PROJECT REPORT ON

REPLACEMENT OF BINDING MACHINES

WITH STRAPPING MACHINES
Submitted

In partial fulfillment of the requirement

For the award of the degree of

BACHELOR OF TECHNOLOGY
BY

MINHAZ MOHAMMED M A (114111046)

DINESH MORE (114111023)

Under the Esteemed guidance of

Sri SATYA SRI RAM KOLAVENNU

AGM Mechanical

LMMM Department

VISAKHAPATNAM STEEL PLANT

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DEPARTMENT OF PRODUCTION ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI

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VISAKHAPATNAM STEEL PLANT

CERTIFICATE
This is to certify that the project report entitled REPLACEMENT OF BINDING MACHINE
WITH STRAPPING MACHINE IN LMMM is the work of the following students and is
being submitted in partial fulfillment industrial training program as a part of
curriculum at NATIONAL INSTITUTE OF TECHNOLOGY,TIRUCHIRAPPALLI.

MINHAZ MOHAMMED M A (114111046)

DINESH MORE (114111023)

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PROJECT GUIDE INTERNAL GUIDE

Sri S.S.R.KOLAVENNU Dr. J JERALD

Asst. General Manager (LMMM) Staff Advisor
Visakhapatnam steel plant Department of Production Engineering
NIT - Trichy
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 DEPARTMENT OF PRODUCTION ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY,TIRUCHIRAPALLI
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ACKNOWLEDGEMENT!
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We are grateful to Visakhapatnam steel plant for permitting us
to take up project in Light and Medium Merchant Mill (LMMM)
department.

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We are extremely thankful to Mr.SATYA SRI RAM KOLAVENNU,
ASSISTANT GENERALMANAGER (MECHANICAL) for his esteemed
guidance and without whom this project would not have been
possible.

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We are also thankful to our beloved SIR Mr. BANDI.VENKATA RAO
andMr.R.V.K.CHOWDHARY for helping us in the completion of
this project.

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We would like to express our gratitude to all who helped us
throughout for the successful completion of our project.
CONTENTS
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1. ABSTRACT

2. INTRODUCTION TO VSP

3. INTRODUCTION TO LMMM

4. DESCRIPTION OF THE TOPIC SELECTED

5. STUDY ON BINDING MACHINES.

i. MAJOR COMPONENTS OF BINDING MACHINE

ii. SEQUENCE OF OPERATION

iii.ADVANTAGES AND DISADVANTAGES

6. STUDY ON STRAPPING MACHINES

i. MAJOR COMPONENTS OF STRAPPING MACHINE

ii. SEQUENCE OF OPERATION

iii.TECHINICAL SPECIFICATIONS

7. ADVANTAGES OF STEEL STRAPPING OVER TYING WIRE ROD

COILS.
 8. COMPARISION OF TECHNO ECONOMICS FOR STRAPPING

MACHINES OVER BINDING MACHINE

9. NEED FOR REPLACEMENT OF BINDING MACHINE WITH

STRAPPING MACHINE

10.CONCLUSION

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 ABSTRACT
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Visakhapatnam Steel Plant under Rastriya Ispat Nigam Limited is the first shore based

integrated steel plant in India.

Out of three Hot Rolling Mills which convert steel blooms into finished steel, LMMM

i.e.., Light and Medium Merchant Mill is the largest of all the three and also know as

Mother Mill. As it feeds to two different mills i.e WIRE ROD MILL andBAR MILL.

In LMMM, the finished steel after rolling, cut into final size as per the requirements of

the customer were finally packed by means of binding machines.

Bending machines constitute one of the most important equipment in LMMM and

recent past had become a bottle neck for smooth production.

Following are the some of the important problems encountered in binding

machine.

(a) High maintenance prone equipment causes loss of production/

more down time of the equipment.

(b) Major source for customer complaints.

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In order to overcome both the problems a study was proposed to be made

in-depth analysis suggesting an alternative machine which is the strapping machine.

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 VISAKHAPATNAM STEEL PLANT
AN OVERVIEW !
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1. INTRODUCTION

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Visakhapatnam Steel Plant, an integrated steel plant under the corporate entity of

Rashtriya Ispat Nigam Limited (RINL), is the first shore based integrated Steel Plant in the

country, constructed with the then latest state of the art technology. The Plant with a rated

capacity of 3.0 Mt is a producer of steel products in the longs category like wire rods, re-bars,

angles, channels, blooms and billets.

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Visakhapatnam Steel Plant, the first coastal based Steel plant in India is located

16km southwest of city of destiny, i.e. Visakhapatnam. Bestowed with modern technologies,

Visakhapatnam Steel Plant has an installed capacity of

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3.3 Million Tons of liquid steel per annum and

2.656 Million Tons of saleable steel.

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Visakhapatnam Steel Plant products meet exalting International Quality Standards

such as JIS, DIN, BIS, BS etc.

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 Visakhapatnam Steel Plant has the distinction to be the first integrated Steel Plant

in India to become a fully ISO-9002 certified company. The certificate covers quality systems of

all Operational, Maintenance, Service units besides Purchase systems, Training and Marketing

functions spreading over 4 Regional Marketing Offices, 20 Branch offices and 22 stock yards

located all over the country.

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Visakhapatnam Steel Plant by successfully installing and operating efficiently Rs.

460 corers worth of Pollution Control and Environment Control equipment and converting the

barren landscape by planting more than 3 million plants has made the Steel Plant, Steel

Township and surrounding areas into a heaven of lush greenery- This has made Steel Township a

greener, cleaner and cooler place, which can boast of 3 to 4 degrees centigrade lesser temperature

even in peak summer compared to Visakhapatnam city.

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Visakhapatnam Steel Plant exports quality pig iron and steel products too Sri

Lanka, Myanmar, Middle East, USA and Southeast Asia (pig iron). RINL-VSP was awarded

Star Trading House status during 1997-2000.

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Having a total manpower of about 17250 Visakhapatnam Steel Plant has

envisaged a labour productivity of not less than 230 tonnes per annum year of Liquid Steel which

is the best in the country and comparable with the international levels.

