VOL.

II - 2007

For private circulation only

Message from Directors

t is often said that "Change" is the only thing that is constant in this world. It is a hard fact of life. We believe that hard things are put in our way, not to stop us, but to call out our courage and strength. Success comes to those who brave to take charge of the changed situation and act to shape their own destiny. That is what we have always done at Ferromatik Milacron India. Indian economy has continued to grow at 9% plus growth rate. We feel proud and jubilant of our progress. Our markets are attracting world attention for investments as well as participation, throwing up new challenges. Competition has turned intense on all fronts - price (cost), performance, quality, delivery. One needs to manage all these par excellence to be a winner. We need best of the people to give us a win. Now, what confronts us is - skilled manpower has become scarce. The demand for skilled personnel has grown higher than the supply.

Jay Woerner - Vice President Asian Operations Milacron Inc., Chairman - FM India

We are answering this situation in two ways. We are doing our best to create more trained people to serve the industry. We encourage and welcome students from institutes to join us for the in plant training which they are required to undergo as part of their curriculum. We have also enlarged our company trainee pool to 30. These fresh graduates and diplomas undergo one year shop floor and classroom training. They are either absorbed by FMI in regular roles or made available to the industry, based on the need. As a second step, we are making our machines simple and easy to operate, while they are fully loaded with concurrent advanced technologies to guarantee reliable quality and performance. Our machines delivered over last 6 months have one common control with common menu and texts. Few other actions will follow.

Mahendra N. Patel, Director

Industry too has recognized our commitment to serve the industry beyond our business gains. Some have conferred on us the title of "Sensitive Organization"sensitive to customer needs. We feel amply rewarded.

Lead Story

Opportunities for Plastics in Automotive Industry

he Indian automobile industry has emerged as one of the fastest growing manufacturing sectors with increasing home consumption (passenger cars 1.37 millions and two wheelers 6.5 millions), and adding to it exports of parts as well as fully built vehicles. The dream project of TATA's "Put the developing world on 4 wheels" with one lakh rupees car spells that Indian Auto Industry has matured to be globally cost competitive. Realizing this fact the world's top car, motor cycle, truck and bus makers turn to India and are setting up production bases in India.

Polymers proved that they could be lighter and stronger than the traditional materials and so they offered light-weight, more fuel-efficient, stronger, safer cars than before. Flexibility of design and manufacturing, cost advantages and easy maintenance of plastic components will continue to support the growth of plastic goods for the next several years. Given the inherent qualities of plastic products, including its low maintenance requirements and durability, plastic components are now being used more and more in the wide range of applications of automotive sectors. Technical developments in plastic processing, equipment manufacturing and engineering have also increased the use of plastics in the automotive plastic component sectors. Indian demand for new plastics manufacturing equipment especially in the injection moulding sector is likely to grow atleast at an annual rate of 10% for the next five years or more. Expectations from the Machine for Automotive Components: They range from general expectations such as - Low Rejection Rate, High Productivity - Low Power Consumption, Minimum Downtime - Precise Shot Weight and Consistency To Unique expectations such as - Wide Platen Area - Large Mould Weight Carrying Capacity - Wide Application Versatility to process all types of polymers commodity to engineering plastics and special process sequences such as valve gate sequencing and coining. Ferromatik Milacron India provides cost effective solution to meet the requirements of our customers. We offer variety of design concepts in machine such as Toggle Clamp, Direct Hydraulic Clamp, Two Platen and All Electric to meet individual application requirements and processing technology. Features such as auto mould height setting, tonnage setting from screen, precise reproduction of optimized parameters from previous mould setup data make mould change easy and qualify the machine for JIT line supply. Our machines are equipped with simple to operate control and host of options for every processing need such as fabric / vinyl sheet lined mouldings for auto structurals to glass fiber filled / high temperature polymer processing capabilities for under hood parts and auto electricals. We have very strong presence with more than 400 injection moulding machines running at automotive plastic parts manufacturers for lighting, interior, engine parts, exterior and under the bonnet applications. Suitable Machine Size 50T-200T 200T-400T Major Applications Air ducts, Head light reflector, Tail light case, Lens, Door handle, Wiring harness, Buzzer Radiator part, Inside handles, Head light reflector, Tail light case, Lens, Housing for interior & exterior mirror, Oil filter housing, Air filter, Odometer, Instrument cluster Door trim, Air intake system, Fuel intake system, Engine cover, Arm rest & handle, Battery, Radiator fan, Wheel cap, Seat base, Helmet, Head lamp cowling, Mud guard Centre console, Door panels Bumper, Body panel, Instrument panel, Grill, Mud guard

