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ACE Presentation

ACE is a trusted consulting firm providing engineering services and automation solutions for the polymer compounding industry. Our services include plant engineering, project management, diagnostic services, training, and documentation. Contact us today!

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ACE Presentation

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  1. ACE Presentation

  2. Associated Consulting Engineers Consulting – Plant Engineering, project management Technik – Start up and service support, diagnostic Services – Retainer ship, training, documentation Associated consulting Engineers, 21, Saibaba park New civil road, Valsad 396001 India www.acepolytech.com

  3. The Company • We are group of professionally qualified engineers with more than 9 decades of cumulative experience in industry • We are into providing engineering services and automation solutions for polymer compounding industry for the last 20 years • Authorized service partners for Krauss Maffei Berstorff, Elin motoren, (BKG Under Water Pelletizer, Kreyenborg group, Promixon mixer – currently not active)

  4. Business Philosophy • Quality- Tools & Training are our key investments • Commitment, Transparency & Integrity as basis of business • To deliver our collective skill & knowledge to our customer and society at large • Profit is a by product of hard work & essential to continued hard work • Compete with cooperation

  5. ACE – Current Focus • Consultancy – • Selective projects in india • Strategic tie ups with European experts for services outside india. This is now in initial phase of joint approach to project. • Technik • Acquire More principles from Europe • Offer off site services • Focus on spares / sourcing • While maintaining focus on plastics, expand in • Related area like food & pharma • Develop generic capabilities – mechanical – alignment, precision repairs – gear box • Services – to continue more as sustaining measure to support of development of above plans • Retainership • Training / documentation

  6. Business scope • Inspection, Overhaul & Repair of AC/DC motors & Gear boxes & other key up & downstream equipments for twin screw extruders • On site diagnostic services, inspection and installation of up and down stream equipments for compounding plant following proper SOP’s

  7. Our workshop Approx 10000 Sq ft floor area

  8. Our service approach within 1 day 300 km 200 km 100 km

  9. Instruments • Make : SPX Powerteam Hydraulic puller • Model : PH103C & RPS1010 • Capacity : 10T • Spread : 432mm • Stroke : 381mm • Pump capacity : 700 bar • Make : Enerpac Hydraulic cylinders & pumps • Model : RC-102 & P-392 • Capacity : 5T, 10T • Pump capacity : 700 bar

  10. Make : SKF vibration meter • Model : CMAS 100 SL • Velocity range: 0.7 to 65mm/s • Acceleration range: 0.2 to 50 gE • Temp range: -20 to 200°C • Make : Easy Laser shaft alignment tool • Model : XT-440 • Shaft Diameter range: 20mm to 500mm • Accuracy: 0.001mm

  11. Make : TPI Vibration analyser kit • Model : 9080 plus • Frequency range – 2 Hz to 1K Hz (ISO) 1 kHz to 10 kHz (BOU) • Max frequency resolution - 1.25 Hz @ 800 lines FFT setting • Measure – Acceleration in g Velocity in mm/s (or inch/s) Bearing noise in BOU (bearing damage units) Displacement (mm, microns, inch) • Smart trend meter with recording facility • VibTrend PC software

  12. Make : Bosch Endoscope with image and video recording facility • Model : GOS 10.8 V-LI • Camera cable length = 1.2m • Display size = 2.7” • Make : Megger Insulation Tester 10KV • Model : MIT 1025 • Digital display • Software generated report

  13. Make : Easytherm Bearing Induction Heater • Model : 3.5 • Diameter 15mm to 420mm • Max weight: 70 kg • Max temp: 240°C Make : RSK Presicion level guage (accuracy 0.02mm /m) Model : 541-1502 Length : 150mm & 300mm

  14. Make : Mitutoyo digital outside micrometer Range: 0 to 300 mm • Make : Mitutoyo Bore guage with expansion rodes • Model : Series 511 • Range: 18mm to 250mm • Length of measurement : 3m

  15. Make : SKF Thermal camera Model : TKTI 10 • Large colour display • Storage upto 1 GB data • Software generated report • with thermal & digital image • Make : Circutor System analyser Model : C-80 • Measure in true RMS • Measurement of harmonic • distortion in current & voltage • Automatic data recording in internal • memory

  16. Make : Allosun Electronic stethoscope • Model : EM410 • Frequency range – 100 Hz to • 10K Hz • Ambient noise permitted – 100 dB • Make : Lutron Digital anemometer Model : AM-4201 • Accuracy – 99.9 % • Measure in m/s, km/h, ft/min • Data hold function