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2. EVOLUTION
 Visakhapatnam Steel Plant was conceived in the year 1970 as a unit of Steel Authority of

India Limited (SAIL) to augment its long products capacity and to service the southern markets.

Announcement for Visakhapatnam Steel Plant was made in the Parliament in the year 1970 and

the foundation stone was laid in 1971 by the late Prime Minister Smt. Indira Gandhi. The

feasibility report of the plant was made in 1973 and the Indo-Soviet Agreement was signed in

1979. The comprehensive detailed project report was made in 1980 and the project was

sanctioned by Government of India in 1982. In the same year, a separate company called

Rashtriya Ispat Nigam Limited was formed.

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The plant was to be commissioned by 1986 as per original schedule. However,

because of severe cash crunch, in the year 1986, a rationalized concept was adopted to lower the

capital costs. Some of the envisaged facilities were dropped and the nameplate capacities of steel

making and rolling mills were increased for making revenue generation more attractive.

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Finally, the plant was fully commissioned in the year 1992. Due to the long

gestation period of 22 years from concept to commissioning stage, the capital cost of the project

went up from original estimate of Rs.2256 crs in 1979 to Rs.8594 crs in 1992. As a result of

high capital cost and large borrowings the company had to bear high interest and depreciation

burden resulting in continuous losses. This has resulted in huge cost over runs and high capital

related charges and Visakhapatnam Steel Plant at the time of commissioning itself had a net loss

of over Rs.2000 crs.

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 While the plant was picking up production, the South East Asian financial crisis

severely affected the steel market which led to continuous drop in steel prices both in domestic

and international markets. Also from 1998, the steel industry, worldwide, was affected by

recession. Steel demand declined, forcing the steel producers to throttle production levels. Many

unviable production units in the world had to close down. Indias exports were hit adversely and

domestic consumption remained almost stagnant. Sales realizations plummeted and profitability

of the Indian steel producers was adversely affected. All these conditions brought a tremendous

pressure on the financials of the company.

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3. THE TURN-AROUND

Despite these adverse conditions, the Vizag Steel collective rose to the occasion

and over the last few years Vizag Steels performance has improved on all fronts including

production, techno-economics, marketing and financials. The emphasis initially had been

towards total employee involvement, then to technology up gradation and process management

and then to managing external environment.

At this juncture, the leadership played a crucial role in providing direction

focusing on critical issues and empowering employees. A number of sustenance and performance

improvement programmes were initiated to put the company on the growth trajectory. The

emphasis was on attaining rated capacity at the earliest, improving techno-economic

performance, improving health of equipment, cost reduction and process innovations. Systematic

and standard operation practices and structured systems were developed and Vizag Steel was the

first integrated steel plant in the country to be accredited with all the three International
Standards for Quality (ISO 9001), for Environment Management (ISO 14001) and for

Occupational Health and Safety (OHSAS-18001).

All these initiatives gave positive results and the company started its journey to

excellence by crossing its rated capacity levels in the year 2001-02. Since then the company

has been operating consistently beyond the rated capacities. Currently, the plant is

operating at 120% of its rated capacity.

The Plant turned around in the year 2002-03 by achieving for the first time a

net profit of Rs.521 crs. The improved performance saw Vizag Steel become a Zero debt

company and is a net positive company today having wiped off all its accumulated losses.

All these efforts of Vizag Steel were well recognized by one and all. For its

excellent performance in the year 2002-03, Vizag Steel was conferred with the Prime Ministers

trophy for the best Integrated steel plant in the country. During the year 2002, Vizag Steel

was awarded with `SCOPE excellence award for turnaround for its outstanding performance.

Vizag Steel has been winning the National Energy Conservation award for the last seven years

and has also won the Special Prize for National Energy Conservation for successfully annexing

the first prize for three consecutive years. Vizag Steel has been constantly achieving excellent

MOU rating from the government for its excellent performance. It was bestowed with the World

Q u a l i t y C o m m i t m e n t Aw a r d a t P a r i s . I n 2 0 0 5 , Vi z a g S t e e l b a g g e d s i x

VishwakarmaRashtriyaPuraskar Awards out of the 28 awards announced by Ministry of Labour,

a tribute to the involvement of its employees and participatory approach of the management.

Best Water Management, Best Financial Management and Best Safety & Occupational health

awards from Confederation of Indian Industries are some of the prestigious awards received.
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4. VIZAG STEEL TOMORROW:
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Armed with a vision to become world class integrated steel plant, the Vizag Steel

Collective is charged with a steely resolve to face a challenging tomorrow. Some of the

initiatives taken to make Vizag Steel a world class organization are:

Adoption of business excellence through CII-Exim Business

Excellence Model.

Initiation for BPR & ERP.

Implementation of Six Sigma methodology.

Implementation of 5S for outstanding housekeeping.

Bench marking with world class companies.

Introduction of Knowledge Management to harness the inner potential of

employees.

Introduction of e-commerce.

Acquisition of captive mines in India and abroad through joint venture, so as to

have a level playing field with its competitors.

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In line with its vision to become a continuously growing company, Vizag Steel

recast its expansion plan to double its capacity from its present 3 mT to 6.3 mT by 2008-09. The
approval for its recast expansion plan was obtained on 28th Oct 05 in a record time of 10

months. The expansion has been planned to further strengthen its long product leadership in the

country through production of special bars, wire rods and structurals, in view of its high brand

image and also envisaged demand in line with the infrastructure growth of the country. A

seamless tube plant has been planned for the first time in an integrated steel plant to cater to the

growing oil and gas industry and reduce dependence on imports of seamless tubes. The next

phase of expansion to 10 mT is planned for completion by 2012-13 which will include flat

products also to provide a rich product mix.

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With excellent performance levels continuing during the current year also and the

ensuing expansion wherein Vizag Steel has set up an ambitious target of completion of its

expansion in a record 36 months at international standards, Vizag Steel looks to new horizons.

Vizag Steel collective has proved its mettle time and again and is all set to take up new

challenges and soar to new heights to emerge as a World Class steel plant.

