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Composite Business Unit
To discuss….
• Sintex Group
• Bright Autoplast (BAPL)
• Sintex Wausaukee Composites Inc (SWC)
• Synergy – Customers to ser...
Sintex Group - Active Thinking
The world of Sintex is one that is driven by ideas;
it is the key to the Group’s growth ove...
Plants |35
Countries |9
Continents | 4
Solutions Engineered across the globe 5
Global Manufacturing Bases
6
7
BAPL Foot prints
Strategically located in the automotive corridors
of India, offering a range of mfg capabilities for
Th...
8
▶ BODY-AIR CLEANER,UPPER
▶ ELEMENT -AIR CLEANET
▶ PACKING-ELEMENT
▶ BODY-AIR CLEANER,LOWER
▶ LOWER CASE DIFFUSER, UPPER
...
9
Defroster Grill Gap HiderRadio Centre
Stack Bezel
MFD Cover
Pull Handle
Shifter Bezel
Assembly
Climate Control
Head Beze...
10
Front & Rear Bumper Assembly
Automotive Exterior Systems
Fuel Tank – 220 L
Hydraulic Reservoir
11
Technologies in Use
• LRTM Light Resin Transfer Molding
• RTM Resin Transfer Molding
• HLU Hand Lay / Open Molding
• LCM L...
LRTM
• Vacuum to close mould and inject resin
• Two-sided finish with lower tooling cost.
• Consistent dimensional toleran...
Soft Touch & Compression Moulding
14
• Soft Touch Interior Parts
• Semi structural strength
• Superior Finish
• Production...
Product Range
Synergy – Customers to Serve Globally
Initiative of Sintex divisions
Sintex-Wausaukee, Sintex-Nief, Sintex India, and Brig...
Kalol
Inland Truck
Mundra
Sea transit
Port of Norfolk
TOFC
Chicago Rail Yard
Inland Truck
Warehousing at Gillett
Sintex + ...
Nief Plastic + BAPL = Happy Customer
Exchange of Technological expertise & Locational Advantage
Moulding Area: 9000 Sq Ft
Capacity: 18000 parts per year
with parts up to 5 sq. met. Area
Painting: Connected with existin...
Plant Layout
Designed for Process Control & Productivity
Mould Path Material Path
Mixing of Resin, Additives, Promoter,
Filler etc
Gelcoat by Spray; Positive pressure
booth, Unidirectional door movement,
...
Reinforcement cutting section
Carbon, Glass etc
Resin Injection & Moulding Area
4 Moulds can be used at a time
Plant Infra...
Inside View Trimming Booth, Floor &
Cutting tools with Vacuum suction,
Adhesive dispensing for Metal –
Composite – Composi...
Plant Infrastructure..
Maturation Booth
Ensuring Complete Curing
Inside View
87
Gelcoat Spray on Mould
Moulded Part
Gelcoat Finish
Initial Products..
Initial Products..
2K PU Painting in conveyor paint shop
No extra efforts for Surface Preparation
Safety, Health & Control
PPEs for everybody Eye Wash
Quick Relief
Entry for authorized
personnel only
• Integrated facility: RM testing to assembly of Product. Under One Roof.
• Gelcoat by spray; Good for finish & consistenc...
Operational Strategy
Product
Quality
Globally
Same
1 Tech by
SWC-USA
2 People
Training
by SWC
3 RM
Localization
by BAPL
4 ...
Why & When LRTM?
30
* Construction & Mining Equipments * Agricultural tractors and other machines
* Off road vehicles * Mass transit – Rail an...
Thank you
Lite Resin Transfer Moulding at Bright Autoplast
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Lite Resin Transfer Moulding at Bright Autoplast

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New facility, American Technology, Most advance in India and useful for 500-5000 parts per year requirement

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Lite Resin Transfer Moulding at Bright Autoplast

