Bony Group of Companies

Business Segments
Compounding

Moulding
Division

- Rubber

- O Rings

- Non
Asbestos
Friction
Material

- Rubber
Moulded
Parts
- Rubber to
Metal
Bonded Parts
- Brake Blocks
(Rail)

Prime India
Polymix (P) Ltd.

Extrusion
Division
- Turbo
Charges
Hoses
- Air Clean,
Radiator &
Coolant
Hoses

Metallic

Sheet Metal

Flexible Hoses
- Cross Over
Piping
- Convolutions

LED
Division

- Press Work
- Fabrication

Bus

Aggregate

Division

- Sign
Boards

- Air
Conditions

- Street
Lights

- Rear
View
Cameras

- Coach
Lights

- Fleet Mgt.

- Fuel Hoses
- Brake Hoses

Bony Polymers (P) Ltd.

Saket Fabs (P) Ltd.

Bony Systems &

Technologies Ltd.

Introduction
Bony Polymers (P) Ltd. is a reputed name in the field
of Manufacturing Rubber Moulded Parts, Rubber to
Metal Bonded Parts, Non Asbestos Friction
Materials, Hoses, Hose Assemblies & Fuel Tubes for
automotive and non automotive sectors.
Bony Polymers (P) Ltd. was established in the year
1981 & our specialised products have been utilised by
renowned OEMs.
The aim is, to make the Bony Polymers (P) Ltd. and its
products a benchmark at all levels of International
Standards.

Bony Polymers (P) Ltd.

Becorit GmbH

Technical Collaboration between Becorit GmbH

(Germany) and Bony Polymers (P) Ltd. for
manufacture of
Non Asbestos Friction
Materials

K Type Brake Block

L Type Brake Block

Bony Polymers (P) Ltd.

Meiji Flow Systems Co., Ltd.

Agreement between Meiji Flow Systems Co.

Ltd. (Japan) and Bony Polymers (P) Ltd. for
Licensed Assembly and Testing of Hydraulic
Brake Hoses

Hydraulic Brake Hoses

Technical Association
In Technical Association with
EATON FLUID POWER INDIA.

Bony Fluid Power

System

(A Division of Bony Polymers (P) Ltd.)

An Association you can rely on

An Association of Quality

Bony Polymers (P) Ltd.

Agency Agreement between TES

and BPL for selling in India

(TES)

Our Vision

To achieve world class

standards in Quality of Products,
Services and Human resources

Overall Man Power

Category

Strength

Production

817

Quality Engineering
(Planning & Assurance)

28

Engineering (Product Dev. & Tool Engg.)

21

Research & Development

22

HR, IR, Govt. Liaising & Security

15

Others

10

Total

913
Total Staff

= 220

(Junior Mgt. to COO)

Total Operatives

= 693

Organization Strength
Extensive R & D and Product Testing Facility
In-house R & D recognized by Govt. of India,
Ministry of Science & Technology
Certified Quality and Environment Management
Systems
Technical Expertise to meet Global requirement
A Fast Growing Company which has a growth
Rate of 25 to 30 % every Year for the last 10 Years

Quality Certification & Approvals

Govt. of India
Ministry of Science & Technology
recognition for In-house R&D
units
An ISO/TS-16949:2009
(Recertification under new version)
An ISO 14001:2004 (EMS)

VDA 6.3

by : MANN & HUMMEL,SIEMENS VDO

& KNORR- BREMSE

Customer Awards for Excellent Performance

Environment
Registered with IMDS
(International Material Data System )

The IMDS is the automotive industry material data system.

In the IMDS, all materials used for car manufacture are
archived and maintained.

Certified ISO 14001:2004 Company.

Our Expertise
Expertise in the development & processing of the
following Elastomers:

NATURAL RUBBER (NR)

STYRENE BUTADINE RUBBER (SBR)
POLYBUTADINE RUBBER (PBR)
ISOPROPYLE ISOBUTYENE RUBBER (IIR)
CHLOROPRENE RUBBER (CR)
NITRILE BUTADINE RUBBER (NBR)
HIGH NITRILE BUTADINE RUBBER (HNBR)
POLYACRYLIC RUBBER
FLUORO ELASTOMER (FKM)
CHROLROPRENE SULPHONATED MONOMER (CSM)
EPICHLOROHYDRIN (ECO)
SILICONE
AFLAS
NBR/PVC
EPDM
OTHER SPECIALIZED ELASTOMERS.