  17. Model : High pressure pump • Capacity : 0 to 2000 bar

  18. Diagnostic tools • Vibration analysis (TPI) • Industrial endoscope with image recording (Bosch) • Thermal imaging (SKF) • Laser alignment tool (Easy Laser) • Bore measurement (Mitutoyo) • Insulation tester (Megger UK) • Oil analysis (out sourced)

  19. Typical compounding plant

  20. Feeders: Capabilities We have wide experience with different type Loss-In-Weight feeders. We have handled following type of feeders - • K-Tron : 100+ • Brabender : 25+ • Sonner : 10+ • Schenck : 10+

  21. Feeders: Services

  22. Motors: Capabilities We are handling following types of motor of rating 5 to 1500 KW - • Water cooled motor • Air cooled motor Major motors that we have handled till now are of make - • Elin motoren • Siemens • Baumuller

  23. Motor: Services

  24. Example Elin motor Tunnel boring machine motor complete overhaul with rewinding

  25. Motor Inspection sample report

  26. Motor IR test sample report

  27. Laser alignment using easy laser alignment kit (XT-440)

  28. Laser alignment sample report

  29. Diagnostic package examples • Vibration analysis by TPI vibration analyser kit

  30. Gear box thermal image by SKF thermal camera • Electrical parts thermal image by SKF thermal camera

  31. Gear box: Capabilities This is one of the major service we provide. We have attended following makes of gear boxes till now - • Siemens/ Flender • Zambello • SEW • PIV • Other German make

  32. Gear Box: Services

  33. Example Gear box overhaul • Make – German GB • Bearings & seals worn replaced • Replaced in 5 days

  34. Example Gear box overhaul • Make – German GB • Problem: Bearings & seals worn • Replaced in 6 days

  35. Barrel & Screw: Services

  36. Melt pump: Services

  37. Screen Changer & PDV: Services (as required)

  38. Pelletizer: Services

  39. Descaling of cooling channel • Why descaling?? Even when not blocked a relatively thin layer of scale or corrosion can act as an insulator and have a huge impact on the efficiency of your circuit • GWK make pump unit with online temp and pH measurement • Capable to remove all types of scales formed inside the cooling channels • Equipped with 4 way valve to reverse flow to ensure quick & complete removal of scales • Separate tanks for both chemical and water flushing • Drain tank for neutralize descalant and then dispose off

  40. Descaling process flow

  41. Descaling sample report

  42. Thermography • Instrument – SKF TKTI 10 • The SKF TKTI 10 is a digital camera with advanced thermal imaging capabilities. It is ideal for use as a Predictive Maintenance (PdM) tool. Thermography is a non-invasive technique and is well suited for mechanical and electrical inspections, energy conservation and plant safety activities.

  43. It has a large backlight 3 ½” colour screen which gives clear & sharp resolution. • Special features – • It is designed for easy operation • Temperature range : -10 deg C to +350 deg C • Multiple temperature measurement • Difference between temperature measured • 20° x 20° field of view and 47 x 47 pixel detector • Image storage : radiometric data & digital image • Thermography applications: • Overheated connections for high & low voltage installations, cable insulation • Mechanical issues like hot bearings, overheated motors • Mould inspection

  44. Thermography sample report

  45. IT enabled services( proposed)Mobile application , external to customer ERP,

  46. Services - • Looking only for high end services – if and when required . • Now have place to offer shop services. • Ready to invest in tools and training as required. • Can work as front end – make all preparation at site for KMB technician to take over – possibility of a overall saving in time • A joint services has potential of addressing cost sensitive Indian market for services – quote possible that most European share in services in India is disproportionately low compared to population of equipment. • Can actively assist in spares sourcing in India • Can also support in ME / Iran / Far east when required.

  47. ACE focus on services • Mechanical • Twin screw gear box • Kneader gear box • Specialised mixers • De scaling barrels / jackets/ moulds • Laser alignment • Thermography • Electrical ( partly with strategic tie ups) • Thermography • AMC for control system – PLC / FC • Feeders ( Loss in weight systems)

  48. Approach & Schedule • Form a new company with majority shareholding by Kaushik – 3 /4 quarter 2019 – mostly closely held private limited liability company. • Actively search for European partner – This will accelerate growth in multiple ways • Creditability in india and Europe • Acquiring more principles • Additional fund to accelerate tools acquisition • Add staff & train Adequate for present

  49. Our team Mr. Kaushik D Naik Proprietor of the company ME (Prod.) GDMM, DBM Chartered Engineer Mr. Bharat D Patel Senior associates Mechanical

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