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ITRODUCTION TO COMPANY
Geminy Industrial Corporation have the most mechanised manufacturing setup for complete
domestic and semi-industrial sewing machines in the country. At present the total covered
area of the world-class production facility is 12000 sq. meters in 50000 sq. meters of land in
government approved industrial area at Ludhiana, Punjab located on national highway (NH1)
Ludhiana- Delhi Road. It is within close proximity to ICD. Geminy currently produce
500000 sewing machines and 220000 sewing machine stands per annum and 500 tons of grey
iron casting for the market. Geminy have a skilled and semi-skilled work force of 700
workers.
In 1981, Geminy had set up a semi-mechanized foundry with a rich background in sewing
machine assembly. In order to modernize the process and improve the quality and quantity of
casting, Geminy have now upgraded to a fully mechanised process. Geminy recently
Imported Two Nos. New Fully Automatic Horizontal Flask less High pressure Molding Lines
from Koyo, Japan with 700*600*160~250/mm mold size and capacity of 250 Molds per
hour. Geminy also installed a Fully Automatic Sand Plant with processing capacity of 60
Tons per hour.
For uniform machining, Geminy continuously upgrade our machining setup with New
automatic hydraulic SPMs. A new fully conveyorised paintshop has been installed which has
improved the quality and life of product.
Geminy have also setup a world-class pattern shop/tool room with CNC and VMC machines.
This set up has provided us with a spare capacity of more than 500 tons of casting. With the
state of the art manufacturing set up. Geminy are looking forward to join hands with any
reputed organisation to produce high precision Industrial Sewing Machines for garment
manufacturers in India. Geminy are also looking for prospective buyers for grey iron castings
as per their specifications at a very competitive rate.

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Geminy is one of the leading company of sewing machine. Geminy deal in domestic and
semi-industrial sewing machines. Domestic sewing machines are those which are used for
domestic use to produce in less amount, whereas semi-industrial sewing machines are used
for professional purposes to produce in bulk . These are made with High Pressure Moulding
Lines. Some of the domestic products are:

Geminy tailor sewing machine - We provide superb quality Geminy tailor sewing
machine. This machine is nickel plated with needle bar and heavy duty with straight
stitch function which is used by small studios. It can be operated by hand also.

Geminy tailor composite sewing machine - This machine is manufactured with the
use of and advanced manufacturing process which ensures high quality & durability.
These machines can be operated by hand or electric motor.

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Geminy family sewing machine - Our family machine is made with good quality
material that will provide outstanding performance throughout the life. These
machines can be operated by electric motor easily. This is a family machine which
can stitch any type of clothes for the whole family.

Geminy deluxe sewing machine - This machine is precision built for a lifetime of
sewing pleasure. It will require a minimum amount of servicing, & will give the
maximum in satisfaction. It has nickel pated needle bar.

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Geminy link sewing machine - These machines are made for heavy duty steel
material fully tempered parts made of highly computerized machinery. This is a
soundless machine which dont make any noise. This can be used for home purpose
also.

Geminy super sewing machine - This machine has the strength to sew denim & other
thicker fabrics. Sewing machines for denim provide stability & comfort when sewing
heavy duty fabrics & can sew thicker with stronger seams for extra strength on any
handmade garments.

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Geminy streamlined sewing machine - This is a technologically advanced machinery.

It is convenient to operate and has forward & reverse feed mechanism.

Three star tailor sewing machine - Geminy provides us high quality three star tailor
sewing machine. This machine helps to meet the customers exact requirement. This
can be operated by hand or electric motor.

Three star composite sewing machine - With the help of talented vendors we are
providing a qualitative array of three star composite sewing machine. It has
oscillating shuttle race.

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Three star family sewing machine - This machine is manufactured under the
supervision of extremely qualified professionals who has the full knowledge about all
the parts.