LOCATION:

The plant is located in Visakhapatnam city, which is on the coast of Bay of

Bengal. Visakhapatnam city is an important commercial center of Andhra Pradesh. It has

the deepest port and is one of the principal outlets for countrys exporting Iron ore. The

city has many large industries such as The Hindustan Petroleum Refinery, Bharat Heavy

Plates and Vessels Ltd. Coromandal Fertilizers, Hindustan Zinc, and Hindustan Shipyard

etc. The city is situated on the main broad gauge railway line between Calcutta and
Madras and is well connected with other major cities and state capitals by rail, road and

air. The Visakhapatnam Steel Plant is located southwest of VisakhapatnamHarbor and is

about 26 km from Visakhapatnam city. The township and the plant have been built on an

area of 27, 000 acres, between the national highway no. 5 and the Bay of Bengal.

CLIMATE:

Visakhapatnam has worm and humid climate, April to June is the warmest

months of the year and December to February are the coldest months of the year. The city

benefits from the Southeast monsoon (October to December). The average rainfall is

973.6mm and highest mean monthly maximum temperature is 37.8 degree centigrade.

MODERN TECHNOLOGY:

In Visakhapatnam steel plant modern technology has been adopted in

many areas of production, some of them for the first time in the country.

Selective crushing of coal

7 meter tall coke ovens

Dry quenching of coke

On ground blending of sinter base mix

Conveyor charging and bell less top for blast furnace

Cast house slag granulation for blast furnace

100% continuous casting of liquid steel

 Gas expansion turbine for power generation, utilizing blast

furnace top gas pressure

Hot metal Desulphurization

Extensive treatment facilities of effluents for ensuring proper

environmental protection

Computerization for process control

Sophisticated high speed and high production rolling mills

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MAJOR PLANT FACILITIES:

The production facilities in the Visakhapatnam steel plant are most

modern amongst the steel industry in the country. The know how and the technology

have been acquired from different parts of the world from the reputed and established

sources. Some of the novelties of the Visakhapatnam steel plant are:

7 meter height coke ovens of VSP are the tallest so far built in the country.

Dry quenching of coke has been adopted which will not only improve the quality of coke

and economics of coke production, but also contribute significantly to the reduction of

environmental pollution.

Base mix yard for sinter plant introduced for the first time in the country

helps in excellent blending of the feed material to the sinter machine and production of

consistent good quality sinter.

3200 cubic meters two blast furnaces with bell less top charging

equipment and 100% cast house slag granulation. The granulation of the entire molten

slag arising at the furnace cast house avoids the need to transport molten slag and

optimizes utilization of slag.

100%continuouscasting of liquid steel into blooms result in less and better

quality of blooms.
 The VSP have three sophisticated and large rolling mills have been

entirely computerized to ensure consistent quality and efficient performance.

The major production departments of Visakhapatnam steel plant are the

Raw materials handling system, Coke ovens, Sinter plant, Blast furnace, and Steel

melting shop and Rolling mills.

Extensive facilities have been provided for repair maintenance as well as

manufacturing of spare parts. There is a Central machine shop, Structural shop, Forge

shop, Foundry, Wood working shop and Loco repair shop. Visakhapatnam steel plant has

got its own Air separation plant for production of oxygen and acetylene plant for

production of acetylene gas. A captive power plant has also been provided for power

generation with 4 units, each of 60 MW generation capacities.

RAW MATERIAL LINKAGES:

The steel plant is getting its supply of iron ore- lumps and fines from the

Bailadilla deposits in Madhya Pradesh (MP) blast furnace grade lime stone from

Jaggayyapeta in Andhra Pradesh, SMS grade lime stone from Badnapur in MP, blast

furnace grade lime stone from the Kotni-sonor deposits in MP. 20% of cocking coal

requirements will be met by imports through the Visakhapatnam harbor while the balance

will come from the Bengal-Bihar. Coal for power generation will come from Talcher in

Orissa.
POWER SUPPLY:
A peak construction power requirement was about 12MVA. This was

arranged from the Gajuwaka substation of APSEB at 33KV.

The plant have captive power generation unit consists of 3 nos. turbo

generators, each having 60 MW capacity. An additional requirement of operational power

around 150 MVA is being met from the APSEB grid.

Operational power supply is initially at 220 KV, which are subsequently

stepped down to 400 KV.

WATER SUPPLY:
Requirements of water during the peak of construction were of the order

of 4.5, Mgd. This was met from the Meghadrigedda, and Raiwada schemes of Andhra

Pradesh state government.

Operational water requirements of 70 Mgd. Of the steel plant are being

met from the Yeleru water supply scheme provided by the AP government. This involved

construction of a storage reservoir at Yeleswaram and a 153 KM long linked canal to the

plant site apart from Kanithi Balancing Reservoir (KBR).

REPAIR AND MAINTENANCE SHOPS:

The repair and maintenance shops are required to manufacture spares and

replaceable items and will cater to the capital and running maintenance of the various

units of the steel plant. The activities of the repair and maintenance shops are extremely
wide and varied in nature. The experience of the Indian steel plants has been kept in view

in planning the repair and maintenance facilities.

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Table-1: Annual requirement of spares and replaceable items (tons)
For the purpose of procurement, it is estimated that 15 percent of the total

requirement of spares and replaceable items will be imported for technological reasons

while those obtained from ancillary units will constitute about 35 percent and the balance

has been envisaged to be produced within the steel plant.

The production capacity of VSP is indicated in the table:

S.NO. Department Annual capacity (in

000 tons)
1 COKE OVENES 2261
2 SINTER PLANT 5256
3 BLAST FURNACE 3400
4 STEEL MELT SHOP 3000
5 LMMM 710
6 WRM 850
7 MMSM 850

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MAJOR PRODUCTS OF VISAKHAPATNAM STEEL PLANT
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STEEL PRODUCTS By PRODUCTS

ANGLES NUT COKE GRANULAED SLAG

BILLETS COKE DUST LIME FINES
CHANNELS COAL TAR AMMONIUM SULPHATE
BEAMS TOULENE
SQUARES XYLENE
FLATS BENZENE
ROUNDS NAPTHALENE
REBARS ANTHRACITE OIL

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TECHNOLOGICAL HIGHLIGHTS OF VSP:
The plant uses the most modern technology. The features of the

technology are:

7m tall Coke Oven Batteries with coke dry quenching.