400T-600T

600T-800T 1000T-2300T

Our Patron

Sun Vacuum Formers Pvt. Limited

S un Vacuum Formers Pvt. Limited, is a TS - 16949 certified company located at

the automotive hub of India, Gurgaon. The company is managed by a team of professionals having extensive experience in the automotive sector. At the helm of affairs of the company is Mr. Subhash Sathe, Managing Director who has an active support of Mr. Ish Budhiraja and Mrs. Indrani Sathe, Directors. Sun Vacuum made a modest beginning in 1986 with vacuum forming and has come a long way since then to become a leading supplier of plastic moulded components to Maruti Suzuki, the largest manufacturer of cars in India. The Company has a technical collaboration with Alphatec Corporation, Japan, to have a cutting edge technical expertise into mould making and designing.
Sun Vacuum Formers Pvt. Limited - OperationTeam

Group's customer base includes Automobile Giants such as Maruti Suzuki, General Motors and other OEMs of Automobile manufacturers. It's subsidiary Sun Steering is into manufacturing and supplying Steering Wheels to Maruti Suzuki and seat base to Honda Scooters & Motorcycles Ltd. The association of Milacron with Sun Vacuum dates back to 18th Sep 1997, when the first machine i.e. Sigma 110 was supplied. Since then this association has grown on continuously to become a bond of trust and resulted in addition of 18 Ferromatik Milacron Injection Moulding Machines ranging from 50T-660T and has now become one amongst the largest customers of Ferromatik Milacron in Northern India. Ferromatik Milacron feels pride in sharing growth and success with Sun Vacuum, one of our esteemed customers.

Happenings

Mr. Jay Keswani of Ethylene Products and Lubricants Ltd., Nigeria accompanied by his daughter Natasha on 23rd April 2007, watering the tree that grew from sapling planted on 20th October 2001

S. V. Divgi addressing the gathering at Customer Meet, Kochi

S. Srinivas with Mr. A. Subramanyam - Executive Director of Moldtek Technologies Ltd., at IPLEX 2007

Vivek Sharma with Mr. Munawar Rajput, GM of Plascon Pet Bottler Pvt. Ltd. & Mr. Mohamed Athar Khan at PPP, Pakisthan 2007

Processing Tips

Sink Mark
epressions on the surface of the moulded part is called sink mark, if the thermal contraction (localized shrinkage) cannot be compensated. Shrinkage is the development of size variation due to defective part design or uneven cooling of moulding. When the gate freezes, the pressure in the mould relaxes because the temperature is falling. So two opposite effects are working on the material in the mould. 1. The Pressure is falling - This allows the material in the mould to expand. 2. The Temperature is falling - This causes the material in the mould to contract. Sink Marks & Voids occur when the pressure reaches zero before the temperature has reached the Ejection Temperature. If the temperature in the mould reaches the Ejection Temperature before the pressure reaches zero, you will get residual pressure in the moulding.

..... MACHINE

Probable Cause Injection speed high Pack and hold pressure low Insufficient metering

Possible Remedy Reduce the injection speed or use profile Increase pack and hold pressure Increase shot size Optimise transfer position Optimise pack and hold time Reduce melt temperature Increase nozzle orrifice if allowed Increase cooling time

..... MATERIAL ..... MOULD

Moisture in granules

- Check the moisture in material - Use blowing agents - Use lower MFI material - Reduce the mould wall temperature - Check the ventilation - Check water flow through mould for blockage (creates "hot spot") - Increase the gate size or runner size, if required - Check mould material for good thermal conductivity - Check for balance melt flow on multi cavity

High wall temperature

Ferromatik Milacron India Ltd. Cordially invites you to visit us at K 2007, Germany from 24th - 31st October 2007 Plastivision India 2007, Mumbai from 6th - 10th December 2007

Training Programme on Injection Moulding Machines

Contact FMI Regional / Area Offices :
DELHI 011-2983 9102 / 9188 / 44871 MUMBAI 022-4005 5459 - 62 / 66 CHENNAI 044-2361 3319 KOLKATA 033-2282 2909 HYDERABAD 040-2340 2159 / 2160 BANGALORE 080-2340 8984-85 PUNE 020-2614 0200 CHANDIGARH 0172-508 6622 BADDI 93187 64784 HARIDWAR 01334-235357 DAMAN 0260-246 5150 KERALA 93870 61913

FERROMATIK MILACRON INDIA LTD.

(Formerly known as Cincinnati Milacron Ltd.)

92, Phase-I, G.I.D.C. Vatva, Ahmedabad - 382 445, India. Tel.: +91-79-2589 0081, 2589 0133, 2583 0063 Fax : +91-79-2583 0125 E-mail : salesfmi@milacron.com Website : www.milacronindia.com
Edited and published by Sales & Marketing team on behalf of Ferromatik Milacron India Ltd.

10/2007 marg