumpur, Malaysia.

Tel: (+6) 03 - 425.6 5.589 | Fax: (+6) 03 - 425.7 5.589

AUTUS CONSULTING @2016

Ahmad Fezal Bin Zakaria

Sales & Project Manager

* fezal@ikatantekun.com

) (+6) 017-362.79.71


| BHARAJ |

16

How do you compete technologically on

your product offerings?

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 machineries are considered

as a first choice for many rubber related

industries starting from Automotive, Sports,

Pharmaceutical, Footwear, Tyre, 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.

We focus on

providing high

quality machinery

at a competitive

price. The wide

range of machinery

made by Bharaj is

well-accepted

worldwide.

@Bharaj

@Bharaj

Know Your Supplier | JUNE 2016


| BHARAJ |

How do you ensure that you deliver high

quality solutions and services to your

customer?

As I mentioned before, we focus on

providing high quality machinery at a

competitive price. Our dedicated service

department gives prompt back-up support

for our customer's after-market needs. We

design and manufacture latest technology

rubber machinery that saves power,

compact in size, has low maintenance,

requires minimum labour through smart

automation and are user friendly. We are

certified by leading bodies like TUV, ISO,

CRISIL and also an accredited export

house. Our quality department works with

stringent norms right from raw-material

sourcing to equipment final finish.

We design and manufacture

latest technology rubber

machinery that saves power,

compact in size, has low

maintenance, requires

minimum labour through

smart automation and are

user friendly.

When a customer places a service request,

how do you handle it?

We now have a dedicated service

department for responding the service query

immediate and resolving the problem is

totally depends upon the nature of service

call.

Image: Bharaj Make Sheeting Line

of 75 Liter Kneader and

22x60 Mixing Mill

17

@Bharaj

@Bharaj

Know Your Supplier | JUNE 2016


| BHARAJ |

VISION:

To increase the productivity by

supplying smart, cost effective

machines.

MISSION:

To offer the market our best efforts in tune

with highly sophisticated technical products

and services. As global market expects from

an International player .

As process partners with comprehensive industry knowledge,

our teams of specialists provide good quality products, thus

achieving the optimisation of technology, systems & expertise.

In this manner we strengthen the competitive strength of our

customers throughout the world.

18

(L-R):

Amardeep Singh Bharaj (Director - Sales & Projects),

Balraj Singh Bharaj (Founder Chairman), and

Jaspal Singh Bharaj (Director - Technical)

Know Your Supplier | JUNE 2016


Information On Equipment, Technology, Innovation & Suppliers

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Because we publish digitally on our portal and promote on social

media differently, Buyers get all information of Your Products &

Solution anytime and anywhere - on any smart gadgets they

use (Phone, Tab, Laptop or Desktop).

1.DISPLAYYourProductsRegularlytoBuyers.

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| BHARAJ |

@Bharaj

@Bharaj

Image: India’s first fully Automatic

Tyre Cord Calender Line

21

What are your infrastructure and

capabilities?

Bharaj has a ultra –modern and stateof-the-art

manufacturing plant near

Mumbai measuring 30,500 Sft and

2400 Sft corporate office. Our plant is

equipped with high tech CNC machines

and other latest equipments, gadgets to

make the best quality product. We are

certified by TUV and also offer CE

marked customized machinery.

Would you say Bharaj is innovative?

Bharaj is indeed innovative. We listen

carefully to our clients process related

problems adopt them to make it process

friendly. Every second machine has

something new to offer. We believe in

giving more value on our products.

Every second machine has

something new to offer.

Are you launching any new products this

year? Any expansion plans?

Yes. Bharaj believes in 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. We are expanding our

product range that includes new line-ups.

It's all under wraps for now. However, you

can expect Bharaj to make a grand

announcement of the launch of our new

range of machinery shortly.

Know Your Supplier | JUNE 2016


| BHARAJ |

Product

Range

- CE and Non-CE Equipment

- Vacuum / Compression Type Rubber Moulding Machine

- Cold Feed Rubber Extruders (Plain / Vent / Pin Barrel / Co-Extrusion)

- Heavy Duty Rubber Mixing / Refiner / Cracker / Grinder Mills

- Rubber Dispersion Kneaders

- Hot Feed Rubber Extruders

- Silicon Rubber Extruders, Mills and Strainers

- Calenders with complete lines (2, 3 & 4 Rolls)

- Batch-Off Units / Vulcanizers / Bale Cutters / Conveyors / Rotocures

- Tread Cooling Lines

Key

Customers

Trelleborg Group (World Wide), Bridgestone Tyres, Ceat Tyres, Anand

Group, Metzeller, Dupont, Loadstar, Parker, Gates India, Momentive

Performance Materials, Wacker Silicons, etc

22

@Bharaj

@Bharaj

Image: Bharaj Make

22"x66" Three-Roll

Calender Line.