Biggest Blast Furnaces in the country.

Bell less top charging system in Blast Furnace.

100% slag granulation at the BF cast house

Suppressed combustion L-D gas recovery system.

100% Continuous casting of liquid steel

Tempcore and Steel more cooling process in LMMM& WRM

 Main product ion Layout
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Raw Material Handling Plant (RMHP)

Coke ovens and Coal Chemical Plant (CO&CCP)

SINTER PLANT (SP)

BLAST FURNACES (BF)

STEEL MELTING SHOP (SMS)

CONTINUOUS CASTING DEPARTMENT (CCD)

LIGHT AND MEDIUM MERCHANT MILL (LMMM)

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BRIEF DETALS ABOUT PLANT!

Raw Material Handling Plant (RMHP)

VSP Annually requires quality raw materials viz. Iron Ore, fluxes (Lime stone,

Dolomite), coking and non coking coals etc., to the tune of 12-13 million tones for producing

3 million tones of Liquid Steel. To handle such a large volume of incoming raw materials

received from different sources and to ensure timely supply of consistent quality of feed

materials to different VSP consumers, Raw Materials Handling Plant serves a vital function.

This unit is provided with elaborate unloading, blending, stacking and reclaiming facilities

viz. Wagon Tipplers, Ground and Trace Hoppers, Stock yards crushing plant, vibrating

screens, single/twin boom stickers, wheel on boom and blender reclaimers.

In VSP peripheral unloading has been adopted for the first time in the country.

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Coke Ovens & Coal Chemical Plant ( CO & CCP)
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 VSP Annually requires quality raw materials viz. Iron Ore, fluxes (Lime stone,

Dolomite), coking and non coking coals etc., to the tune of 12-13 million tones for producing

3 million tones of Liquid Steel. To handle such a large volume of incoming raw materials

received from different sources and to ensure timely supply of consistent quality of feed

materials to different VSP consumers, Raw Materials Handling Plant serves a vital function.

This unit is provided with elaborate unloading, blending, stacking and reclaiming facilities

viz. Wagon Tipplers, Ground and Trace Hoppers, Stock yards crushing plant, vibrating

screens, single/twin boom stickers, wheel on boom and blender reclaimers.

In VSP peripheral unloading has been adopted for the first time in the country.

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Coke Ovens & Coal Chemical Plant ( CO & CCP)
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Blast Furnaces, the mother units of any Steel Plant require huge qualities of strong, hard and
porous solid fuel in the form of hard metallurgical coke for supplying necessary heat for
carrying out the reduction and refining reactions besides acting as a reducing agent.
Coke is manufactured by heating of crushed coking coal (below 3 mm) in absence of air at
temperature of 1000 C and above for about 16 to 18 hours. A Coke Oven comprises of two
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Sinter Plant (SP)

Sinter is a hard and porous ferrous material obtained by agglomeration of Iron

Ore fines, Coke breeze, Lime Stone fines, Metallurgical wastes viz., Flue dust, Mill scale, LD
slag etc.
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in Blast furnaces help in increasing productivity, decreasing the coke rate and improving the
quality of hot metal produced.
Sintering is done in 2 number of 312 Sq, Metre, Sinter machines of Dwight Lloyd type of
heating the prepared feed on a continuous metallic belt made of pallets at 1200-1300 C.
Hot sinter discharged from Sintering machine is crushed to +5 mm 50 mm size and cooled
before dispatching to Blast Furnaces.
Parameters of Sintering Machines are:
- Effective area : 312 Sq. Metre
- Sintering area : 276 Sq. Metre
- Sinter bed height : 300 mm
- Capacity : 450 TPH each
- No. of wind boxes : 26
The dust laden air from the machines are cleaned in scrubbers and electrostatic
precipitators to reduce the dust content to 100 mg/m3 level before allowing to escape into the
atmosphere and thus helping in maintaining a clean and dust free environment.
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Blast Furnace(BF)

Hot Metal is produced in Blast Furnaces, which are tall vertical furnaces. The

furnace is named as Blast Furnace as it is run with blast at high pressure and temperature. Raw

materials such as sinter/iron ore lumps, fluxes (limestone/dolomite) and coke are charged from

the top and hot blast at 1100 C-1300 c and 5.745 KSCH pressure is blown almost from the

bottom. The furnaces are designed for 80% Sinter in the burden.

VSP has two 3200 Cu. Metre blast furnaces (largest in India) equipped with

Paulworth Bell less top equipment with conveyor charging. Rightly names as

Godavari&Krishna after the two rivers of AP, the furnaces will help VSP in bringing

prosperity to the state of Andhra Pradesh.

Provision exists for granulation of 100% liquid slag at blast furnace cost house

and utilization of blast furnace gas top pressure (1.5 2.0 atmospheric pressure) to generate 12

MV of power in each furnace by employing gas expansion turbines.

The two furnaces with their novel circular cast house and four tap holes each are capable of

producing 9720 tonnes of hot metal daily or 3.4 million tones of low sulphur hot metal

annually.

