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Rajkot Bearing PDF
Rajkot Bearing PDF
Gujarat
Rajkot
Certificate of originality
Original w ork of TERI d one und er the project “IN DIA: TERI-SDC
Partnership: Scaling up Energy Efficient Technologies in Sm all Enterprises
(EESE)”
This d ocum ent m ay be reprod uced in w hole or in part and in any form for
ed ucational and non -profits purposes w ithout special perm ission, provid ed
acknow led gem ent of the source is mad e. SDC and TERI w ould appreciate
receiving a copy of any publication that uses this d ocum ent as a source.
Disclaimer
This d ocum ent is an output of an exer cise und ertaken by TERI supported by
the Sw iss Agency for Developm ent and Cooperation (SDC) for benefit to
MSME units in the cluster. While every effort has been m ad e to avoid any
m istakes or om issions, TERI and SDC w ould not be in any w ay liable to any
person by reason of any m istake/ omission in the publication.
Published by
T E R I Press
The Energy and Resources Institute
Darbari Seth Block
IH C Com plex, Lodhi Road
N ew Delhi-110 003
Ind ia
TERI places on record its sincere thanks to the Sw iss Agency for Developm ent and
Cooperation (SDC) for supporting the long -term partnership project focusing on energy
intensive MSME clusters in Ind ia.
TERI team is indebted to Rajkot Engineering Association (REA), GIDC (Lod hika) Ind ustrial
Association (GLIA), AJI (GIDC) Ind ustries Association and Shapar -Veraval Ind ustrial
Association for provid ing support an d inform ation related to bearing units in Rajkot. TERI
also places on record the support provid ed by Mr Sri N H Kantesaria (Chief Manager,
GLIA), Mr Bhavesh Patel (Presid ent, REA) and Mr H aresh H advani (Partner, ISK Bearing
Ind ustries) for their support and cooperation in organizing field visits and interactions w ith
m anufacturers of cages, rolling elem ents and bearings d uring the stud y for preparation of
the cluster profile report. TERI extend s its sin cere thanks to Mr Jignesh Patel (IIF Secretary
w estern region) and Mr Dilip Sarkar (Executive Secretary, REA) for facilitating field visits.
Last but not least, our sincere thanks to MSME entrepreneurs and other key stakeholders in
the cluster for provid ing valuable data and inputs that helped in cluster analysis.
Rajkot bearing industries
Overview of cluster
Rajkot is one of the prom inent bearing clusters in the country. Rajkot is largely know n as an
ind ustrial hub situated in Saurashtra region of Gujarat state. The Rajkot d istrict located in
south-w est region of Gujarat state has m ore than 23,000 ind ustries spread ing over an area of
around 25 square kilom etres in 15 d ifferent ind ustrial estates.
The m anufacturing activities are concentrated in three m ain ind ustrial estates – Aji, Metod a
and Shapar. The current trend of ind ustrial grow th is tow ard s engineering and auto
ancillaries. The d istrict has various m anufacturing units for m achine tools, ind ustrial
equipm ents, lathe m achines, m etallurgical industries, electronics, engineering and auto
ancillary sector. The small and m ed ium ind ustries are d om inated by found ries, bearings,
engineering & autom obile w orks, textile related units, gold & silver jew ellery, handicrafts,
spices, m ed icines, and w all clocks.
The Indian bearing ind ustry is estimated at Rs 100 billion. The d om estic ind ustry caters to
the 74% of total d emand for com m on varieties and sizes. The organized sector units
contribute 1 around 53% of the ind ustry sales. The im ports are about 26% of the total d em and
of the ind ustry. The bearing ind ustries in Rajkot generate around 15,000 d irect or ind irect
em ploym ent. A m ajority of them is associated w ith bearing assembly units, roller and cage
m anufacturing ind ustries.
There are about 150 bearing ind ustries operating in the cluster. Most of these ind ustries are
registered und er m icro, sm all and m ed ium categories. Majority of the units are either sm all
or m icro type. The total turnover of bearing ind ustries in Rajkot is estim ated to be around Rs
1500 crores w ith the annual turnover of m ajority of ind ustries in the cluster (50%) are
around Rs 2-10 crores. The d istribution of the bearing ind ustries based on typ e and annual
turnover are show n in the figures.
