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
 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

6
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.

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 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.

8
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) Tapping machine

Vertical machining centre (VMC800) Honing machine
Vertical tool centre (VTC) Chuck mate
Vertical machining and boring (VM8) Vertical milling machine (FN2V1)
CNC Lathe (ECONO CNC) Horizontal milling machine (FN2EH2)
Radial arm drilling machine (RD32) External grinding machine (K130U,)
Gear shaping machine Internal grinding machine (GIF80)
Thread roller Copying lathe
Horizontal hobber Turret lathe
Broaching machine 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 Enterprise Lathe
Spot welding machine Horizontal band saw
Vertical band saw MIG Welding unit
14T Pneumatic press Centre lathe
80T Press brake Tube Bending Machine
80T Shearing machine Nibbling Machine
16T Press Abrasive cutter

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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.

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 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

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 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

13
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

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