Our Expertise
Versatile with following international standards :
ASTM D 2000 for automotive components
SAE 100 R, SAE J-1403, SAE-30R6, SAE 30R2,
SAE20R4 for hydraulic hoses, radiator hoses,
engine coolant hoses vacuum brake hoses and
hoses for CNG application.
JIS 6403 Standards, JASO F404 for O-Ring
DIN standards
ISO standards
Customer Specific standards

Product Range

Segments Catered

Railways
18%

Cars 10%

Two Wheelers 45%

Trucks & Buses

10%

Construction & Agri.

Machinery 15%

Power Plant

Our Products
Anti vibration mounts

Our Products
Buffers & Transmission Mountings

Our Products
O - Rings

Seals & Gaskets

Our Products
Grommets for wiring harness

Our Products
Dust Covers & Cover Ball Joints

Our Products
Boots & Bellows

Insulators for Carburettors

Our Products

Suspension bushes
Bush swing arm
Bush engine hanger &
Silent blocks

Our Products
Isolators & Exhaust Hangers

Our Products
For Locomotive & Coaches

Our Products
Radiator & Coolant Hoses

Vacuum Brake Hoses

Heater & Water Hoses

Inter Cooler & Turbo charger (Silicon) Hoses

Our Products
Fuel Tubes

CNG & LPG Hoses ARAI Approved

Our Products
High Pressure Hydraulic Hose Assemblies

Our Products
High Pressure Hydraulic Hose Assemblies

Esteemed Customers : Two Wheelers

OEMs
Hero Honda
HMSI.
Yamaha Motors
Suzuki Motorcycles

Tier 2
Anu Industries
Denso India Limited
FCC Rico Limited
Hero Motors
Lifelong India Ltd.
Munjal Showa
A.G.Industries
Autofit Pvt. Ltd.
Magnum Components
Munjal Auto
Multilink
Napino Auto
Rico Auto
Majestic Auto Ltd.
Pricol Ltd.
Wings Auto

Esteemed Customers : Car

OEMs
Maruti Suzuki India Ltd.
Honda Siel Cars India
Mahindra & Mahindra

Tier 2
Arvin Meritor
Nissan (Delphi Packard)
Delphi steering
Tata (Minda)
Hyundai (Motonics)
Land Rover (Mann &
Hummel)
Mag Filters& Eq. P.Ltd.
Toyota (Tata Yazaki)
Toyota (Toyoda Gosei)
Ford (Yazaki Wiring)
Ford (Cooper Standard)
SKH Metals Ltd.
MGI Coutier Exotech
Sun Vacuum Formers Ltd.

Esteemed Customers: Commercial &

Construction Equipments

OEMs

Ashok Leyland
Swaraj Mazda
Tata Motors
Mahindra Navistar
JCB India Limited
Escorts Agri machinaries
Claas India Limited
Eicher International Ltd.
L & T Komatsu
Telcon

Tier 2
Toyo Spring
QH Talbros
Jamuna Auto
Alkraft
Banco
Tata Toyo

Esteemed Customers

Bony Group Plant Locations

Existing
Under Construction

Haridwar
(Plant 5)

Lucknow
(Plant 6)

Mixing (Plant 1)
Molding &
Extrusion
(Plant 3)

Prithla
(Plant 8)
Molding
(Plant 4)
Manesar

Friction
Material
(Plant 2)
Sheet Metal Plant
(Saket Fabs.)
(Plant 7)

Existing Units

BONY POLYMERS (P) LTD. (PLANT-1) PLOT NO. 9E/6 (FBD)

R&D
COMPOUND
PREPARATIONS

Existing Units
BONY POLYMERS (P) LTD. (PLANT-2) PLOT NO. 77/6 (FBD)

Friction
Materials for
Railways and
Automotives

Existing Units
BONY POLYMERS (P) LTD. (PLANT-3) PLOT NO. 37 P/6 (FBD)
Corporate Office
Moulding Shop
Extrusion Shop
A state of art facility which has a shop floor area of about 70,000 Sq. Ft., Which will
accommodate Moulding and Extrusion operations.