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Source: Technology study report on bearing industries, M SM E DI, Government of India
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Cluster profile - Rajkot bearing industries
Above prod ucts of Rajkot bearing cluster could be grouped prim arily in to three kind s of
prod uct m anufacturers nam ely (1) cage m anufacturers, (2) rolling element m anufacturers
and (3) bearing assem bly units. Around 60% plants in Rajkot are bearing assem bly units,
w hich take cages, rolling elem ents from outsid e
vend ors and assem ble bearings. A prod uct-w ise
d istribution of bearing ind ustries in the cluster is
provid ed in this figure.
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Cluster profile – Rajkot bearing industries
chrom e bearing steel, w hich has com position sim ilar to EN -31 (100 CR 6 as per BIS
specifications). The raw m aterials for bearing races are in the form of rod s and seam less
hollow tubes w hich are spherod ised annealed steel. Alloy steel w ire rods are used for the
m anufacture of rollers and balls. The cages and retainers are mad e out of plain carbon steel
of 1008 & 1015 grad e. Other m aterials like stainless steels are also used as per the custom ers
Cages: The m aterial used for m anufacturing cages is CRC strips of C2015 bearing grad e steel
having carbon percentage at 0.08% (m axim um ) and m agnesium ranging from 0.25% to
0.45%.
Rolling elements: Steel balls/ rollers of grad e 20, 16 & 10 w ith close tolerance sm ooth
surface m ad e using SAE 52100 high carbon chrom e bearing steel w ire rod s m ad e up of
ferroalloy containing carbon.
The sources of major raw m aterials are provid ed below .
Ind ian Seam less Metal Tube, Pune
Ind ian Seam less Steel & Alloy, Pune
Mahind ra Ugine Steel Com pany Khopoli
Jindal Steel Works Ltd
Diad o Stell Com pany Ltd , Japan
Ascom etal Ind ustries, France
CRC sheets for cages Wire rod for rolling Forged rings for
element bearing races
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Cluster profile - Rajkot bearing industries
Production process
The bearing m anufacturing ind ustries in Rajkot im ports the assem bly com ponents of
bearing from local vendors. The com ponents includ e inner and outer races, cages, rolling
elem ents and rivets. The heat treatm ent and super finishing of rolling elem ents are d one
before final assem bly of bearing. The generic process steps of m anufacturing bearing
prod ucts are explained below .
Raw material: Raw materials for bearing manufacturing ind ustries are d ifferent
com ponents of bearing that is inner and outer races, cages, rolling elem ents and rivets .
These com ponents are procured from local vend or as per specifications.
Assembly of races and rolling
elements: At first inner and outer races
are assem bled and then rolling elem ents
are inserted m anually or using press for
taper roller bearings.
Riveting and w ashing: Riveting is d one
on ord er to ensure com plete assem bly of
bearing com ponents. Washing in oil is
d one rem ove any burs and foreign
particles from bearing surface.
Filtering and demagnetizing:
Contam ination, if any from the batch
com position is rem oved using both
filtering elem ent and d em agnetiser.
Clearance testing: Clearance testing is
d one in the lab using feeler gauge to
check the alignm ent of the assem bled
com ponents.
Packaging and dispatch: The final
m arketable prod ucts are packed as per
m arketing and d espatch requirem ent.
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Cluster profile – Rajkot bearing industries
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Cluster profile - Rajkot bearing industries
end shot blasting is d one to achieve surface finish. Visual inspection is d one before final
d ispatch of cages.
Bearing cages
Technologies employed
Bearing ind ustries in the Rajkot cluster use conventional m achines like lathe m achines for
rough turning and CNCs m achines for finished turning operations of races. Grinding
m achines like centre-less grinding, face grinder, d uplex grinding and super finishing
m achines are used along w ith air com pressor, heat treatm ent furnaces, head er m achines and
presses in the m anufacturing of com ponents of the bearings. Som e of the prim ary process
technologies are explained below .
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Cluster profile – Rajkot bearing industries
Race finish turning on CN C Rollers super finishing machine Rolling element heat
machine treatment furnace
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Cluster profile - Rajkot bearing industries
Energy consumption
Electricity is the m ain source of energy for m ost of the bearing
units in the cluster. These units are d epend ent on grid to m eet
their electricity need s. The average connected load of a bearing
ind ustry is d epend ent on kind of prod ucts and installed
capacity. A m ajority of the u nits have LT connection, about
20hp to 40hp . The bearing assem bly units of m ed ium size have
H T connection about 150 kVA to 700 kVA.
