Customised Solutions is our Forte 1
Introduction 80,000 Sq.Ft. of Manufacturing space, Centrally Air-Conditioned Tool Room Complete set up of Design, Manufacturing and Testing facilities under one roof meeting global standards Designed and Manufactured over 2000 high precision 101 class moulds Capable of handling multiple clients simultaneously in seam less manner 2
About Founder & MD A Dayanand Reddy Vasantha Tool Crafts, is the brain child of Technocrat Founder & Managing Director A Dayanand Reddy, a post graduate Mechanical engineer in Tool Design & Manufacturing has rich design and Manufacturing experience Recognitions: Outstanding new generation entrepreneur -- Indian Plastic Institute (IPI) Special contribution award towards tooling development Salcomp. India Manufacturing Excellence Awards - Silver Certificate for the year 2015 Recognition from Plasticon in excellence for Innovative Dies & Moulds year 2015 Firsts First to set up state of the art ultra modern robotic cell in entire South East Asia First in India to build Turn Table Rotary Mould and Cube Moulds First in India to have Direct Metal Laser Sintering technology in house for Conformal Cooling 3
Major Milestones 2002 Fully Hot Runner Mould 2010 First Bi Injection Mould 2012 Set up of Fully Automated Machining Cell 2013 First Stack Mould & Rotary Bi-injection Mould 2014 In House Laser Sintering (DMLS) & Vacuum heat treatment 2014 First Cube Mould 1989 Established 1992 First Un Screwing Mould & Moulding Facilities started 4
Business Statistics Others 15.0% FMCG 70.0% Health Care 5.0% Electrical & Engineering 10.0% 25 20 15 IN USD Millions 12 AVERAGE SALES GROWTH OF 15% YOY LAST FIVE YEARS MORE THAN 60 % OF EXPORTS SHARE 19 16 14 21 10 5 0 2011-12 2012-13 2013-14 2014-15 2015-16 5
Tool Directory High Lights Sr.No. Description Qty. 1 Total Tools 2246 Others 500 Personal & Beauty Care, 956 Health Care 190 Food & Beverage 250 Home Care 350 Total 2246 Moulds Nos. Personal & Beauty Care Home Care Food & Beverage Health Care Others Cavitation 96 128 144 64+64 No of Moulds High Cavitation moulds 13 06 01 02 2 Total Cavitation 35000 3 Hot Runner Moulds 1200 4 Bi Colour Moulds 35 5 Stack moulds 06 6 Unscrewing moulds 450 7 Flip top cap moulds without IMC 185 8 Flip top cap moulds with IMC 120 Description High Cavitation faster cycle time moulds Cavity Nos Cycle time Sec Bi colour 32 14 Unscrewing 144 07 Flip top with IMC 96 12 Stack 64+64 07 6
Services and Capabilities Services Mould Design Mould Flow Analysis Prototyping Mould Manufacturing Project Management Capabilities Flip top cap moulds Vertical and Horizontal In Mould Closing Unscrewing Moulds Hydro motor Rack & Pinion Servo Drive Bi Colour / Two Shot Injection Moulds Punch Back Over Moulding Rotary Cube Stack Moulds Spray Through Cap and Dispenser Moulds Mould Testing and Qualification Direct Metal Laser Sintering for Conformal Cooling channels in Metal Inserts 7
Design & Engineering A Well equipped and established design & engineering department Infrastructure to support designing of 300 Moulds 6000 Stacks annually 25 Work Stations, 10 ~ 15 Years Experienced designers Design for Manufacturability (DFM) Value addition in terms of Product Design CAD / CAM Pro-Engineer UniGraphics AutoCAD Mould flow Analysis software MoldEx Mould Flow Software DelCam IGES (Surface & Wireframe) STEP DXF 8 Para solid
Manufacturing Manufacturing facility High end CNC machines to support high precision and high speed machining needs 18 CNC Milling- 4 High Speed CNC + 14 CNC 15 CNC EDMs 4 wire EDMs 45 Conventional Machines In house grinding and polishing facility EROWA Holders Integration by Chameleon Handling Systems - Robotic Cell 2 Yasda High Speed Milling 1 Makino V55 Graphite Milling 2 Zimmer & Kriem Sparking 1 Zeiss CMM Transclean Advantages: Minimum Human Involvement, Precision Machining, High Productivity, Consistency & Repeatability, cavity to cavity and mould to mould Interchangeability 9