Injection
Moulding
Unit
Moulding
shop

Hose Section
Extrusion
shop

Existing Units
BONY POLYMERS (P) LTD. (PLANT-4) 34/3, IMT MANESAR, GURGAON

15000 Sq. Feet

Existing Units
BONY POLYMERS (P) LTD. (PLANT-5)
PLOT NO. 6, INDUSTRIAL PARK IV, BEGUMPUR VILLAGE, HARIDWAR

Manufacturing
Facilities

Mixing

Computerized Ingredients Weighing System

Mixing & Pre Blanks Preparation

Moulding

Injection Moulding Machine

BARREL VOLUME UPTO 10000 CC
CLAMPING FORCE UPTO 400 TONS
No. of Injection Moulding Machine: 50
(38+12)

Vacuum Compression Moulding Machine

Capacity :300 tons

Capacity :200 tons

Surface Preparation
14 Tanks Metal Pre-Treatment Line

Adhesive Application
AN AUTOMATED ADHESIVE APPLICATION SYSTEM

Extrusion

Co-Extrusion

High- Precision Fuel Tubes

Pressure Hoses and
Long Length Air Pipes.

Hose Braiding & Knitting Machine

Hose Extraction & Proof testing Machine

Hose Assembly

Crimping Machines

Crimping Machines

Testing Facilities
Fully Functional Laboratory

Parameters We Meet
High Tensile and Elongation
High Compression Resistance
Oil Resistance/Fuel Resistance
Electrical Resistance
Ozone Resistance / Weather Resistance in open atmosphere
High Temp. Resistance /Low Temp. Resistance
Static and Dynamic Stiffness
Axial, Radial and Torsion Test
Shear & Fatigue test
High Air Pressure Resistance &Vacuum Resistance
Other critical Metallurgies of Engine & Transmission parts

Rheometer and Rubber Process Analyzer

For testing of compound

curing behaviour

For testing of viscous and elastic

components & dynamic
characteristics of rubber compounds

Testing Equipment
Vibration Simulator
For measuring Dynamic
Stiffness or tan-delta ( loss factor )
of mounts at high vibration
frequency

Testing Equipment
Universal Testing
Machine
(15 tonne Instron)
For measuring
deflection at load of
Metalastic ant vibration
mounting

Testing Equipment
Endurance Testing Machines

Life cycle testing :

Engine mounts
Mount rubbers
Shock absorber components.

Capacity:30 tons

Testing Equipment
Fatigue Testing
Machine
Measures resistance of metalastic
antivibration mount to repeated
compressive load cycling at
defined frequencies

Measuring Equipment
Cordinates Measuring Machine (CMM)

Profile Projector

Testing Equipment
Ozone Chamber
For simulating weather
resistance upon exposure
of a stressed rubber component
to high ozone concentration

Testing Equipment
Torsional Fatigue
Testing Machine

Testing Equipment
Dust Cover Mud
Endurance Test Rig

Testing Equipment
Humidity Chamber

Testing Equipment
High Voltage
Tester

Low Temperature
Testing up to 70c

Measuring cold
flexibility of Hoses &
Rubber Components

Testing Equipment

IRHD Hardness
Tester

Abrasion
Tester

Resilience
Tester

ELECTRONIC
DENSIMETER

Mooney
Viscometer

MICRO HARDNESS
TESTER

Dispersion
Analyser

Testing Equipment
Hose Leakage Testing

Under water with air pressure

Testing Equipment
Hose Durability
Testing Machine
Measure resistance of
Vibrating / radiator / heater
hoses to air circulating
hot coolant under
simulated
engine condition