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Cluster profile – Rajkot bearing industries
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Cluster profile - Rajkot bearing industries
Recuperator for w aste heat recovery from hot flue gasses of natural gas fired furnace
The roller elem ents m anufacturers use N G fired or electrical heat treatm ent furnaces. The
exit flue gas tem peratures of natural gas fired furnaces used in th ese units are in the range of
450-600 oC and there are no w aste heat recovery system s available w ith furnaces. The w aste
heat available w ith high tem perature flue gases can be recovered in a m etallic recuperator
system to preheat com bustion air that can result in significant im provem ent in furnace
efficiency (over 10%) substantial red uction in fuel consum ption. Energy savings of 8-15%
can be achieved d epend ing on the type of process, process cycle tim e and flue gas
tem perature.
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Cluster profile – Rajkot bearing industries
(v) Lighting
T-12 tube lights (of 52W includ ing choke) and halogen lam ps (150W and 250W) are
generally used by bearing units in the cluster. These inefficient lightings can be replaced
w ith energy efficient LED lighting (LED tube lights of 10W and 20W) and flood lam ps and
high bay lam ps (20W, 40W and 80 W) w hich w ould provid e better illum ination and energy
savings. Since a large num ber of lam ps are used in the units, the existing lighting m ay be
replaced w ith EE lighting in a phased manner.
Major stakeholders
The prim ary stakehold ers in the cluster are the manufacturing units based in Rajkot and the
lead ing ind ustry association of the region –Rajkot Engineering Association (REA), GIDC
(Lod hika) Ind ustrial Association (GLIA), AJI (GIDC) Ind ustries Association and Shapar -
Veraval Ind ustrial Association . The other key stakehold ers includ e Central Manufacturing
Technology Institute (CMTI), N ational Sm all Ind ustries Corporation (N SIC), District
Ind ustries Centre (DIC), MSME-DI (Rajkot), SIDBI, Ind ian Institute of Found rym en, Rajkot
chapter m achinery supplier, etc.
Out of these stakeholders, REA is the m ost proactive in the region. It has about 1000
m em bers d raw ing from all categories of ind ustries in Rajkot. The association ad d resses the
issues related to the w elfare and grievance red ressed of their mem ber ind ustries. Presently
there are no ind ivid ual ind ustry associations for bearing ind ustries.
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About TERI
A d ynam ic and flexible not-for-profit organization w ith a global vision and a
local focus, TERI (The Energy and Resources Institute) is d eeply com m itted to
every aspect of sustainable d evelopm ent. From provid ing environm ent -friend ly
solutions to rural energy problem s to tackling issues of global clim ate change
across m any continents and ad vancing solutions to grow ing urban transport and
air pollution problem s, TERI‟s activities range from form ulating local and
national level strategies to suggesting global solutions to critical energy and
environm ental issues. The Ind ustrial Energy Efficiency Division of TERI w orks
closely w ith both large ind ustries and energy intensive Micro Sm all and Med ium
Enterprises (MSMEs) to im prove their energy and envir onm ental perform ance.
About SD C
SDC (Sw iss Agency for Developm ent and Cooperation) has been w orking in
Ind ia since 1961. In 1991, SDC established a Global Environm ent Program m e to
support d eveloping countries in im plementing m easures aim ed at protecting t he
global environm ent. In pursuance of this goal, SDC Ind ia, in collaboration w ith
Ind ian institutions such as TERI, cond ucted a stud y of the sm all-scale ind ustry
sector in Ind ia to id entify areas in w hich to introd uce technologies that w ould
yield greater energy savings and red uce greenhouse gas em issions. SDC strives
to find w ays by w hich the MSME sector can m eet the challenges of the new era
by m eans of im proved technology, increased prod uctivity and com petitiveness,
and m easures aim ed at im proving the socio-economic cond itions of the
w orkforce.
About SAMEEEKSHA
SAMEEEKSH A (Small and Medium Enterprises: Energy Efficiency Know led ge
Sharing) is a collaborative platform set up w ith the aim of pooling know led ge
and synergizing the efforts of various organiza tions and institutions - Indian and
international, public and private - that are w orking tow ard s the d evelopm ent of
the MSME sector in India through the prom otion and ad option of clean, energy -
efficient technologies and practices. The key partners are of SAMEEEKSH A
platform are (1) SDC (2) Bureau of Energy Efficiency (BEE) (3) Ministry of
MSME, Governm ent of Ind ia and (4) TERI.
As part of its activities, SAMEEEKSH A collates energy consum ption and related
inform ation from various energy intensive MSME sub -sectors in India. For
further d etails about SAMEEEKSH A, visit http:/ / w w w .sam eeeksha.org
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