Know Your Supplier | JUNE 2016


| BHARAJ |

@Bharaj

@Bharaj

23

Image: Bharaj Make Star Blade Cutter

- Heavy Duty - 40 Tons.

Core

Competencies

- Design, Manufacturing, Supply, & Commissioning of Rubber Machinery

in the areas of rubber mould manufacturing, rubber moulding,

extrusion and mixing technology.

- After Market Sales, Spares & Service Support.

USP’s

- Quick Deliveries, and Prompt Back-up Support

- Designs that are power-saving, compact, requires minimum labour,

and has zero maintenance.

- Latest Technology machinery that are user-friendly.

Know Your Supplier | JUNE 2016


WhatIsYourStoryToday?

Every Machinery Has....

Every Technology Has...

And As Equipment Supplier,

YOU Denitely Have...

A Story

Let Equipment Buyers Know You, Your Products & Your Technology Better.

ReachMachineryBuyersFastIn3Steps

1.DISPLAYYourProductsRegularlytoBuyers.

2.COMMUNICATEYourCompetenciesDifferently.

3.ATTRACTMoreBuyerstoYourBrandInformatively.

ADVERTISE On

RUBBER Rubber

Machinery

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M

http://rubbermachineryworld.com

M

TYRE Tyre

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http://tyremachineryworld.com

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Buyers get all information of Your Products & Solution anytime

and anywhere - on any device (Phone, Tab or Computer).

For more details and your customized advertising, please visit

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Supplier

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Rubber & Tyre Equipment - Accessories

Technology & Innovation

Special Edition

Rubber & Tyre

Machinery

World

Information On Equipment, Technology, Innovation & Suppliers


| BHARAJ |

@Bharaj

@Bharaj

Image:

Bharaj Team during a Trial (Top)

Plant & Factory Building (Left)

Varied Product Range (Bottom)

Our plant is equipped with

machines, latest equipments

and gadgets to make the best

quality product.

25

Know Your Supplier | JUNE 2016


| BHARAJ |

@Bharaj

@Bharaj

26

Image: Fully automatic

compression moulding machinery

What changes do you see happening in

the rubber processing machinery

industry? How are you positioning and

preparing Bharaj for these changes?

I feel that there is a big transition phase

with customers emphasizing on electricity

consumption cost, and demand for

maintenance-free equipment. Newer

designs are more compact suiting the

customized requirements of our customers.

We are expanding our product range that

includes new line-ups focusing on rubber

machinery that are efficient, high in

productivity and user friendly.

We are expanding our product

range that includes new line-ups

focusing on rubber machinery

that are efficient, high in

productivity and user friendly.

What's your approach towards

communication? How easy is it for your

existing customers and future buyers to

reach you and exchange information?

We believe in transparent and quick

communication. Bharaj team members are

always available for our customers and

reachable on phone or email irrespective of

our normal office working hours.

Know Your Supplier | JUNE 2016


Information On Equipment, Technology, Innovation & Suppliers

| BHARAJ |

Our vision is to increase the

productivity of our customers by

supplying smart, cost effective

machines. Over the next few years,

I see Bharaj emerging as a strong

leader.

Is Bharaj in good financial health and

sufficiently funded to grow?

Yes, Bharaj is good financial healthy and is

sufficient funded to grow.

Where do you see Bharaj in the next 10

years?

Our vision is to increase the productivity

of our customers by supplying smart, cost

effective machines. Over the next few

years, I see Bharaj emerging as a strong

leader in our various business segments

with dedicated divisions catering to

different markets.

27

What is your advice on equipment

selection to buyers of rubber and

tyre machinery?

Capital machinery is a very important part

of any company, it is going to earn money

every minute, saving something on initial

Amardeep Singh Bharaj

Director (Sales & Projects)

capital equipment should not be the motto,

one should keep in mind production

capacities.

