SUBMITTED BY AJAY PAUL PG/K/2010/02

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14th February 2011

Eveready Industries India Ltd

Company Profile
Kolkata, West Bengal, India Power Products - Manufacturer, Export / Import, Public. Ltd. Firm Since 1905 Eveready Industries India Ltd. Is heralded as the market leader of India when it comes to dry cell batteries and flashlights. Today the brand Eveready is synonymous with power, with a durable franchise that has spanned over a century. Its a name that has progressed with the country, be it lighting up a slushy monsoon path or keeping beat with a nation young with achievers. In this new millennium, sales of Eveready Industries India Ltd. Have reached over US $200 million. The
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flagship of the Williamson Magor Group, Eveready has expertise in the areas of manufacturing, cultivating, marketing and distributing a diverse range of products. The portfolio ranges from carbon zinc batteries, rechargeable batteries, alkaline batteries and flashlights to packet tea and bulk tea. In fact the group has over 130 years of experience, growing the worlds finest teas in the most challenging of terrains. Some of the best tea brands in the world have a blend with the produce of Williamson Magor gardens. Thus from the first flush of tea in the gardens to the first invigorating sip in the morning, Eveready is always there to revitalise your day.

Products
Manufacturers and marketing and distributing and Exporters of products as covering Batteries. Batteries: Carbon Zinc, Rechargeables, Alkalines. Premium Gold, Jaago and Classic. Exports: Heavy-Duty series, the Super Heavy - Duty series and even the Alkaline series.

Raw Materials
This section, as well as the following section, will focus on alkaline batteries. In an alkaline battery, the cylinder that contains the cells is made of nickelplated steel. It is lined with a separator that divides the cathode from the anode and is made of either layered paper or a porous synthetic material. The canister is sealed at one end with an asphalt or epoxy sealant that underlies a steel plate, and at the other with a brass nail driven through the cylinder. This nail is welded to a metal end cap and passed through an exterior plastic seal. Inside the cylinder, the cathode consists of a mixture of manganese dioxide, graphite, and a potassium hydroxide solution; the anode comprises zinc powder and a potassium hydroxide electrolyte.

The Manufacturing Process

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The cathode

1 In an alkaline battery, the cathode actually doubles as part of the container. Huge loads of the constituent ingredientsmanganese dioxide, carbon black (graphite), and an electrolyte (potassium hydroxide in solution)are

Mixing the constituent ingredients is the first step in battery manufacture. After granulation, the mixture is then pressed or compacted into preformshollow cylinders. The principle involved in compaction is simple: a steel punch descends into a cavity and compacts the mixture. As it retracts, a punch from below rises to eject the compacted preform. delivered by train and mixed in very large batches at the production site. The mixture is then granulated and pressed or compacted into hollow cylinders called preforms. Depending on the size of the battery being made, several preforms may be stacked one on top of another in a battery. Alternatively, the series of preforms can be replaced by an extruded ring of the same material.

2 The preforms are next inserted into a nickel-plated steel can; the combination of the preforms and the steel can make up the cathode of the battery. In a large operation, the cans are made at the battery factory using standard cutting and forming techniques. An indentation is made near the top of the can, and an asphalt or epoxy sealant is placed above the indentation to protect against leakage.

The separator

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3 A paper separator soaked in the electrolyte solution is then inserted inside the can against the preforms; the separator is made from several pieces of paper laid at crossgrains to each other (like plywood). Looking down at an open can, one would see what looks like a paper cup inserted into the can. The separator keeps the cathode material from coming into contact with the anode material. As an alternative, a manufacturer might use a porous synthetic fiber for the same purpose.

The anode

4 The anode goes into the battery can next. It is a gel composed primarily of zinc powder, along with other materials including a potassium hydroxide electrolyte. This gel has the consistency of a very thick paste. Rather than a solution, it is chemically a suspension, in which particles do not settle (though an appropriate filter could separate them). The gel does not fill the can to the top so as to allow space for the chemical reactions that will occur once the battery is put into use.

