INDUSTRIAL ORIENTATION REPORT

2016
SUBMITTED TO
DEPARTMENT OF INDUSTRIAL ENGINEERING
PANDIT DEENDAYAL PETROLEUM UNIVERSITY
GANDHINAGAR

BY
NIKUNJ M. PATEL
14BIE027

Acknowledgement
I am extremely grateful to my university that gave me
opportunities to get exposed to the activities in various Industries
under Industrial Orientation programme. I am grateful to all the
companies, which helped us for great learning and giving such
opportunities.
I especially thank PDPU administration for arranging such an
organized Industrial orientation, where we got to look into industries
and organized which somehow upgraded our practical thinking and
concepts.
I would like to deliver special thanks to the respective faculties
that helped and guided us during the visits. Lastly, special thanks to
all the workers and officers of the industries who guided us a lot
during the visits.

Index

Industrial Orientation time table

CocaCola Pvt Ltd

KHS Machinery Pvt Ltd

Ferromatik Milacron

12

Maruti Panchal Cylinders Pvt Ltd

16

Knack Technopack

18

Scheduled visits
SN

Date of visit

Name of
Organisation

Location

Faculty

22nd April, 2016

Coca Cola Industries

Ltd.

Kheda

Mr. Balaji Rao

Mr. Kishan Fuse

28th April, 2016

KHS Machinery

Ahmedabad

Mr. Manikanta
Ravindra

6th May, 2016

Ferromatik Milacron
Pvt Ltd.

Ahmedabad

Mr. Sagar Patil

Ms. Mallika
Taneja

9th May, 2016

Maruti Panchal
cylinders Pvt Ltd.

Kalol

Mr. Kishan Fuse

9th May, 2016

Knack Technopack

Kalol

Mr. Kishan Fuse

HINDUSTAN COCA-COLA PVT LTD.

Introduction
HCCBPL is the largest bottling partner of The Coca-Cola Company
(www.thecoca-colacompany.com) in India. It is a part of The Coca-Cola
Co pa ys Bottli g I est e ts Group BIG a d respo si le for the
manufacture, package, sale and distribution of beverages under the
trademarks of The Coca-Cola Company.
Coca-Cola India Pvt Ltd. - (www.coca-colaindia.com) is a Wholly-Owned
Subsidiary of The Coca-Cola Company, USA. While building the consumer
franchise for The Coca-Cola Company trademarks, it also leads world class
governance systems for the operations of all partners in bottling, suppliers,
distributors and other stakeholders.
Hindustan Coca-Cola Beverages Pvt Ltd. - As part of the Bottling Investments
Group of The Coca-Cola Company, HCCBPL has 24 bottling plants at strategic
locations in various states spread across India. It covers approximately 65% of
bottling operations for the Coca-Cola System in India. HCCBPL has an extensive
distribution system spanning more than a million outlets operating with world
class execution standards. The focus of the system is to develop strong
customer value while delivering preferred choice of refreshment at an arm's
length of desire to the consumer.

Description of the visit

The students were first given safety instructions in small groups through
AV. Then, the students were divided into groups and were taken into the
manufacturing units.
After the visit, each student was provided Coca-Cola beverage as refreshment.

Production Procedure
There were various products that were being produced at the plant. In
each unit a different work was carried out. The production process was active
at the time of our visit. There were separate areas for mixing, flavouring,
bottling, testing, filtering, packaging, etc. We observed that maximum number
of machines were from KHS industries.

Company Products
The Coca-Cola Company offers a wide range of products to the
customers including beverages, fruit juices and mineral water. The Company is
always looking to innovate and come up with, either complete new products or
new ways to bottle or pack the existing drinks. The Coca-Cola Company has a
wide range of products out of which the following products are marketed by
HCCBPL:

Correlation of practical things to the educational curriculum:

We were able to understand the mechanisms used in the industry. We
also saw at what pressure fluid is filled and how much sugar, syrup and
flavour are added in a bottle of beverage.
The machinery was fully automatic and hence gave us a clear idea of
what kind of machinery is used in an actual industry.

KHS MACHINERY PVT LTD.