RMW

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| INSIGHT |

This section is bought to you in association with our brand display partners

Image Source: RMF

29

13

Things You Should

Know About Hydraulic

Power Pack

https://rubbermachineryworld.com/2016/03/16/13-thingsyou-should-know-about-hydraulic-power-pack/

If you have seen or used an Internal Mixer,

Bale Cutter, Press, or any Hydraulic

machinery then you have witnessed a

Hydraulic Power Pack in operation.

Here are 13 things you should know about

Hydraulic Power Pack.

Know Your Supplier | JUNE 2016


| INSIGHT |

1. By definition, hydraulic power packs are

self-contained power-units used instead

of a built-in power supply, to transmit

power from one location to another and

thus run your rubber machinery. A

hydraulic system employs enclosed fluid

to transfer energy from one source to

another, and subsequently create rotary

motion, linear motion, or force.

2. Hydraulic power packs come in different

shapes and sizes; some are very large and

stationary whereas others are smaller

and compact. The mechanical

characteristics and specifications of a

hydraulic power pack dictate the type of

applications for which it can be effective.

The relief lines also control the direction of

flow through the system.

▪ Motor to power a pump

▪ A pump to perform two actions. Firstly, it

creates a vacuum at the pump inlet and

with the help of atmospheric pressure,

forces fluid from the reservoir into the inlet

line. This fluid is then fed to the pump. The

pump then delivers this fluid to the pump

outlet and force feeds it into the hydraulic

system.

Electric

Motor

Pressure

Switch

Accumulator

Hydraulic

Valve

Manifold

Block

30

3. You can identify hydraulic power packs

through its main components. Because

irrespective of the size of the unit, all

power packs will have the following;

▪ A hydraulic reservoir (or tank) which holds

the enclosed oil. This is a storage unit

designed with enough volume for the oil in

the pipes to drain into it. They also ensure

this oil is stored and maintained in the best

possible condition. Reservoirs will come in

different sizes. Common auxiliaries for a

reservoir include filler/breathers and drain

ports, level gauge, level switches and

inspection covers.

▪ Regulators that control and maintain the

amount of pressure that the hydraulic

power pack delivers. These are very vital.

▪ Pressure Supply lines and Relief lines. The

supply line supplies fluid under pressure to

the pump and the relief lines relieve

pressure between the pump and the valves.

Pressure

Gauge

4. Some of the important factors that

influence a hydraulic power unit's

performance are pressure limits, power

capacity, and reservoir volume. In

addition, its physical characteristics

including size, power supply, and

pumping strength are also significant

considerations. Reputed suppliers take

great care to ensure that a large, durable

hydraulic power unit is built for

functioning under a range of

environmental conditions.

Air Breather

Pressure Gauge

Adaptor

Web Image only for representation. All

Copyright belongs to Original Owners.

Know Your Supplier | JUNE 2016


| INSIGHT |

32

5. Hydraulic power packs have other

components like

▪ Filters: Filtration is a critical part of a

hydraulic power pack, ensuring wear is

minimised and efficiencies are

maintained. Basic suction strainers do

not allow large contaminants to enter the

pump. Pressure filters are normally

configured at the pump outlet and ensure

only filtered oil enters the hydraulic

system. Contamination within the system

is filtered out by the return filter before it

enters the hydraulic reservoir.

▪ Pressure Control valves that limit or

control the hydraulic pressure within the

hydraulic system.

▪ Directional Control hydraulic valves

(manual, electrical, pneumatic or

hydraulic operated) direct the oil flow

around the system to operate actuators,

motors or other functions.

▪ Cooling is another other key

consideration, where efficiencies within a

system or machine will produce heat in the

oil; this must be cooled to ensure long life

and high-efficiency.

Check

Valve

Tank-Top

Filter

▪ Accumulators: These are containers that

can be attached to the hydraulic actuators.

They collect oil from the pump and are

intended to build and maintain fluid

pressure to supplement the pumping system.

▪ Coolers and Heaters: As part of the

temperature regulation process, an air

cooler can be installed near or behind the

filter unit to prevent temperatures from

rising above operational parameters.

Likewise, a heating system, such as an oilbased

heater, can be used to elevate

temperatures when necessary.

▪ Power Unit Controllers: The hydraulic

controller unit is the operator interface

containing power switches, displays, and

monitoring features. It is necessary for

installing and integrating a power unit into

a hydraulic systems, and can usually be

found wired into the power unit. Oil level

and temperature protection switch,

Pressure switches and filter clogging

switches are quite common.