The seals

5 Though the battery is able to produce electricity at this point, an open cell is not practical and would exhaust its potential rapidly. The battery needs to be sealed with three connected components. The first, a brass "nail" or long spike, is inserted into the middle of the can, through the gel material and serves as a "current collector." The second is a plastic seal and the third a metal end cap. The nail, which extends about two-thirds

The container of a typical alkaline battery, consisting of preform inserted into a steel can, also doubles as the cathode. The anode in
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the middle is a gel composed primarily of zinc powder. The separator between the anode and cathode is either paper or synthetic fiber that has been soaked in an electrolyte solution. In the finished battery, a plastic seal, a steel nail, and a metal top and bottom have been added. The nail is welded to the metal bottom and extends about two-thirds of the way into the can, through the anode. of the way into the can, is welded to the metal end cap and then passed through the plastic seal.

6 This seal is significantly thinner in some places than in others, so that if too much gas builds up in the can, the seal will rupture rather than the entire battery. Some battery designs make use of a wax-filled hole in the plastic; excess gas pushes through the wax rather than rupturing the battery. The seal assembly meets the indentation made in the can at the beginning of the process and is crimped in place. 7 The opposite end of the can (the positive end of the battery) is then closed with a steel plate that is either welded in place or glued with an epoxy-type cement.

The label

8 Before the battery leaves the factory, a label is added identifying the type of battery, its size, and other information. The label is often paper that is simply glued to the battery. One large manufacturer has its label design printed on plastic shrink wrap: a loose fitting piece of heat-sensitive plastic is wrapped around the battery can and then exposed to a blast of heat that makes the plastic shrink down to fit tightly around the can.

Quality Control
Because battery technology is not especially new or exotic, quality control and its results are especially important as the basis for brand competition. The ability of a battery to resist corrosion, to operate well under a variety of conditions, to maintain a good shelf and usage life, and other factors, are the direct results of quality control. Batteries and ingredients are inspected and tested at almost all stages of the production process, and the completed batches are subjected to stringent tests.

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11th February 2011

Holoflex Limited

Company profile
Holoflex Limited is one of the leading manufacturers of Holograms and allied products in India. An ISO 9001:2000 & ISO 14001:2004 Certified Company, their state-of-the-art manufacturing facility in Salt Lake, Sector V, Kolkata houses some of the most sophisticated machinery required for secure and high quality Holographic applications. Besides thry have our branch offices in Delhi, Mumbai, Chennai & Guwahati. As one of the pioneers of this technology in India, Holoflex Ltd. entered a nascent market, which needed extensive education on the concept of holograms. Today Holoflex Ltd. provides a variety of customized holographic solutions to various government departments in India as well as numerous corporate houses in India and across 25 countries all over the world. Their effort to achieve the highest level of excellence in product quality has been recognised even by the apex body of Hologram manufacturers across the globe. International Hologram Manufacturers Association (IHMA), London who conferred upon Holoflex the highest level of award in the field of Commercial Holography The IHMA Award for producing the Best Hologram Label worldwide consecutively in 2003 & 2004.

Products
Manufacturer & exporter Holoflex product bouquet includes dot matrix master, holograms in reels / sheets with variable information, holograms with scratch coating, ready-to use stock image holograms, regular / holographic shrink sleeves, wads and hot stamping foils.
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Raw Materials
Holograms made by individuals are usually exposed on very high resolution photographic film coated with a silver halide emulsion. Holograms made for mass production are exposed on a glass plate pretreated with iron oxide and then coated with photoresist. The photoresist material will chemically react to the specific wavelength of light that will be used to create the hologram. Because of their availability at a relatively low cost, helium-neon lasers are most commonly used by individuals who make their own holograms. Commercial hologram manufacturers use different laser types such as ruby, helium-cadmium, or krypton-argon ion. After exposure, the film or photoresist plate is processed in chemical developers like those used in photography. Both nickel and silver are used to make the production masters that will be used to stamp multiple copies of the holograms onto polyester or polypropylene film. Aluminum is used to create the reflective coating on the back of embossed holograms.

