anang - factory visit

Respected Mr. Dinesh Korjan sir,
 
 This is regarding to the experiences of factory
visit………..
 The very first visit was of a very small unit of
aluminium sheet production at “sudarshanpura”, Jaipur.
They produced aluminium sheet of the thickness of 1 to
3 mm for utensils. The sheets are further supplied to
the utensil making unit. The raw materials they use
are aluminium scrap in the form of old utensils, wires
& bus body parts, which they get from the local
market. 
Mr. Rajendra Singh the owner of this unit told the
whole process of recycling the metal. The process is
same for all the metal but the temperatures vary at
stages for different materials.
 The whole process is started with the collection of
raw material. Then the raw material was heated till
the melting point (650o C for aluminium) in a Furness,
this unit has the “air blast oil fired farness”, in
which oil is used as the fuel & air is blow with the
help of electric blower at 3000 RPM. The oil used in
the farness is diesel grid oil called farness oil. In
this process the pure metal in liquid form is settled
down & the impurities i.e. the oxides covered that.
That oxide form called the cover flux, which contains
cobalt, Zink oxide, the metal & it’s oxides as well in
the form of ash.  Then that molted metal is pored in
the “cast iron book mould” for 10 to 15 min. to form a
thick slab called billet. These billets then further
go through the hot rolling then go to annealing & then
for the cold rolling process to give the needed
thickness (i.e. 1mm to 3 mm for that unit  to made
utensils like bowls, pressure cooker etc). The gap
between the rollers, across the roller length needs to
be maintained constant and thickness gauges of
relevant sizes would help maintain the gap. The time
consumes in the annealing process is 2 to 4 hours. The
annealing farness was also the oil fired one. Then the
sheets were cutting into circular & square form for
the given size & the remaining scrape from the cutting
was again recycled. The whole process takes 3 to 4
days.
 Then the second visit was of a small of aluminium
sheet making where the Propezene machine was using for
continuous sheet making & the sheet was engraved in a
particular pattern for making the bus flooring. 
 Then the third visit was of a wood workshop at
“malviya industrial are” where the initial steps of
furniture making were being done. The owner of the
unit is Mr. Sameer Weiton passed from NID in 1997. He
told about the work, the process, quality & basic
characteristics of wood & the need of export &
domestic market in terms of wooden furniture.
 First he told that there are 2 basic types of wood
that is the plywood & the solid wood. In the process
of making a final product of wood first there is need
of drying the wood because if the wood is not
completely dry then the product will deform latter on.
So for that the unit has a sizzling plant which was a
air tight cabin with heaters & fans & the walls of the
cabin was insulated with the thermocol & cement
applied on it. the wood in billet form was arranged in
the sizzling plant for 15 to 20 days & during the
sizzling period the wood release 15 to 20 liters water
per day.
 This unit has three types of machines the manual, the
electric & the pneumatic. The other machines were like
that:
  The lathe machine (electric) for turning the wood.
The band saw (electric) for cutting the wood at
curves, angles & straight orientation. Planer that is
one and two sided (electric) & the four sided
(pneumatic) which has blades & measurement (in mm)
option. Then the spinners molder to cut a curve. The 4
blades of this machine were arranged in a circular bit
are the tunksion carbide blade & called the FHS
(function high speed) blades. Then the router machine
(electric) for making fine grooves (specially used in
jalli making).  Then the panel saw machine (pneumatic)
for cutting the plywood of larger size. This machine
was using for the straight cut as well as for the
shampher. Then the multiple boring machine for making
more than one bore of same or different sizes at a
time. By the help of this machine one can make 20 to
22 bore at a time. The unit has it’s tooling shop
where the blunt blades of the tools can be sharpen
again. 
  The entire pneumatic machines in this unit have the
air suction feature by which the problem of
respiratory disease decreased & the disposal of
wastage became easier. In this unit we saw better
examples of contemporary work need for today’s market.
We saw here the good mixture of different materials to
get a better result.
 Then the fourth visit was plastic unit again at
“sudarshanpura”. The owner of this unit Mr. Y. S.
Bhati told us about the press molding of the plastic.
The process is remaining same for all kind of plastic.
All the plastics can be remolded except the nylons.
They are using plastic granules for molding. The unit
was making the parts of submersible pumps. They were
using delerine, nylon, abs, pp, poly carbonate
plastics for product making.
 Overall these visits provided us knowledge of the
basic materials, their characteristics, the
possibilities in the material & the way of using the
material in a proper way for the proper result.
          Regards
                  Anang