6. Hydraulic power packs come with a

variety of valve connections. This means

that you can power a variety of rubber and

tyre machinery by using the appropriate

valves. Most manufacturers segregate their

models into a 'standard', 'mini', 'micro' or

'bespoke' power pack categories.

Heat

Exchanger

Suction

Filter

Geared

Coupling

Gear

Pump

Web Image only for representation. All

Copyright belongs to Original Owners.

7. When picking a hydraulic power pack

there are a variety of pumps and options to

pick from. Hence, it is important to pick the

right power pack to meet your machines

needs. It is also important to consider a

power pack that will help maximise

productivity and minimise cost.

Know Your Supplier | JUNE 2016


| INSIGHT |

This section is bought to you in association with our brand display partners

8. In rubber and tyre machinery, you would

need custom design of your hydraulic

power packs depending on the features

you select and how you select. For eg, you

could either opt for a single power pack

for your drop door and hydraulic ram

operations of a mixer; or choose separate

power packs for individual operations

depending on the circumstances at your

plant.

properly and safely for extended periods

of use. Maintaining hydraulic power

packs is relatively simple. You should

check the tubing for any noticeable

problems such as dents or cracks. You

should also inspect the reservoir to check

for any corrosion or rust. And do regularly

change the hydraulic fluid as per

recommended maintenance schedule of

your hydraulic power pack

34

9. Your supplier should review the pressure

and flow data together with you. And

they should also take load profiles and

the thermal budget into account. Doing

this ensures that you get a power pack

that precisely meets your technical

requirements and operates economically.

10. It is ideal if you or your machinery

supplier get everything integrated from a

single source. Because, fewer interfaces

means your hydraulic system gets built

faster. Your costs are lower, too.

11.Experts recommend use of highefficiency

low-noise internal gear pumps

when designing power packs. Your

supplier may consider accumulator

charging technology or variable speed

drives as may be the case for your

application. Multiple pressure circuits

are another option.

12.Hydraulic power packs require regular

maintenance to ensure they work

13. Hydraulic power packs must be installed

and mounted in a clean and dry location

void of any standing water or accumulated

run-off.

Summarizing, you should opt for a power

pack that has low power consumption,

requires very little installation space, and

operates with low cooling requirements.

This would mean that your operating costs

are very low for the unit and it's easy to

integrate into your main machinery. All of

these would help you procure power packs

featuring high reliability and availability on

the one hand, and easy and cost-effective

integration into your rubber machinery on

the other.

Did I miss some aspects?

Would you like to add more to this list?

Comment on our web portal to share your

knowledge with us and other readers too.

RMW

Know Your Supplier | JUNE 2016


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| TIPS |

Image: Image from

Web only for representation

36

Know Your Supplier | JUNE 2016


| TIPS |

The Biggest Problem with Heat

Transfer Efficiency in Rubber

Machinery (And How You Can Fix It)

https://rubbermachineryworld.com/2015/11/18/the-biggestproblem-with-heat-transfer-efficiency-in-rubber-machinery/

37

Know Your Supplier | JUNE 2016


| TIPS |

Rubber processing has a bizarre energy

pattern, when seen from a layman's

perspective. Because you add heat into

your process and then you cool down!

Even a thin coating of water

scale will act to insulate the

water system’s surface and

retard the transfer of heat.

Heat addition and removal is repeated in

each of your subsequent stages as well.

When you process rubber, energy is

consumed across the value chain – right

from transport of raw rubber, to the

various processing operations (be it rubber

mixing, rubber extrusion, rubber

calendering, moulding etc) to convert into

your suitable product and then

transportation of your product.

mineral deposits. These deposits could give

you varying degrees of water-related

problems that affect your operating

efficiencies and/or even leading to more

costly equipment downtime issues.

This could be in your Rubber Machinery like

Mixer, Mixing Mill Rolls, Calender Rolls,

Press, Extruder, Heat Exchangers, Moulds,

and factory equipment like Boilers, Chillers,

Compressors, and TCU's or other Ancillary

Units, etc.

38

This implies that you need to cool down

your rubber processing machinery

regularly, which simultaneously involves

heat exchange from a hot medium to a

cooler medium.

And the most common medium to cool is

water.

But where there's water, you will face

water-related problems caused by its

Source: Tangram

You would notice that the mineral deposits

accumulate quickly regardless of screens or

treatment actions adopted. Even a thin

coating of water scale will act to insulate the

water system's surface and retard the

transfer of heat.

Hence, scaling is the biggest problem

affecting the heat transfer efficiency in

rubber machinery.