Design
A three-dimensional, physical object can be used to create a hologram. The holographic image is normally the same size as the original

object. This may require construction of a detailed scale model of the actual subject in a size suitable for the holographic image. Altematively, the artwork that is to be reproduced as a hologram can be computer generated, in which case software controls the laser exposure of the image file, one pixel at a time. (Pixels are the individual dots that comprise a graphic image on a computer screen or printout.)
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The Manufacturing Process

Various manuals are available that explain to amateur holographers how to make holograms at home. The following steps describe the commercial mass production of a holographic image of an actual, three-dimensional object. Mastering

1 A laser is used to illuminate the physical object, with the reflected light falling on the photoresist plate. Simultaneously, a reference beam from the laser also falls directly on the photoresist plate. The interference patterns of these two light beams react with the photosensitive coating to record a holographic image of the object. Common exposure times are between one to 60 seconds. In photography, slight motion of the object or the film results in a blurred image. In holography, however, the exposed plate will be blank (contain no image at all) if during the exposure there is movement as small as one fourth the wavelength of the laser light (wavelengths of visible light range from 400 to 700 billionths of a meter). A typical photoresist plate has a 6 in (15.24 cm) square working area; an extra half-inch (1.25 cm) of space on two edges allows the plate to be clamped into position. Because many holograms are smaller than this, several different images can be "ganged" (clustered) onto one plate, just as numerous individual photographs are exposed on one roll of film.

2 The plate on which the original hologram is recorded is called the master. After being exposed, the master is processed in a chemical bath using standard photographic developers. Before proceeding with production, the master is inspected to confirm that the image has been properly recorded. Because of the chemical reactions caused by the laser and the developer on the photoresist, the developed plate's surface resembles the surface of a phonograph record; there are about 15,000 grooves per inch (600 per cm), reaching a depth of about 0.3 microns (1 micron is a thousandth of a millimeter).

Electroforming

3 The master is mounted into a jig (frame) and sprayed with silver paint to achieve good electrical conductivity. The jig is lowered into a tank along with a supply of nickel. An electric current is introduced,

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and the master is electroplated with nickel. The jig is removed from the tank and washed with

deionized water. The thin, nickel coating, which is called the metal master shim, is peeled off the master plate. It contains a negative image of the master hologram (the negative is actually a mirror image of the original hologram). Using similar processes, several generations of shims are created. Those made from the metal master shim are known as "grandmothers," and they contain positive images of the original hologram. At this stage, numerous copies of the original image are "combined" (duplicated in rows) on one shim that can be used to print multiple copies with a single impression. Successive generations of shims are known as "mothers," "daughters," and "stamper shims." Because these generations alternate between negative and positive images of the original, the stamper shims are negative images that will be used during actual production runs to print the final product holograms.
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Embossing

4 Stamper shims are mounted in embossing machines. A roll of polyester film (or a similar material) that has been smoothed with an acrylic coating is run through the machine. Under intense heat and pressure, the shim presses the holographic image onto the film, to a depth of 25 millionths of a millimeter. The embossed film is rewound onto a roll.

Metallizing

5 The roll of embossed film is loaded into a chamber from which the air is removed to create a vacuum. The chamber also contains aluminum wire, which is vaporized by heating it to 2,000F (1,093C). The sheet is exposed to the vaporized aluminum as it is rewound onto another roll, and in the process it becomes coated with aluminum. After being removed from the vacuum chamber, the film is treated to restore moisture lost under the hot vacuum condition. A top coating of lacquer is applied to the film to create a surface that can be imprinted with ink. The roll of film, which may be as wide as 92 in (2.3 m), is sliced into narrower rolls.

Converting

6 Depending on what type of film was used and what kind of product is being made, one or more finishing steps may be done. For instance, the film may be laminated to paper board to give it strength. The film is also cut into shapes desired for the final product and may be printed with messages. Heat-sensitive or pressure-sensitive adhesive is applied to the back of holograms that will be affixed to other objects or used as stickers.