Quality Assurance State of the Art Metrology Equipment: Host of Standard Quality Equipment with software Minitab for generating CP and CPK reports 7 CMMs of various measuring ranges, and an Optical Inspect CMM for inspecting critical plastic parts all of them from Zeiss Max. Measuring Range of 1000mmx1200mmx600mm Accuracy of (1.9+L/300) µm Min. Measuring Range of 500mmx500mmx500mm Accuracy of (2.4+L/300) µm O Inspect Measuring Range 400 mm x 400mm x 200mm Accuracy (1.7+L /250) µm 10
Why Vasantha High-end design capabilities Design for manufacturability (DFM) Value addition in terms of product design, optimum mould design and optimum cycle times Mould flow analysis 3D mould design using PROE Strong mould design concepts World class infrastructure High end CNC machines, Automated machining cell In-house vacuum heat treatment (2014 ) In-house laser sintering machine (conformal cooling) Precision finishing, excellent polishing capabilities ( SPI A1, A2) Effective documentation procedures from design to mould qualification with traceability capabilities State- of- the- art all electric injection moulding machines for mould trials and moulding 11
Why Vasantha State of the art metrology equipment's CMMs from Zeiss O - Inspect from Zeiss Measurement capability Dimensional guidelines Gauge R&R In-house Jigs and Fixture manufacturing and qualifying capability Project management Knowledge to interpret quality reports Facilitates from DFM to mould commissioning Weekly reviews (internal and customer), updates with photographs of mould progress 12
Why Vasantha Mould qualification 4 hours of dry run, 8 hours mould qualification run (MQR) for parts Observe for foreign particles Disassemble and check mould for any scoring / wear tear Ability to align for cleanroom moulding- coatings, graphite impregnated guide bushes, servo electric technologies, etc. Parts qualification Scientific injection moulding (SIM) Optimized cycle time Cp, cpk study using minitab software Mould commissioning & service support Mould commissioned by trained personnel Preventive maintenance training Exclusive team for mould service and spares support 13
Sampling Capabilities Injection Moulding Machines Sr. No. Injection moulding machine Model Type Capacity Qty. 1 FERROMATIC MILACRON HYDRON 450 with all electric bi- injection unit Hydraulic 450 T 1 2 HUSKY HYLECTRIC Hybrid 400 T 1 3 FANUC ROBOSHOT S-2000 I 300B Electric 300 T 1 4 L&T DEMAG Aswa 250 Hydraulic 250 T 2 5 FANUC ROBOSHOT α- S 150 i A 6 FANUC ROBOSHOT α S 100 i A Electric 150 T 2 Electric 100 T 1 7 Larsen & Toubro DTS 100 LNC5 Hydraulic 100 T 1 8 FANUC ROBOSHOT α S 50 I A Electric 50 T 1 14
Sampling Capabilities Bi colour injection units for 50 T to 150 T IMM m/c and 300 T to 450 T IMM m/c Make Capacity Qty. Mold Masters - emulti 0 to 20 g 03 Plasdan 0 to 10 g 01 Plasdan 0 to 50 g 01 Ferromatic 0 to 200 g 01 Backed up with all requisite support of ancillary equipment such as, dehumidifiers, chillers and mould sweat protector to validate and qualify the moulds to global standards Component testing laboratory consisting, vacuum leakage tester, universal testing m/c (UTM), profile projector, height master, torque tester, conditioning chamber 15
High Precision and High Cavitation Moulds 16
High Precision and High Cavitation Moulds 17
High Precision and High Cavitation Moulds 18
Major Customers Domestic and International 19
Major Global Supplies Russia Canada UK Belgium Poland USA France Germany Italy Turkey China Mexico Brazil Congo Egypt Saudi Arabia Kenya Tanzania Bangladesh India Thailand Vietnam Philippines Sri Lanka Indonesia South Africa Australia 20
Products Covered Bi Color Caps Flip Top Caps Spray Thro Cap Pumps /Dispensers Water Bottle Cap Tamper Evident 21
Products Covered Spout and Cap CRC Shoulders Conical Standup Cap Medical 22
Products Covered Electrical & Switchgear Automotive & Engineering 23
Products Covered Automotive & Engineering 24
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