Geminy Industrial Corporation have a different types of shops to complete the process like

Melting Shop
Molding Shop
Core Shop
Sand Plant
Machine Shop

Paint Shop

Assembly Unit

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Sewing Machine Stand has been designed for the proper sewing of all types of apparels. This
stand is ideal for classes, retreats, and little places. Geminy has been working in sewing
machines products since 1937. This stand is designed in various sizes and shapes in order to
meet the exact requirements of all valuable consumers. Sit on chair and complete your all
sewing projects using this stand.

PROJECT WORK
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During training period my project work was precision casting process. In precision casting
the automotive casting is an integral part of the procedure of production of a majority of
parts in the automotive industry. Casting has for long been used for a vast range of industries
that make use of iron parts. This manufacturing process involves a liquidized material being
poured in to a hollow mould of the desired shape. The liquid material is then allowed to
solidify and the solidified part, called casting, is ejected out of the mold with great care. With
a majority of automobile parts being made from iron and required to have precise shapes
with very specific measurements, ,strong>automotive casting has gained unparalleled
importance in the industry ever since the introduction of automobiles. With the automobile
industry seeing remarkable growth in the recent years, the requirement for error-free and
flawless automotive casting is at its peak.
There are types of procedures used in automotive casting:

Grey Iron Casting: This procedure is essentially used for the parts that need non
critical tensile strength. The castings made from this procedure offer excellent
thermal conductivity, making them suitable for important automobile parts such as
rotors and brakes. These automotive castings get a grey color due to the presence of
graphite. Silicon is also used in the process as stabilizing agent for the graphite
present.

Ductile Iron Casting: A relatively modern automotive casting procedure, this casting
provides incredible ductile strength to the parts formed by it. Using a variety of
materials in addition to iron, the automobile parts produced with this process have the
capability to withstand high levels of stress over long periods of time.

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Automotive casting is a very precise procedure, with fine margins being extremely important.
A majority of parts are manufactured with molten iron being placed in the moulds designed
with accurate dimensions. In this day and age where almost all the parts of a vehicle are
made of cast iron, automotive casting procedure involves a special emphasis being placed on
ensuring that all the parts are manufactured with no fault. Help from professional experts
should always be sought for these procedures in order to make sure that the parts produced
are perfectly fit for use. Geminy sewing machines are the largest manufacturer of precision
castings in india.

Figure 1 GEMINY SEWING MACHINE BODY

Figure 2 CASTING PORTFOLIO

Melting Shop

Dual track induction Furnace of 1800 KW with 3 tons per hour capacity.

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2 Nos. Divided Blast, Coke Fired, Cupola Furnace with 5 tons per hour Capacity.

2 Nos. E.O.T. Crane 5 tons capacity with magnets for material handling.

2 Nos. Hanger Type & Tumbling Shot Blasting Machines.

Molding Shop

2 Nos. Fully Automatic Horizontal Flaskless Molding Machine

from Koyo,Japan with 700*600*160~250/mm mold size and capacity of 250 Molds
per hour..

Cooling Convayers and Shake-outs

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Sand Plant

Fully Automatic PLC Equipped Sand Plant with 60 Tons/Hr Capacity Sand mixer.

Sand Cooler.

Polygon Sieve.

Vibratory Conveyors

Knock Outs

Over- Band Magnet Separators

Dead Clay Removal Equipment

Magnet Pulley

Conveyors

Bucket Elevators

Automatic New Sand Feeding, Bentonite and Coal Dust Feeding System

Sand Storage Hopper-250 Tons

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Core Shop

Cold Box Core shooters

Shell Sand Core making machines

Co2 Gas Core making facility

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METHODOLOGY OF WORK
Machine Shop
We have a state of the art machining facility. Gauges and inspection points during machining
ensure that optimum quality is maintained.The machinery is upgraded according to need
through our well-equipped tool room. The tool room is equipped with the latest machinery,
which has been further detailed:

Vertical Machining Center with table size of 1280*700*650mm

Surface Grinders

Cylindrical Grinders

Milling Machine

Lathe Machines

Drilling machines

Paint Shop
We have recently installed a fully conveyorised paint shop with thermostatic baking ovens
that has provided us an advantage in quality and quantity. The paint finish and luster has
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improved.
This modern paint facility has a surplus painting capacity of more than 2000000 sewing
machines per annum, which can be used for industrial sewing machines as well.