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21th April 2011 TATA TINPLATE COMPANY OF INDIA Ltd

Company profile
TCIL has a history of pioneering several industry initiatives since its inception in 1920. The latest in this line of firsts is the setting up of the Solution Centre last December. It is the first step in TCILs efforts to graduate from being a mere downstream steel business towards its vision of becoming a total metal packaging solution provider the hallmark of a global major in the packaging business. TCIL is today the largest indigenous producer of tin coated and tin free steel sheets in India, enjoying 35-40% market share and undoubtedly the industry leader for 85 years. The company exports about 20-25% of its production directly to end-users (can-makers) and its products are well accepted in the markets of SE Asia, Middle East and some developed countries in Europe. Headquartered in Kolkata, the Companys Works is located at Jamshedpur, Jharkhand. There are presently 12 offices in India and a distribution network with 17 stocking points. TCIL Works, situated at Golmuri, Jamshedpur has presently two dual processing line for ETP/TFS and Cold Rolling Mill (CRM).The company has commenced CRM-2 set-up as a backward integration in feeding the second tinning line with TMBP coils.

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Manufacturing Facilities - Stages of Production

All tinplate originates as in the steel-making furnace (Tata Steel), where the proper chemistry for steel is obtained to meet the specific needs of the end user. All tin mill products start their production process in a Basic Oxygen Furnace (Tata Steel).

Hot Rolled Coil Manufacture

Once the steel is produced, the continuous casting process transforms molten steel into slabs in one continuous operation. Continuous casting is a highly energy- and cost-efficient process that produces a slab of excellent quality and consistency. Continuous casting methods are now used in virtually all carbon steel production facilities to produce products of consistent, high quality. Next, the slab goes into the Hot Strip Mill (HSM) of Tata Steel where its thickness is reduced and it is wound in a down coiler into coil form. This is where the Hot Rolled Coil (HRC) is procured as the basic raw material by TCIL from Tata Steel.

Pickling Process
To remove the scales adhering to the hot rolled coils Tinplate Company uses its Push-Pull shallow bath Hydrochloric Acid Pickling Line. The line has 3 pickling tanks and 5 rinse tanks. The Pinch Roll # 1 in the entry section pushes the strip that is "paid off" and the Pinch Roll # 3 in the delivery section pulls it thro the process section of the line. The line has a cascading system for rinse water and online trimming facility.

6 Hi Cold Rolling Mill

Tinplate, as a packaging material, continues to be most preferred, both in packaging food products like processed food, vanaspati, ghee, etc., and also where criticality of application is important, as in the case of battery jackets and pesticide cans, to name a few select areas. Understanding the need of increased indigenisation, TCIL commissioned its state-of-the-art 120,000 tonnes per annum Cold Rolling Mill having the
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benefit of synergy with TATA STEEL, from where raw material is available in the form of Hot Rolled Coils for the manufacture of TMBP coils. The mother mill of the complex is a 6 High, continuous variable crownreversing mill. The pickled strip is "paid off" from a Pay-Off Reel and fed into the cold rolling mill. Depending on the input thickness, desired output gauge and pass schedule designed by the mill operator, the hydraulic system sets the draught. After the first pass that has run between the POR and Reversing Reel # 2, the tail end is fed into the Reversing Reel # 1. The strip is run reverse and forward between RR1 and RR2, thro the CR mill, with the thickness being reduced in each pass. The thickness gauges at the entry and the exit side of the mill gives real time feed back thro the automation system to the mill's hydraulic system for online correction of roll force and hence the thickness.

Electrolytic Cleaning
During the process of cold rolling cooling oil is used to keep the temperature of the roll and the strip within limits. This cooling oil mixed with water in an emulsion has to be removed for further processing. This is achieved in the Electrolytic Cleaning Line. The line uses alkaline dunk and ortho-silicate electrolytic cleaning to remove the emulsion oil coating. The strip is then scrubbed, rinsed, dried and rewound on a reel into coils. These coils are then tilted 90o and taken for annealing.

Annealing
Annealing is done to relieve the stresses that are built into it during the process of cold rolling which makes the steel strip hard and brittle. Annealing is done using the batch annealing process. Degreased coils are stacked four high on a base. An annealing cover is placed over this stack and pure hydrogen is pumped in. Then the heating hood is placed and programmed to heat the coils to predesigned temperatures. This follows a heating - soaking - cooling cycle with cut off temperatures and times depending on the hardness required by the customer. After the process that takes 32 - 38 hours, the coils are discharged from the base.