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Steel Melting Shop(SMS)
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Steel is an alloy of iron with carbon upto 1.8% hot metal produced
in Blast Furnaces contains impurities such as carbon (3.5 4.25 %) silicon (o.4 0.5%)
manganese (0.3 0.4%) sulphur ().04 % max) and phosphorous (0.14% max) is not suitable
as a common engineering material. To improve the quality the impurities are to be
eliminated or decreased by oxidation process.
VSP produces steel employing three numbers of top blown oxygen
convertors called LD convertors (L&D stand for linz andDonawitz two towns in Austria
where this process was first adopted) or Basic oxygen furnaces/convertors. Each convertor
is having 133 Cu. Metre volume capable of producing 3 million tones of liquid steel
annually. Besides hot metal, steel scrap, fluxes such as calcined lime or dolomite from part
of the charge to the convertors.
 99.5% pure oxygen at 15-16 KSCG pressure is blown in the convertor
through oxygen lance having convergent divergent copper nozzles at the blowing end.
Oxygen oxidizes the impurities present in the hot metal, which are fixed as slag with basic
fluxes such as lime. During the process heat is generated by exothermic reactions of
oxidation of metalloids viz., Si, Md., P and Carbon and temperature rises to 1700 C enabling
refining and slag formation.
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Different grades of steel of superior quality can be made by this process by

controlling the oxygen blow or addition of various ferro alloys or special additives such as

fesi, FeMn, SiMn, coke breeze, Allumimium etc., in required quantities while liquid steel is

being tapped from the convertor into a steel ladle. Convertor/LD gas produced as by product

is used as a secondary fuel.

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Characteristics of VSP Convetors:

- Capacity : 150 tonnes per heat/blow

- Volume : 133 Cu. Metre

- Convertor Sp.Volume : 0.886 Metre Cube per tonne

- Tap to Tap Time : 45 mts. To 60 mts

- Height to diameter ratio :1.36

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- Lining

i) working : Tar Dolomite Bricks

ii) permanent : CromeMagnesite bricks

- Av. Lining Life : 2445 heats (2004)

 CONTINUOUS CASTING DEPARTMENT (CCD)
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Continuous casing may be defined as teaming of liquid steel in a mould with a false bottom

through which partially solidified ingot/bar (similar to shape and cross section of the mould)

is continuously withdrawn at the same rate at which liquid steel is teamed in the mould.

Facilities at a continuous casting machine include a lift and turn table for ladles,

copper mould, oscillating system tundish, primary and secondary cooling arrangements to

cool the steel bloom. Gas cutting machines for cutting the blooms in required length (Av. 6

metres long).
At VSP we have six-4 strand continuous casting machines capable of producing 2.82 million

tones/year blooms of size 250 X 250 mm and 250 X 320 mm. Entire quantity of molten steel

produced (100%) is continuously cast in radial bloom casters

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ROLLING MILL
Blooms produced in SMS-CCD do not find much applications as such and are required to be

shaped into products such as billets, rounds, squares, angles (equal and unequal) channels, I-PE

beams, HE beams, wire rods and reinforcements bars by rolling them in three sophisticated

high capacity high speed.

Blooms produced in SMS-CCD do not find many applications as such and are required

to be shaped into products such as billets, rounds, squares, angles (equal and

unequal), channels, IPE beams, HE beams, wire rods and reinforcement bars by rolling

them in 3 high capacity, high speed fully automatic rolling mills namely Light and
Structural Mill (MMSM) and Medium Merchant Mills (LMMM), Wire rod mill (WRM) and

Medium Merchant.

LIGHT AND MEDIUM MERCHANT MILL (LMMM):

LMMM comprises of two units. In the billet/break down mill 250X320 mm size blooms

are rolled into billets of 125X125 mm size after heating them in two nos. of walking beam

furnaces of 200 TPH capacities each. This unit comprises of 7 stands (2 horizontal 850X1200

mm and five alternative vertical and horizontal stands 730X1000 mm and 630X1000 mm).

The billets for rolling in bar mill of LMMM are first heated in two strand roller hearth

furnace of 200 T/H capacity to temperature of 11500 C 12000 C. The bar mill comprises of 26

stands- 8 stand double strand roughing train, two nos. of five stand, double strand Intermediate

train & two nos. of four stand single strand finishing trains.

The mill is facilitated with temperature core heat treatment technology, evaporative cooling

system in walking beam furnaces, automated piling & bundling facilities, high degree of

automation and computerization.

The mill is designed to produce 710,000 tons per annum of various finished products

such as rounds, rebars, squares, flat, angles and channels besides for sale.

WIRE ROD MILL (WRM):

Wire rod mill is a 4 strand, 25 stands fully automated and sophisticated mill. The mill

has a four zone combination type reheating furnace (walking beam cum walking hearth) of 200

TPH capacity for heating billets received from billet mill of LMMM to rolling temperature of

1200 0C .
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Fig: WRM PRODUCT
The heated billets are rolled in 4 strand No twist continuous mill having a capacity of

8,50,000 tons of wire rod coils and having the following configuration:

- 7 stand two high 4 strand horizontal roughing train.

- 6 stand two high 4 strand horizontal intermediate mills.

- 2 stand 4 strand pre finished mill

- 10 stands 4 strand No twist finishing mill.

The mill produces rounds in 5.5 mm to 12 mm range and rebars in 8 mm to 12 mm range.

The mill is equipped with standard and retarded stelmore lines for producing high quality wire

rods in low, medium and high carbon grade meeting the stringent national and international

standards viz. BIS, DIN, JI S , BS, etc. and having high ductility, uniform grain size, excellent

surface finish.
!
!
MEDIUM MERCHANT AND STRUCTURAL MILL (MMSM):

!
This mill is a high capacity continuous mill consisting of 20 stands arranged in 3 trains.

Roughing train having 8stands

4 two high horizontal stands

2 vertical stands

2 combination stands

!
Intermediate train having 6 mill stands as per the details:

2 high horizontal stands

2 combination stands

2 horizontal stands/ 2 universal stands

!
Finishing train having 6 stands

2 combination stands

4 horizontal stands/ 4 universal stands

 !
The feed material to the mill is 250X250 mm size blooms, which are heated to

rolling temperatures of 1200 0C in two walking beam furnaces each of 130 TPH capacities. The

mill is capable of producing 8,50,000 tons of rounds, squares, flats, angles (equal and unequal) T

bars, Channels, IPE beams/ HE beams (UNIVERSAL BEAMS) having high strength and

close tolerances.