Assembly
Assembly of the sewing machines is done by chain system. There is lapping arrangement
after every station that results in smooth running of the machine and well trained quality
control inspectors.
We have inspectors at the end of each line to ensure best quality. We have also installed the
latest packaging machines.
Furthermore, we are interested in investing in our set up to make high quality Industrial
Machines

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CASTING STEPS

There are six steps in this process:

1. Place a pattern in sand to create a mold.
2. Incorporate the pattern and sand in a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting.

Mold materials
There are four main components for making a sand casting mold: base sand, a binder,
additives, and a parting compound.
Molding sands

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Molding sands, also known as foundry sands, are defined by eight characteristics:
refractoriness, chemical inertness, permeability, surface finish, cohesiveness, flowability,
collapsibility, and availability/cost.
Refractoriness-This refers to the sand's ability to withstand the temperature of the liquid
metal being cast without breaking down. For example some sands only need to withstand
650 C (1,202 F) if casting aluminum alloys, whereas steel needs a sand that will withstand
1,500 C (2,730 F). Sand with too low a refractoriness will melt and fuse to the casting.
Chemical inertness -The sand must not react with the metal being cast. This is especially
important with highly reactive metals, such as magnesium and titanium.
Permeability -This refers to the sand's ability to exhaust gases. This is important because
during the pouring process many gases are produced, such as hydrogen, nitrogen, carbon
dioxide, and steam, which must leave the mold otherwise casting defects, such as blow holes
and gas holes, occur in the casting. Note that for each cubic centimeter (cc) of water added to
the mold 16,000 cc of steam is produced.
Surface finish- The size and shape of the sand particles defines the best surface finish
achievable, with finer particles producing a better finish. However, as the particles become
finer (and surface finish improves) the permeability becomes worse.
Cohesiveness (or bond) - This is the ability of the sand to retain a given shape after the
pattern is removed.
Flowability - The ability for the sand to flow into intricate details and tight corners without
special processes or equipment.
Collapsibility This is the ability of the sand to be easily stripped off the casting after it
has solidified. Sands with poor collapsibility will adhere strongly to the casting. When
casting metals that contract a lot during cooling or with long freezing temperature ranges a
sand with poor collapsibility will cause cracking and hot tears in the casting. Special
additives can be used to improve collapsibility.
Availability/cost The availability and cost of the sand is very important because for every
ton of metal poured, three to six tons of sand is required. Although sand can be screened and
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reused, the particles eventually become too fine and require periodic replacement with fresh
sand.
In large castings it is economical to use two different sands, because the majority of the sand
will not be in contact with the casting, so it does not need any special properties. The sand
that is in contact with the casting is called facing sand, and is designed for the casting on
hand. This sand will be built up around the pattern to a thickness of 30 to 100 mm (1.2 to
3.9 in). The sand that fills in around the facing sand is called backing sand. This sand is
simply silica sand with only a small amount of binder and no special additives.
Types of base sands
Base sand is the type used to make the mold or core without any binder. Because it does not
have a binder it will not bond together and is not usable in this state.
Silica sand
Silica (SiO2) sand is the sand found on a beach and is also the most commonly used sand. It
is made by either crushing sandstone or taken from natural occurring locations, such as
beaches and river beds. The fusion point of pure silica is 1,760 C (3,200 F), however the
sands used have a lower melting point due to impurities. For high melting point casting, such
as steels, a minimum of 98% pure silica sand must be used; however for lower melting point
metals, such as cast iron and non-ferrous metals, a lower purity sand can be used (between 94
and 98% pure).
Silica sand is the most commonly used sand because of its great abundance, and, thus, low
cost (therein being its greatest advantage). Its disadvantages are high thermal expansion,
which can cause casting defects with high melting point metals, and low thermal
conductivity, which can lead to unsound casting. It also cannot be used with certain basic
metal because it will chemically interact with the metal forming surface defect. Finally, it
causes silicosis in foundry workers.
Olivine sand
Olivine is a mixture of orthosilicates of iron and magnesium from the mineral dunite. Its
main advantage is that it is free from silica, therefore it can be used with basic metals, such as
manganese steels. Other advantages include a low thermal expansion, high thermal
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conductivity, and high fusion point. Finally, it is safer to use than silica, therefore it is popular
in Europe.
Chromite sand
Chromite sand is a solid solution of spinels. Its advantages are a low percentage of silica, a
very high fusion point (1,850 C (3,360 F)), and a very high thermal conductivity. Its
disadvantage is its costliness, therefore it's only used with expensive alloy steel casting and to
make cores.
Zircon sand
Zircon sand is a compound of approximately two-thirds zircon oxide (Zr2O) and one-third
silica. It has the highest fusion point of all the base sands at 2,600 C (4,710 F), a very low
thermal expansion, and a high thermal conductivity. Because of these good properties it is
commonly used when casting alloy steels and other expensive alloys. It is also used as a
mold wash (a coating applied to the molding cavity) to improve surface finish. However, it is
expensive and not readily available.