Temper Mill
The mill is a four high two-stand tandem mill with a facility to give a further reduction of upto 30%. After the process of annealing the strip becomes
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soft. To put it to further use the surface has to be given the proper finish and hardness. For this purpose the strip is passed thro the temper mill. Normally a skin pass is given (80% of product). This is dry temper rolling; where the hardness and shape is controlled in the first stand and the surface finish in the second stand. In the rest (20%) of cases a post annealing secondary cold reduction of upto 30% is given by controlling the draught in the first stand. This process is known as Double Cold Reduction. This process also uses a cooling emulsion for roll and strip cooling. This imparts higher hardness and strength to the strip enabling thinner sections to be put to use in place of thicker plates

Coil Preparation Line (CPL)

Full hard and / or tempered coil before being tin plated has to be trimmed to the required width as per the customer's order. For this purpose the coil is passed thro' the CPL with edge trimming facility. The coil is "paid off" and passed thro' the trimmer to cut off both sides to the ordered width of the end product and then rewound. While rewinding the edge guide system thro a continuous feedback process ensures that the two sides of the coil winding is without any projected edges. This is done to facilitate handling of the coils. The full hard cold rolled coils are packed and shipped out of this mill to customers.

Electrolytic Tinplating Line

The unique properties of tin provide a coating on the steel that protects the contents, while providing the steel with an attractive appearance, corrosion resistance and ease in bonding, welding and painting. Tin is applied to both sides of the black plate coil through an electrolytic process. The thickness of the tin coating (called coating weight) is dependent upon the end-use application. Typical applications for electrolytic tinplate include food and beverage containers, paint trays, battery tops and paint, varnish and aerosol cans. The Tinplate Company of India Limited pioneered the Indian Industry when they put up the country's first tinning line in 1922. The growth of TCIL has been a continuous process of development and modernization to keep Indian Tinplate at par with international standards. The technological advances had led to the introduction of Electrolytic Tinplate (ETP), while the spiraling and prohibitive cost of tin resulted in the manufacture of a suitable substitute, namely Tin Free Steel (TFS) or Electrolytically Chromium coated steel(ECCS). To keep pace with these
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developments, TCIL was the first to set up a combination line capable of producing both ETP and TFS. The plant was commissioned in 1978 and has an installed capacity of 90,000 tonnes per annum. The line can be run upto a speed of 247 m/min and is capable of processing coils ranging from 0.17 mm to 0.60 mm in thickness and 600 mm to 965 mm in width.

The Electrolytic Tinplating line is the only one of its kind in India. It has a facility to coat the line with tin or with chromium / chromium oxide (Tin Free Steel). The ETP uses the FEROSTAN process, where in an acidic bath of Stannous Sulphate is the electrolyte. The strip is "paid off" and passed thro the looping tower - which stores material to enable the line to run continuously, even while the entry is stopped for welding the tail end of one coil to the head of the next. The strip then passes into the cleaner solution to remove any remnant traces of oil or emulsion. Then it goes thro the pickling bath where the Sulphuric acid removes any oxide that may have formed in the CRM complex. This acid also etches the plate, to prepare it for the electro-deposition of tin. After the surface is fully prepared for plating it passes into the plating section. Here the strip enters the bath with pure tin being used as anode and the strip itself as the cathode. By passing the required direct current - this is dependant on the coating weight required by the customer - in the bath the plate is coated. Thereafter it passes into the melting furnace where the deposited tin is melted to give it a brighter finish and also make it adhere to the base material better. After this the strip is chemically treated to reduce the action of atmosphere on tin and then coated with oil to facilitate handling. In case the order is for tin free steel, the strip is passed directly from the pickling bath to the chrome plating section. Here by using chromic acid bath and inert anodes a layer each of chromium and chromium oxide is deposited on the strip. Since this coated steel does not have any tin plating on its surface it is called tin free steel. The strip is then passed thro the online inspection to segregate any sheet that falls outside the acceptable range of thickness, sheets with pinholes in them and then cut up as per order and piled into packets of about 1500 KGs. This is then shipped out to customers in trucks or containers, the latter mainly for overseas customers.