Know Your Supplier | JUNE 2016


AMCL MACHINERY LIMITED

SERVICE TO THE NATION FOR FOUR DECADES

Product Range

Rubber Mixer – 76" liter and 270 liter.

• Mixing Mills – 16", 22", 26" and special sizes

• Hot feed extruders – 6" and 8"

Rubber Calenders – 2/3 rolls.

• Bias Tyre Building machine – RB1/RB3

• Automatic LCV Tyre Building Machine – RB1619

• Automatic Truck Tyre Building Machine-RB2022

• Mechanical Tyre Curing Presses – Scooter to Truck size

• Bladder Curing Presses

• Tube Splicers

For all your enquiries please contact:

AMCL MACHINERY LIMITED

Works: Plot No.A1/1, MIDC, Butirobi-441122, Nagpur

Mumbai office: 202, Ackruti Centre Point, MIDC Central Road, Andheri (East), Mumbai-400 093.

Contact person: Mr. S.H. Mehta

Mobile No. +91-9004697430. Email: shmehta@amcl.in Website: www.amcl.in


| TIPS |

To increase heat transfer efficiency, lower

maintenance cost, conserve overall energy

consumption and thus enhance the usable

life of your machinery, removing scales in

all your water-cooled or water-heated

rubber and tyre equipment is very

important.

In a simple rubber machinery like the

mixing mill, the presence of scales on rolls

leads to localized hot spots affecting your

mixing quality. In the case of boilers, scales

can be very damaging leading to even

boiler rupture. When water scale, lime and

rust deposits accumulate on the water side

of chambers, rotors and the drop door of

the Mixer, it causes temperature of your

rubber stock to rise and gradually lead to a

loss in production.

Different machinery has different safe and

effective method to remove scales. Recently,

Image: RYDLYME

40

Know Your Supplier | JUNE 2016


KELACHANDRA MACHINES

(MFRS. OF RUBBER INDUSTRIAL MACHINERY)

Chingavanam - 686 531, Kottayam, Kerala. India.

Phone Off: +91- 481-2430325. Fax: +91- 481-2430596

e-mail: km1912@gmail.com


| TIPS |

42

I was shown an instruction sheet, from one

of the descalers (RYDLYME), on the process

to descale a rubber mixer that I found

interesting.

Here's the process reproduced. I hope you

too find it informative.

1. Take mixer out of service.

2. Close water supply valve at header as

shown in the sketch above.

3. Drain all water from all sections of

mixer.

4. Connect Descaling Solution pump

discharge hose to water header. Header

usually supplies all circuits.

5. Connect return hoses to drain lines from

all circuits and place into the Descaling

Solution receiver.

6. Close water supply valves to gate and

jacket circuits.

7. Start pump and pump the descaling

solution into rotors to purge the water

from this circuit to sewer. When the

descaling solution begins to discharge

from this hose, return to the receiver.

To increase heat transfer

efficiency, lower maintenance

cost, conserve overall energy

consumption and thus

enhance the usable life of

your machinery, removing

scales in all your watercooled

or water-heated

rubber and tyre equipment

is very important.

8. Open water supply valve to gate and

maintain Descaling Solution circulation

through this circuit.

9. Open water supply valve to jacket and

maintain Descaling Solution circulation

through this circuit.

10. If any circuit is NOT flowing properly,

restrict Descaling Solution flow in other

circuits until flow returns to normal in

this circuit.

11. Circulate a total of 120 Litres of

Descaling Solution through all circuits of

mixer until clean. This will require

approximately four hours pumping time.

12. It is suggested to periodically rotate the

rotors during Descaling Solution cleaning

to assure that the Descaling Solution is in

contact with all of the lobes of the rotor.

13. Upon completion of cleaning, flush all

Descaling Solution from all circuits with

fresh water.

14. Disconnect the Descaling Solution pump

and all hoses. The mixer is now ready to

be returned to service.

15. Periodic descaling will keep the

temperatures of the mixer within

acceptable limits, assuring you a better

product and minimize burnt or

improperly mixed stock.

16. Clean out the Descaling Solution System

and store for future use.

Summarizing, scaling is the biggest problem

with heat transfer efficiency in your rubber

machinery. Descaling or cleaning the scales

helps you fix this issue. Hence incorporating

descaling solutions into your preventive

maintenance program is recommended to

keep your equipment running effectively

and economically.

RMW

Know Your Supplier | JUNE 2016


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