Chamotte sand
Chamotte is made by calcining fire clay (Al2O3-SiO2) above 1,100 C (2,010 F). Its fusion
point is 1,750 C (3,180 F) and has low thermal expansion. It is the second cheapest sand,
however it is still twice as expensive as silica. Its disadvantages are very coarse grains, which
result in a poor surface finish, and it is limited to dry sand molding. Mold washes are used to
overcome the surface finish problem. This sand is usually used when casting large steel
workpieces.
Other materials
Modern casting production methods can manufacture thin and accurate moldsof a material
superficially resembling papier-mch, such as is used in egg cartons, but that is refractory in
naturethat are then supported by some means, such as dry sand surrounded by a box,
during the casting process. Due to the higher accuracy it is possible to make thinner and
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hence lighter castings, because extra metal need not be present to allow for variations in the
molds. These thin-mold casting methods have been used since the 1960s in the manufacture
of cast-iron engine blocks and cylinder heads for automotive applications.
Binders
Binders are added to a base sand to bond the sand particles together (i.e. it is the glue that
holds the mold together).
Clay and water
A mixture of clay and water is the most commonly used binder. There are two types of clay
commonly used: bentonite and kaolinite, with the former being the most common.

Oil
Oils, such as linseed oil, other vegetable oils and marine oils, used to be used as a binder,
however due to their increasing cost, they have been mostly phased out. The oil also required
careful baking at 100 to 200 C (212 to 392 F) to cure (if overheated the oil becomes brittle,
wasting the mold).
Resin
Resin binders are natural or synthetic high melting point gums. The two common types used
are urea formaldehyde (UF) and phenol formaldehyde (PF) resins. PF resins have a higher
heat resistance than UF resins and cost less. There are also cold-set resins, which use a
catalyst instead of a heat to cure the binder. Resin binders are quite popular because different
properties can be achieved by mixing with various additives. Other advantages include good
collapsibility, low gassing, and they leave a good surface finish on the casting.
MDI (methylene diphenyl diisocyanate) is also a commonly used binder resin in the foundry
core process.
Sodium silicate
Sodium silicate [Na2SiO3 or (Na2O)(SiO2)] is a high strength binder used with silica molding
sand. To cure the binder carbon dioxide gas is used, which creates the following reaction:
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The advantage to this binder is that it can be used at room temperature and it's fast. The
disadvantage is that its high strength leads to shakeout difficulties and possibly hot tears in
the casting.
Additives
Additives are added to the molding components to improve: surface finish, dry strength,
refractoriness, and "cushioning properties".
Up to 5% of reducing agents, such as coal powder, pitch, creosote, and fuel oil, may be added
to the molding material to prevent wetting (prevention of liquid metal sticking to sand
particles, thus leaving them on the casting surface), improve surface finish, decrease metal
penetration, and burn-on defects. These additives achieve this by creating gases at the surface
of the mold cavity, which prevent the liquid metal from adhering to the sand. Reducing
agents are not used with steel casting, because they can carburize the metal during casting.
Up to 3% of "cushioning material", such as wood flour, saw dust, powdered husks, peat, and
straw, can be added to reduce scabbing, hot tear, and hot crack casting defects when casting
high temperature metals. These materials are beneficial because burn-off when the metal is
poured creating voids in the mold, which allow it to expand. They also increase collapsibility
and reduce shakeout time.
Up to 2% of cereal binders, such as dextrin, starch, sulphite lye, and molasses, can be used to
increase dry strength (the strength of the mold after curing) and improve surface finish.
Cereal binders also improve collapsibility and reduce shakeout time because they burn-off
when the metal is poured. The disadvantage to cereal binders is that they are expensive.
Up to 2% of iron oxide powder can be used to prevent mold cracking and metal penetration,
essentially improving refractoriness. Silica flour (fine silica) and zircon flour also improve
refractoriness, especially in ferrous castings. The disadvantages to these additives are that
they greatly reduce permeability.