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Tin-free Steel/Electrolytic Chrome Coated Steels (ECCS)

Unlike the multiplicity of coating weights with tin, only one standardized chromium-coated product is manufactured. The chromium coating process was developed in the 1960s as an alternative to tin coatings for packaging products cost-effectively, with desirable material properties. Chromium offers excellent lacquer adhesion, storage properties and strong resistance to food corrosion with proper applications of lacquer. Chromium-coated steels are most frequently used for can tops, screw and lug caps, snap and press-on closures and shallow-drawn food cans. Packaging steels are coated with different protective and decorative.

Research & Development

Assurance is sign of commitment and TCIL's commitment to quality is byword in the Indian packaging industry. With the accreditation of ISO 9001, TCIL has joined the league of international players in supplying superior quality Tinplate/TFS in terms of their mechanical properties, dimensional accuracy, shape parameters, corrosion resistance values and rigid packaging. The quality Assurance team at TCIL is equipped with qualified and experienced engineers and chemists trained in all aspects of the Tinplate manufacturing technology from abroad. The process controls and the product inspection standards during Tinplate/TFS production are very stringent to ensure that every sheet undergoes minute scrutiny thus providing 100% customer satisfaction. Quality Grades Single /Double Reduced Electrolytic Tinplate ,Open Top Sanitary Can, Non Oil Can Tinplate and Tin Free Steel (Chrome Plated ) are available in Standard, Seconds and Waste/Waste quality.

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14th February 2011

Emami Limited is in the business of manufacturing personal, beauty and health care products. The company manufactures herbal and Ayurvedic products through the use of modern scientific laboratory practices. This blend enables the company to manufacture products that are mild, safe and effective. The company's product basket comprises over 20 products, the major being Boroplus Antiseptic Cream, Navratna Oil, Bororplus Prickly Heat Powder, Sona Chandi Chyawanprash and Amritprash, Mentho Plus Pain Balm, Fast Relief, Golden Beauty Talc, Madhuri Range of Products and others. The products are sold across all states in India and in countries like Nepal, Sri Lanka, the Gulf countries, Europe, Africa and the Middle East, among others. Manufacturing Emami's products are manufactured in Kolkata, Pondicherry, Guwahati and Mumbai. The company commenced operations at its fully automated manufacturing unit in Amingaon, Guwahati in 2003-04. They are an ISO 9001:2000 company.

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Laminated tube filling process

Tube ascends unit filling nozzle reaches tube bottom when filling. Tube descends gradually while filling to ensure that air bubbles within filled product is kept at the minimum. Filling process adapts a circular design to minimize tension, enable a smooth filling process, maintains dosing volume accuracy with simple cleaning procedures. Filling nozzle changes based on varying tube sizes or filling material viscosity. Filling nozzle is designed for a leak free condition, while the filling pump is simple to detach for cleaning purposes.

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HOT AIR Inner Heat Mechanics: Hot air system adapts an uniform application to able different hot air temperatures to be adjusted without the need for parts changeovers, as well as a choice between plastic or laminated tubes. Special tube end clip molds and exhaust system ensure that filling quality is not affected when heat is being applied to inner tube ends. Accuracy is maintained at high production speed while tube end modes have options to choose from. OPERATING PROCEDURES:: The operator places empty tubes onto inclined chute (whole box of tubes are arranged onto the tube cassette feeder, tubes are discharged automatically; this mechanic is optional), and fed into individual tube holders tube centering sensor adjust tube position, progressive bottom up filling (MAX. 130mm), end sealing, end trimming (Plain) and auto tube ejection.

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END TRIMMING:
Trimming by a (horizontal) cutter is done after the tube sealing station to trim off excess tube ends. Material Supply: Available selection of options, custom made requirements for coding on single or double sides of tube ends also available

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