Introduction
As an international manufacturer of filling and packaging equipment for
the beverage, food, and non-food sectors KHS GmbH holds a leading position
within the industry. The German company was established in 1993 from a
merger involving Holstein & Kappert AG of Dortmund (founded in 1868) and
Seitz-Werke GmbH in Bad Kreuznach (later SEN AG). Based in Dortmund,
together with a workforce numbering approximately 4,600 KHS group*
a hie ed a tur o er of o er
illio i
4. KHS GmbH is a wholly owned
subsidiary of Salzgitter Klckner-Werke GmbH, itself part of the Salzgitter
Group.
At five plants within Germany KHS develops and manufactures the full range of
filling and packaging machines. High-performance systems and equipment for
lower capacities are included in its portfolio.
Besides being the company headquarters, Dortmund is also the center for
sanitizing, pasteurizing, inspection, labeling, and conveying technology. As one
of the four other major sites in Germany the factory in Kleve manages the
company's packaging technology, focusing on the latest final packaging. The
Bad Kreuznach plant concentrates on process, filler, and aseptic technology
and is responsible for filtration systems, beverage blending units, flash
pasteurizers, keg technology, and rinsing, filling, and closure systems. Highperformance palletizers and packing and unpacking systems are built in
Worms. Hamburg is where the company's PET expertise is pooled, with stretch
blow moulders, barrier technology, and Bottles & Shapes PET bottle designs
developed here. Outside Germany KHS has production facilities in the USA,
Mexico, Brazil, India, and China.

Description of the visit

The students were first taken into a conference room for an introduction
to the o pa y. Represe tati es i trodu ed the o pa ys
orki g
procedure and products with help of a presentation. They also gave details of
their academy of training for such industries. Refreshments were given at the
end of session. Then, we were divided into 3 groups for visiting the
manufacturing unit.

Production procedure
The production procedure of KHS was quite different. Different parts of
the machine were imported from other countries and were assembled.
Kanban system is used so that the workers face fewer problems for
assembling.
Different purpose machines were produced at different places in the
industry.
Thereafter, the most interesting procedure was the transportation. They
pack the machine partly dissembled in the pin wood which was
imported from western countries, so that air or other pollutants cannot
damage the machinery.
Transportation cost was very high and had a long procedure.
Company Products
KHS machinery has different machinery for different packaging with
different speeds as required by the customer.
They provide packaging machines of consumable or non-consumable
products as required by the customer.
They provide machines in the field of Food industry, Beverages,
Pharmaceuticals, other packaging industry, etc.
Different speeds from 1000bph-6000bph were manufactured according
to the requirement.

 They provide a complete solution for packaging department of an

industry.

Correlation of practical things to the educational curriculum:

We were able to understand the concepts of automation and
management clearly.
We also saw Kanban system in practical case.

10

FERROMATIK MILACRON PVT LTD.

Introduction
Ferromatik Milacron India is part of Milacron LLC, USA, a global leader in
business area of Plastics Processing Technologies and Metal Working Fluids.
Ferromatik Milacron India (FMI) is the leading manufacturer of Plastic Injection
Molding Machines & Blow Molding Machines in India, serving the entire gamut
of plastic applications in 40 countries across the world in SAARC, Middle East &
Africa including USA. Established in 1995, at Ahmedabad, Gujarat, the plant is
spread over an area of about 52,000 sq.mt . FMI offers today the full range of
Injection Moulding Machines from 50 ton to 3200 ton with capacity to
manufacture 2000 machines per annum. It is accredited ISO 9001:2008 , ISO
14001:2004 .

Company Products
OMEGA SERVO: Hydraulic Injection Moulding Machine 100 to 910 T
MAGNA T SERVO: Toggle Injection Moulding Machine 110 to 500 T
MAXIMA SERVO: Two Platen Injection Moulding Machine 500 to 3200 T
ELECTRON: All Electric Injection Moulding Machine 50 to 550 T
HYDRON SERVO: Hydraulic Injection Moulding Machine 100 to 450 T
PVC LINE SERVO : Dedicated PVC Hydraulic Injection Moulding Machine 100 to
910 T
OMEGA TC-Split Barrel: Two Colour Injection Moulding Machine 450 to 910 T

11

Description of the visit

The assigned official gave instructions regarding to safety in plant.
Following him we visited in-house Machine shop, storage area, Assembly and
Run-off area, Heat-Treatment shop, Paint Shop. The machine shop is
essentially intended for manufacturing in-house manufacturing of critical
components like Valve Mounting Blocks -Hydraulic Manifold, End Caps of
Cylinders etc. It is equipped with High Speed Machining Centers - Mazak &
Mori Seiki, Boring Machines, Vertical Milling Machines (VMC), Cylindrical
Grinders, Surface Grinders, Radial Drilling, Vertical Honing Machines, Turning
Centers. The heat treatment shop is used for hardening of the barrels, feed
screws & tip seat valves etc. Hardening process is Gas Nitriding to ensure
superior quality hardness.