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Sewing apparatus or machines with mechanism for lateral movement of the needle or the
work or both for making ornamental pattern seams, for sewing buttonholes, for reinforcing
openings, or for fastening articles,. Sewing apparatus were invented during the first Industrial
Revolution to decrease the amount of manual sewing work performed in clothing
companies .An early sewing apparatus was designed and manufactured by Barthlemy
Thimonnier of France in 1841.The Industrial sewing apparatus is used for manufacturing not
only apparel such as clothing but also bags, shoes, car seats and sofa, etc.
Industrial sewing machines are tremendous, speedy , and more varied in their size,
cost,outward,appearance, and task. Industrial apparatus, as compared to domestic apparatus,
perform a single dedicated task. Industrial machines are also more cosmic; a motor for
almost any type of machine which can work on any brand .Industrial sewing machine differ
from traditional sewing machine. In olden days working on sewing machine was a difficult
task for women as they had to spent much of there time on sewing machines to stitch a single
shirt. But with the coming of Industrial sewing machine, it reduced the burden of women as
now they dont have spent much time for stitiching a single shirt.
Industrial sewing machine is built for professional tasks and is therefore constructed with
superior durability, parts and motors.
There are four types of industrial sewing machines:

Flatbed-This is the most common type of machine, which resemble traditional sewing
machine. It is extensively used in industrial purposes for stitiching and sewing hard
material products such as suitcase, luggage bags, leather products etc.

Cylinder- bed: These machines feature a narrow, horizontal column as opposed to a

flat base. It provide higher precision required in delicate craftsmanship. This is used
for sewing cylindrical pieces such as cuffs and also for bulky items such as saddles
and shoes.

Post-bed: These machines feature bobbins, feed dogs and/or loopers in a vertical
column that rises above the flat base of the machine. This is used for boot making and
glove making utilize the post-bed machine.

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Off the arm: The least common group, these machines require workers to feed
material along the axis of a horizontal column. It is useful for applications such as
sleeve and shoulder seams.

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Reference
Reference papers reserch papers/Text Books/Web Links

1.http://www.cylex.in/reviews/viewcompanywebsite.aspx?firmaName=geminy-industrialcorp&companyId=10684709&showUrl=http%3a%2f%2fgeminy.in%2fabout.htm
2. www.google.com
3. http://www.scientific.net/AMM.397-400.87
4. http://en.wikipedia.org/wiki/Sewing_machine
5.http://www.google.co.in/url?
sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0CCAQFjAA&url=http%3A%2F
%2Fwwwold.me.gatech.edu%2Fjonathan.colton
%2Fme4210%2Fcasting.pdf&ei=j31MVcyoJNLbuQTnsYGgBA&usg=AFQjCNE660_4lnM
o8ohwfLcmI8-Q3quQDQ&bvm=bv.92765956,d.c2E
6. http://www.antiessays.com/free-essays/The-Sewing-Machine-161773.html
7. P. N. Rao, Manufacturing Technology, Foundry, Forming & Welding, Tata McGraw Hill.
8. A. Manna, A Text book of Manufacturing Science and Technology, PHI Publishers .

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