Testing Equipment
Hose Bending Test Machine

Testing Equipment
Hose Flexure Testing machine
Measure resistance of Air
Brake Hose to high stress
flex cycling

Tool Design
Tool designing -In house
Software used: CAD 2005
Pro-e (wildfire)
Uni-Graphics NX3
Iron CAD
Delcam
Solid Edge
Catia
Tools made on CNC Machines

Tool Manufacturing Facilities

EDM-1
Vertical Milling Machine
Center Lathe
Polishing Machine
Surface Grinder
Drilling Machine

Vertical Milling Center (VMC)

Training & Education

Quality Practices
Continual Improvement Activities being followed:

Advance Product Quality Planning (APQP)

Production Part Approval Process (PPAP)

Measurement System Analysis (Gage R&R)

Process FMEA

Statistical Process Control (SPC)

Total Productive Maintenance (TPM)

Kaizen

Small Group Activities

Jishu Hozen

Future Plan
A RUBBER MIXING
LINE FOR CAPACITY
OF 5000 METRIC TON
PER ANNUM, WHICH IS
A FOURTH
GENERATION MIXING
TECHNOLOGY

Future Plan

Plant In Lucknow)
New Plant coming up in 12000
sq Ft. for supply to TATA Motors
(CMV) Lucknow

Plant Available for Future Expansion

18/3, AJRONDA , MATHURA ROAD,

FARIDABAD

15000 Sq. Feet

Saket Fabs (P) Ltd.

Introduction

A Press Metal
Company
Presses ranging from 20 tonnes to 600 tonnes
Self supporting tool room
Spread over an area of 8000 sq. Yards

Quality Certification & Approvals

An ISO 9001:2000

An ISO/TS-16949:2002
An ISO 14001:2004 (EMS)
Direct On Line to
HHML
Approved by
RDSO (Ministry of Railway)

Esteemed Customers
Major OEMs

Tier-2

Overall Man Power

Category

Strength

Production

72

Quality

Engineering and R&D

Administration

Others

Total

85

Products We Make
(Sheet Metal & Fabrication)

Four Wheeler Products

Railway Products
Two Wheeler Products

Cabin Parts

Back Panel

Seat Pans

Chassis Parts

Plates Set IN LH-RH

Plates Set OUT LH-RH

Cross Member LH-RH

Body Parts

Panel Front Lower

Piller B-Out LH-RH

Hing Assembly

Other Parts

Corner Bracket LH-RH

Mounting Pads

End Plate

Products We Make
(Sheet Metal & Fabrication)

Four Wheeler Products

Railway Products
Two Wheeler Products

Our Product Range

For Locomotive and coaches

Products We Make
(Sheet Metal & Fabrication)

Four Wheeler Products

Railway Products
Two Wheeler Products

Engine Parts

Fuel Filters

Body Parts

Manufacturing
(Sheet Metal & Fabrication)

Manufacturing Facilities
Testing Facilities
Tool Design & Tool Room

Manufacturing Facilities
Press Shop

Manufacturing Facilities
Press Shop

Manufacturing Facilities
Weld Shop

Manufacturing
(Sheet Metal & Fabrication)

Manufacturing Facilities
Tool Design & Tool Room
Testing Facilities

Tool Design
Tool designing -In house
Software used: CAD 2005
Pro-e (wildfire)
Uni-Graphics NX3
Iron CAD
Delcam
Solid Edge
Catia
Tools made on CNC Machines

Tool Manufacturing Facilities

Center Lathe
Surface Grinder
Drilling Machine
Profile milling
Turret milling

Manufacturing
(Sheet Metal & Fabrication)

Manufacturing Facilities
Tool Design & Tool Room
Testing Facilities

Testing Facilities

Cupping Test Machine

Salt Spray Testing Chamber

Testing Facilities

Hardness Tester

Microscope

Group Mid Term Plan

Group Sales Trend & Forecast

106
Million $

63
Million $
40
Million $
30
Million $

150

50
50

300

30
20

220

170

Tentative Plan
1 US$ = Rs. 47

Bony Polymers + Prime India

Saket Fabs
BSTL