12

Heat treatment shop

Then we visited the Assembly and Run-off area where main parts of injection
moulding machine such as Injection unit, Clamping unit, Hydraulics &
Electrical-Electronics etc. were being assembled. As seen in picture, we were
able to see actual assembly of the various parts of injection moulding machine.
The visit to storage area was interesting. As can be seen in picture, the ready to
assemble parts were kept in tall compartments. The paint shop in the plant is
equipped with Pressurized Grit Blasting Room, Pressurized Wet Paint Booths,
Pressurized Solvent Extraction System, PNG fired Paint Baking Ovens.

Assembly area

13

Paint Shop

Storage Area

14

Correlation of practical things to the educational curriculum:

We got to know that the injection moulding machine (IMM) basically consists
of two main parts: Injection unit and Clamping unit. The machine is designated
based upon the force applied at the time of clamping the mould during the
injection. The high capacity IMM are delivered to customer as separate
Injection unit and Clamping unit and assembled there itself. The machine can
be fully hydraulic, fully electric or combination of both.

15

MARUTI PANCHAL CYLINDERS PVT LTD.

Introduction
Maruti Panchal Cylinders Private Limited is a Private incorporated
on 10 April 1997. Company is a leading manufacturer of all types of casted
components, fabricated parts, all size of S.S impellers and bowls for
submersible pumps and industrial pumps.
Maruti Panchal Pvt. Ltd. has employee strength of 100. It was awarded
with ISO 9001:2008. It covers a big part of Indian and German market.

Description of the visit

Students were introduced first to the company by representative. Then
we were introduced to foundry department. After that students were divided
into two groups for visit. After visiting the foundry department, we had visited
heat treatment department. Then we visited workshop of CNC machines and
inspection and packaging department.

Production Procedure
For all the casting they have electrical furnaces. Company uses shell
mould casting. They first prepare a mould from sand-resin mixture. After that
they pour molten metal into the mould and combine two shells and allow it to
cool down.
They use grinding operation to give initial touch to the component. All
the excessive material is removed. Then annealing is done to enhance the
mechanical strength. After cooling it down, component goes into the
workshop.
In the workshop they do all the necessary operation for different
components like to make keyways in impeller with the help of vertical

16

broaching machine, turning operation, drilling operations. They use CNC

machines for the best precision and accuracy.
They use all type of inspection tools like go-no go gauge, callipers, weight
balancing .After that they pack it.

17

KNACK TECHNOPACK
Introduction
Knack technopack was established in the year 1993. Knack
Packaging Private Limited is one of the eminent manufacturers, suppliers, and
exporters of HDPE/PP Woven Sacks, Fabrics & Multicolour Printed BOPP
Laminated PP Woven Sacks / Bags. Those bags are used for packaging of Grain
& Pulses, Foods & Spices, Animal Food, Fertilizers & Chemical, Cement & Wall
Finish, Powder & Granule, Mineral, Detergent, Nuts and Fruits. Company is
having Specialty in bags for Tea & Coffee.

Description of the visit

First we were introduced to general procedure which included
preparation of granules for plastic fabrics, working of automated power looms,
sewing department, working of printing machine, and inspection department.
In preparation of fabrics they use ONGC a d Relia es ra
aterial
HDPE. One huge machine stirs granules and heat it so it converted into semi
liquid form then they cool it and pass it from a machine which converts into a
sheet with required thickness. Then it passes to cutters, it cuts into a small
fabric of plastic. Then one spinning machine, make big reels from that. After
inspecting a reel sample in inspection department, it goes to power looms
department, where power looms wave plastic bags from reel.
After that bags go to sewing department, in this they connect upper side
and lower side of bags. Then the bag goes to printing machine and required
colours are printed on bags

18

Practical aspects of Industrial Orientation

Safety is given more importance than production.
Practical knowledge is important regarding production techniques.
We are now more familiar with some new advanced production
techniques.
Live management skills were observed and understood practically.
Industrial applications.
Team work in industries was also observed.
Dedication and hard-work is necessary for best outcomes.

19

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