!
!
!
!
Fig: MMSM PRODUCT

LIGHT & MEDIUM MERCHANT MILL

INTRODUCTION:

Initial part of LMMM known as billet mill which designed to roll 1, 915,000 T/

Year of 320x 250mm size blooms into 1,857,000T of 125x125mm square billets. While later part

of the mills is known as bar mill which is designed roll 726,000T of billets to 710,000T of

finished light merchant products as per product-mix. The 1046m long mill is located at +5m

level above the ground level. It has got two flat roof type walking beam preheating furnaces,

each 200 tones/ hour capacity, equipment with radiant roof burns to heat blooms to rolling

temperature of 11500C 12000C and one 2-strands roller hearth furnace (200 tones / hour) to
maintain or increase the temperature of billets entering bar mills. This roller hearth furnace

connects them to portions of light and medium merchant mill i.e., billet mill with bar mill. The

billet mill is continuous rolling mill consisting of seven stands (4 Horizontal and 3 vertical).

Maximum rolling speed is 1.6 m/sec. The mill can roll 400 tones of blooms/hour. The flying

shear located after 7 stands cuts the billet to the desired length. Out of 1,915.000 tones of

blooms, billets rolled are about, 1,857,000 tones.

!
!
The Distributions of Billets are:

a) Bar Mill : 726,000 Tones

b) Wire rod mill :885,000 Tones

c) Saleable Billets : 246,000 Tones

DESCRIPTION:

The Light and Medium Merchant Mills (LMMM) of VSP has been envisaged to

produce:

I. 7,10,000Tons/yr of LMMM products,

II. 2,46,000Tons/yr of Billets for sale,

III. 8,85,000Tons/yr of Billets for WRM at 3.0MT stage.

 Entire mill has been laid out at an elevation of +5 meter except the charging grids

and their associated roller tables which are located in the cross bays at +0.01 level. The material

is

!
FIG:PLACING BLOOMS ON TO THE ROLLER TABLE

lifted up to the elevated floor on A-C bay by means of elevators. There are two

walking beam furnaces, which span A-C and C-D bays have their discharge sides situated on C-

D bay. The C-D bay i.e., the Mill bay , which stretches about 960 meter long house the combined

Billet and Bar mill with its inline roller hearth furnace, cooling beds and cold shears. The

finishing facilities viz., bundling and piling installations are laid out across the cold shear

delivery roller table and span both C-D and D-E bays.

Area-wise integrated description is given below:

CHARGING, FURNACE AND DISCHARGING AREAS:

 The feed material for the mill is continuous cast bloom of 250mmX320mm size

having a normal bloom length of 6.3 meter. Cold blooms are charged on the charging grid by

magnet crane according to the rolling sequence list. Each walking beam furnace has defined

track numbers and charging and discharging of blooms from charging grids and furnaces

respectively will be according to the rolling mode i.e., each bloom destined for its defined track

number will be discharged from charging grid in the sequential order. Normally furnace 1 is

intended to feed hot blooms for production of billets and deposition on to billet cooling bed

while furnace 2 is intended to feed hot blooms for onward transmission to Bar mill.

This implies that the cold blooms are tocharged into charging grid in a definite

pattern to suit the particular rolling mode adopted and particular grid can be operated for

discharging of blooms on to roller table upon ON light flashing and the light will go OFF

when preselected number of blooms have been discharged. In order to identify and check the

correct charging pattern the bloom of a changed heat number is given a colour marking.

Rectangular blooms will be placed on the charging grids (3no.) in flat position

(320mm flat) by means of magnet crane. The cranes are capable of loading 3 blooms at a time

and will form a gapless bloom group of maximum 6 blooms each. Each grid is capable of

receiving maximum of 6 groups which are appropriately spaced apart for the folding dogs to

restore the upright position and engage.

Two blooms are discharged on to roller tables (item 2) one by one in the

sequential manner as mentioned earlier. The respective grid will go OFF when the preselected

number of blooms has been discharged on to roller table. When the blooms have passed the roller
table section in front of another grid, the light of that grid will be ON permitting that grid to

discharge blooms. Blooms are discharged on roller table and conveyed to the elevator (item 4).

Defensive blooms, if any, on its travel to the elevator will be detected manually by the operator

and positioned in front of defective bloom grids (item 1a) and will be pushed out of the roller

table.

Fig:WALKING BEAM FURNACE

The roller table (item 2) transports the blooms normally under sequence control of

their respective destined elevators 1 or 2. The blooms are pushed off the roller table by lever type

off on to a ramp from where they are picked up carrier links of elevators and pulled up. They

carry off device downstream and pick up the bloom and places on furnace approach roller table

(item 5). The furnace approach roller table working on sequential control, positions the blooms

while on motion on various sections of this roller by means of light barrier. Since the walking

beam system are to be uniformly loaded different bloom lengths will be classified into two

categories and positioned in front of furnaces automatically.

!

Fig: BLOOM COMING OUT OF WALKING BEAM FURNACE

The bloom on its passage is stopped and its actual weight is recorded. The

material tracking computer system takes over the actual weight, checks with reference weight

and then sets the bloom free for further transport. As soon as the blooms are positioned correctly

and the walking beam furnaces are ready to receive the blooms, the blooms are pushed into the

furnace by furnace pusher (item 10).

As mentioned earlier each furnace is loaded in two rows and each row is meant

for its defined destination. Two furnaces have four tracks and materials are discharged by

discharging units (4 nos.) as per the discharging pattern envisaged for the particular rolling

mode. At the delivery side of the furnace, actual position of blooms is detected by means of a

sensor and its actual position is given out as a coded series of pulses referred to the theoretical

position.

Walking beam furnace has capacity of 200tons/hr. the fuel used in the furnace is a

mixture of Coke oven gas, Blast furnace gas and LD converter gas. The fuel calorific value is
2000kcal/m3. In general the calorific value of Coke oven gas is greater than LD converter gas

and Blast furnace gas.

The walking beam furnace is divided into three zones namely: Pre-heating zone,

Heating zone and soaking zone. The flue gases are sent into recuperator stand where the bloom

is pre heated to a certain temperature. This is pre-heating zone. In the Heating zone the bloom is

heated to the required temperature.

This temperature has to be maintained and this is done in the soaking zone.