  1. 1. Composite Business Unit
  2. 2. To discuss…. • Sintex Group • Bright Autoplast (BAPL) • Sintex Wausaukee Composites Inc (SWC) • Synergy – Customers to serve Globally • Success Stories – Happy Customers • LRTM in Pune • Unique Features • Operational Strategy • Why, When & Where LRTM?
  3. 3. Sintex Group - Active Thinking The world of Sintex is one that is driven by ideas; it is the key to the Group’s growth over 8 decades. This spirit is encapsulated in the motto, ‘Active Thinking’; which is the practice of translating ideas and thoughts into actions with an objective of creating meaningful innovations and solutions. Over the years the Group has added depth and width in its offerings to serve range of industries from automotive, aerospace, electrical, energy to medical and defence. It has focused on mastering cutting edge technologies, innovations and has built state-of-the- art infrastructure to meet its clienteles constantly evolving requirements. Company is listed on “Bombay Stock Exchange” “At Sintex, change is the only permanent feature” – Mr Dinesh Patel, Chairman
  4. 4. Plants |35 Countries |9 Continents | 4 Solutions Engineered across the globe 5 Global Manufacturing Bases
  5. 5. 6
  6. 6. 7 BAPL Foot prints Strategically located in the automotive corridors of India, offering a range of mfg capabilities for Thermoplastic & Thermoset parts Sohna | Indore | Pune | Nasik | Chennai 1| Chennai 2 | Chennai 3 Passenger Vehicles  Passenger cars  Sports Utility Vehicle  Multi Utility Vehicle  Scooters & Motorcycles Commercial Vehicles  Micro & Light Trucks  Heavy Trucks  Passenger Buses & Coaches  Goods Carriers
  7. 7. 8 ▶ BODY-AIR CLEANER,UPPER ▶ ELEMENT -AIR CLEANET ▶ PACKING-ELEMENT ▶ BODY-AIR CLEANER,LOWER ▶ LOWER CASE DIFFUSER, UPPER ▶ LOWER CASE DIFFUSER, LOWER ▶ NECK RESONATOR (INLET PIPE) ▶ BODY-AIR CLEANER,LOWER ▶ RESONATOR, UPPER ▶ RESONATOR, LOWER ▶ DUCT A-AIR,INLET UPPER ▶ DUCT A-AIR,INLET LOWER Technologies in Use • Injection molding • Blow molding • Rotomolding • Vacuum Forming • Rubber injection molding • Fabric insert molding • Vibration welding • Assembly and Testing • Painting Functional Auto Parts- Air Induction System
  8. 8. 9 Defroster Grill Gap HiderRadio Centre Stack Bezel MFD Cover Pull Handle Shifter Bezel Assembly Climate Control Head Bezel Rear Décor Strip Chute Channel Assembly Glove Box Assembly Shifter Trim Plate Shifter Ring Front Décor Strip Automotive Interior Systems
  9. 9. 10 Front & Rear Bumper Assembly Automotive Exterior Systems Fuel Tank – 220 L Hydraulic Reservoir
  10. 10. 11
  11. 11. Technologies in Use • LRTM Light Resin Transfer Molding • RTM Resin Transfer Molding • HLU Hand Lay / Open Molding • LCM Liquid Compression Molding • RIM Soft Touch Urethane • SMC Sheet Molding Compound Moulding • DMC Dough Moulding Compound Moulding Composite Manufacturing Processes Conversion to Composites Mfg Tech Mould Mfg Mould Design Complete Solution Sintex Wausaukee Composites is a premier provider of highly-engineered Composites, Urethane and Structural Plastic component solutions worldwide. • Producing more than 100,000 components for more than 35 OEMs annually. • Experienced workforce including more than 40 ACMA certified “Composite Technicians”.
  12. 12. LRTM • Vacuum to close mould and inject resin • Two-sided finish with lower tooling cost. • Consistent dimensional tolerances and resin/glass ratio • Moderate production rates (500-5,000 parts/year). 1 2 3 13
  13. 13. Soft Touch & Compression Moulding 14 • Soft Touch Interior Parts • Semi structural strength • Superior Finish • Production rate 1,000 – 50,000 parts / year • Structural & Semi structural parts • For Interior and Exterior application • Excellent Mechanical & Electrical properties • Production rates (5000-50,000 parts/year).
  14. 14. Product Range
  15. 15. Synergy – Customers to Serve Globally Initiative of Sintex divisions Sintex-Wausaukee, Sintex-Nief, Sintex India, and Bright Autoplast Objective: Exchange of technological expertise, Leveraging manufacturing cost advantages, Engineering support, Part supply & Logistic management to service Global Customers - Globally 16
  16. 16. Kalol Inland Truck Mundra Sea transit Port of Norfolk TOFC Chicago Rail Yard Inland Truck Warehousing at Gillett Sintex + SWC = Happy Customer Leveraging manufacturing cost advantage & Logistics management
  17. 17. Nief Plastic + BAPL = Happy Customer Exchange of Technological expertise & Locational Advantage
  18. 18. Moulding Area: 9000 Sq Ft Capacity: 18000 parts per year with parts up to 5 sq. met. Area Painting: Connected with existing conveyor paint shop SWC + BAPL = Now Ready…. Arial View of LRTM Cell in the Pune Factory
  19. 19. Plant Layout Designed for Process Control & Productivity Mould Path Material Path
  20. 20. Mixing of Resin, Additives, Promoter, Filler etc Gelcoat by Spray; Positive pressure booth, Unidirectional door movement, Plant Infrastructure.. 1 2
  21. 21. Reinforcement cutting section Carbon, Glass etc Resin Injection & Moulding Area 4 Moulds can be used at a time Plant Infrastructure.. 3 4
  22. 22. Inside View Trimming Booth, Floor & Cutting tools with Vacuum suction, Adhesive dispensing for Metal – Composite – Composite bonding Plant Infrastructure.. 65
  23. 23. Plant Infrastructure.. Maturation Booth Ensuring Complete Curing Inside View 87
  24. 24. Gelcoat Spray on Mould Moulded Part Gelcoat Finish Initial Products..
  25. 25. Initial Products.. 2K PU Painting in conveyor paint shop No extra efforts for Surface Preparation
  26. 26. Safety, Health & Control PPEs for everybody Eye Wash Quick Relief Entry for authorized personnel only
  27. 27. • Integrated facility: RM testing to assembly of Product. Under One Roof. • Gelcoat by spray; Good for finish & consistency. • Automatic Injection Machine with RFID sensor on each mould for program selection. • Vacuum assisted tools and booth for trimming. EHS is utmost important • Structural adhesive dispenser, pre-programmable with variable ratio for Metal to FRP or FRP to FRP assembly • On line painting in Conveyor Paint Shop • All the Process Parameters are Centrally Controlled and Monitored using SCADA based system. This can be remotely accessed for control and troubleshooting Unique Features of Plant
  28. 28. Operational Strategy Product Quality Globally Same 1 Tech by SWC-USA 2 People Training by SWC 3 RM Localization by BAPL 4 Product Engineering by SWC 5 Mould & Process Design by SWC 6 Prod & Supply by BAPL
  29. 29. Why & When LRTM? 30
  30. 30. * Construction & Mining Equipments * Agricultural tractors and other machines * Off road vehicles * Mass transit – Rail and Road * Medical Equipments Where LRTM is used?
  31. 31. Thank you

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