The blooms have to be moved from the charging side to the discharging side and

this is done by skids. Skids are of two types: Moving skid and Fixed skid. These skids are

cylindrical tubes which are insulated on the top surface and through which steam flows in order

to cool the skids. The blooms are rested upon the fixed skids. The moving skids lift the bloom

from the fixed skids, move forward and place the bloom on the next fixed skid. Now the moving

skid is lowered. The motion of the moving skids is controlled by the pneumatic cylinders.

When the furnace walking beam system has completed its horizontal movement,

the sensor has given out the actual position of bloom. This information is utilized by the

corresponding discharging machine (the mobile beam of the machine has already reached to the

discharging line) to complete its remaining stroke and to lift the material off the furnace and

place it on delivery roller table (item 12) provided the respective roller table section is free. If it

is already occupied the discharging machine is held in waiting position and subsequently

deposits the bloom as soon as the respective roller table sections are free. If the discharged hot

blooms are found to be defective the blooms are conveyed along the roller table in the reversed
direction and are pushed over defective bloom grid by bloom pusher. Rejected blooms are picked

up by crane in layers of three and deposited on to transfer car (item 301). The transfer car

transfers the rejected blooms in the cross bay R-Q.

!
!
BREAKDOWN MILL AREA:

Hot blooms travel forward over the roller table under sequence control and is

freed from scale on the move by the descaler unit and is finally positioned over the roller table

section having tilter unit. The tilting (under manual control) is done to make the bloom upright.

The upright bloom now enters the first stand of Billet mill.

As soon as the tail end of this bloom clears stand no. 1 (Photo Cell

Disilluminated), the upstream tilter is again ready to receive the next bloom under sequence

control.

!
 Fig:BLOOM ENTERING INTO STANDS

There are seven stands (four horizontal and three vertical) in the breakdown mill.

In five box passes the bloom is reduced from 320mm X 250mm to 125mm square of 33m length

(referred to nominal bloom length of 6.3m) with a finishing temperature of 11000C-12000C.The

draw-in speed of bloom varies from 0.256m/sec to 0.315m/sec depending upon he discharge

bloom temperature. The stand arrangement is as shown below:

Stand 1 Stand 2 Stand Stand 4 Stand 5 Stand 6 Stand

3 7
Horizontal Vertical

horizontal vertical horizontal Horizonta Vertical

Fig: FOUR CRANK SHEAR

A four crank shear installed behind the mill stand is designed to crop both ends

and to cut fixed billet length between 5.0m to 12.2m or to perform optimum yielding dividing.
When cutting fixed lengths, rest ends up to 1.5m are guided into a scrap bucket (recoil roller

table section open). Rest ends above 1.5m are transported (recoil roller table section closed) to a

location where they are diverted into a short length disposal cradle. Detection of a rest end below

or above 1.5m is automatically done before rest end cut is performed.

Whenever a bloom meant for a bar mill enters BDM, checks are made whether

the pendulum shear at the entry of bar mill is in the process of performing an emergency out of

the proceeding bloom in the very strand for which the new bloom is being rolled in BDM. If it is

so, the new bloom being rolled at BDM must be out into pieces of specified length by the 4-

crank shear. Those pieces are then deposited into the short length disposal cradle as described

earlier.

If optimum yield cutting is performed, for example, for billets, for wire rod mill,

the total finishing length will be cut to get three equal pieces with one minimum crop cut at each

end. Computer calculation of the first billet length is made on the basis of bloom weight, already

stored in the first billet in conjunction with the reduction in the BDM stands, permits to assess

the billets length with substantial accuracy. However the exact billet length measured by the

measuring roll on the four-crank shear is used to calculate the corrective factor. This factor is

also a parameter to calculate the exact discharging cycle for the succeeding BM blooms.

BILLET MILL COOLING BED AREA:

Billets meant for Billet Mill Cooling Beds are stamped on the move on the head

ends and are transferred to cooling beds on the move by means of discharge drums in the form

of feeder screws, which after one full revolution, push the billets running on cooling bed roller
table side wise to a brake plate, where it comes to rest after short breaking distance. They are

disappearing /end stops to limit the braking distances. In order to ensure proper discharge of

billets on the move, proper gap is provided between the blooms by giving a lead of maximum

20% to the run out roller table to that of existing stand V7 of the Breakdown Mill. The two

cooling beds can be charged in one or two rows depending uponthe cut lengths.

! !

Fig:BILLET MILL COOLING BED AREA

Normally the cooling beds are fed in alternating order. Lengths cut from first

billet are transferred to cooling bed-II and are alternately cross-transformed by the rear and

forward drum (2-row charging condition). Cut lengths from next billet are diverted to cooling

bed I and alternately across transferred by the rear and forward drum (2-row charging

condition). However, in case of single row charging condition the two cross transfer drums of

each cooling bed are jointly operated.

The cooling bed is designed as TURNOVER TYPE COOLING beds and

consists of stationary and moving rakes with notches. In order to ensure that the billets remain

straight during the cooling process, the moving rakes turn the billets twice through 900 about

their longitudinal axis in each stroke, thus moving them to two stationary rake notch pitches.
 This movement will always ensure a vacant supporting notch between any two

billets, thus ensuring proper cooling. When these arrive in the lending position, they are picked

up by the magnetic cranes and stored in Billet storage yard for further processing them through

billet inspection and condition line, if so required, for Sale/Wire Rod Mills (WRM). Otherwise

stored billets are sent directly to WRM bay through transfers.

! !

Fig:BILLETS TAKEN AWAY BY MAGNETIC CRANES

 LINE DIAGRAM FOR BAR MILL
LINE-2

LINE-1
LINE-2

LINE-1

FINISHI INTERME ROUGHIN

250

MANUAL AUTO PUM

BAR MILL:

Billets meant for merchant bar mill are cropped at the front and rear end

and are generally have a length of approximately 31.6m. These billets are transported

with a speed of 2m/sec to the inline two-strand roller hearth furnace. These furnaces

have twenty-six rollers inside them upon which the billets are made to travel in order to

increase the billet's temperature.

! !

Fig:ROLLER HEARTH FURNACE

Billets, arriving in succession, enter the reheating furnace, designed for

two-strand feeding via a switch arranged in front of the furnace. Each of the strands has

roller table lines which are divided into three groups. Each of these rollers is water

cooled, overhung type and are separately driven. Billets arriving in succession are

diverted to strand 1 and 2 in alternating Order by the switch. Billets normally arrive at a

surface temperature pi 1'100C at the furnace and are heated and soaked to a discharge

temperature of 1150C/1130C depending upon double/single strand rolling respectively.

The billets enter the first strand of the Bar Mill at the normal entry temper a t u r e of

100C. To achieve the discharge temperature a device will calculate the residence time

of the billets inside the furnace depending upon the inlet temperature of the billets. The

billet will isolate inside the furnace to achieve this residence time.

All billets leaving the furnace are detected by photocells arranged a t the

furnace discharge end and cause automatic speed reduction of the furnace roller table to

suit the mill entry speed of about 0.1m/sec-0.5m/sec plus a lead as preselected. As soon

as the tail end of the billet running on strand-1 or strand-2 of mill clears the furnace
roller table groups (3 groups as previously described). They are successively made speed

synchronized again with furnace approach roller table to receive the next billet.

!
ROUGHNING TRAINS:

The billet head now approaches the first groove a t a predetermined speed.

If, however, entry does not take place (rolls are no roll of the pinch roll (Hem-4-1)

which is located between inline roller hearth furnished and first stand will be shifted

over the billet and lowered down on to the billet and bottom pinch roll is made to rotate

at about 0.6m/sec.

! !
Fig: BILLETS ENTERING INTO INTERMEDIATE STANDS
!
The entering process is assisted due to frictional engagement between

pinch rolls and billet. The pinch roll is also used in case of mill trouble. In case of mill

trouble, it feeds the remainder portion of billet to the pendulum shear for size reduction

into scrap pieces or transports back to the furnace depending upon whether the residual

billet is long or short. The billet, entering the Bar Mill, normally needs no head end crop
cut by pendulum shear because the four Crank shear in Billet Mill has already performed

the job. However, the decision is left to the operator in CP5.

INTERMEDIATE MILL 1

Stand 9 Stand 1.0 Stand 11 Stand 12 Stand 13

Horizontal Horizontal Vertical Horizontal Horizontal

INTERMIDIATE MILL 2
Stand 14 Stand 15 Stand 16 Stand 17 Stand 18

Horizontal Horizontal Vertical Horizontal Horizontal

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!
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Stand 19 Stand 20 Stand 21 Stand 22

Vertical Horizontal Vertical Horizontal

FINISHING MILL 2
Stand 23 Stand 24 Stand 25 Stand 26
Vertical Horizontal Vertical Horizontal

!
FINISHING MILL 1

This mill arrangement permits to roll smaller size section in two-strands such as

rebars, rounds, squares, angles and flats and bigger size structure in single strand. In case of

single strand rolling it is also possible to prepare in parallel with the rolling process, the complete

second intermediate and finishing mill for a new product size. In the roughing train the reduction
in cross section is nearly 30%. In the intermediate mill this reduction is further increased to 25%

and when the billet reaches the finishing mill the reduction is upto 15-20% and also it changes to

circular cross section.

Two box passes followed by a diamond, square, oval, round groove series are

provided in general in the roughing train for double strand rolling to get the necessary

high total reduction. In case of single strand rolling the two box passes are followed by a

uniform diamond square series and profile passes. This is done because of the lower

total reduction involved and because it is necessary specifically for section rolling to

produce larger size starting squares for the larger finishing sizes. In both cases this

series is followed by a diamond-square and/or oval-square series which in the finishing

trains changes over to an oval-round series for the production of rounds. The finishing

speed will be maximum 20m/sec. starting from stand VI9 1/II of the two finishing mills,

loopers are provided between the stands so that twist-free rolling not only will be

possible due to V-H stand arrangement, but also rolling in the absence of tension and

thereby obtain rolled products of good surface qualities and tolerance.

! !

Fig: BILLETS BEING REDUCED TO BARS

 Each of the stands is provided with separate drive. Regulating range from

the main drives and gear ratios has been selected, so that maximum rolling speed in each

stand is achieved. Snap shears are there for emergency cuts only ahead of the finishing

mills. Since this mill design provided for a maximum of nine passes only to be run after

the last cropping out ahead of the respective intermediate mill, no further cropping has

to be done on the upstream side of the finishing trains.

The function of the rotating shears beyond the last stands of the finishing

mills is to crop head end of the material leaving at rolling speeds as required for and/or to

cut it into multiples of specified sales lengths. In addition test pieces can be cut on these shears

which will be directed to Express Laboratory via a conveyor. Space has been provided for defect

scope and section size measuring instrument(future) tobe arranged between the last stand and the

cooling stretch behindeach finishing train. They permit to inspect and check plain rounds,squares

and flats etc.

Roll changes in the roughing mill area will be affected by means of special

change rigs installed near the operating side of the mill. In the intermediate and finishing mill

areas, complete stands will be changed by means of high speed change rigs and the roll changing

operation will be done in separate stand preparation areas, one for horizontal and the other for

vertical stands.

TEMPCORE PROCESS:

The TEMPCORE process which produces a high strength bar from steel of controlled chemical

composition, consists of a special thermo mechanical treatment process from which the name is
derived, i.e. a quenched surface layer is Tempered by the heat of the CORE. The principle is

illustrated schematically in the following diagram:

!
The distinct TEMPCORE advantage and our commitment towards offering the finest product is

exhibited through the following product properties :

*Enhanced Elongation ratio

*Savings in steel

*Higher Strength levels even at higher temperatures

*Better Corrosion resistance

These properties qualify our manufacturing process as unmatched in terms of global standards.

This makes Tempcore TMT bars a name synonymous with superior quality. This world

renowned process leaves a characteristic mark of strength on Tempcore TMT bars thus making

them unique.
!

Fig:BAR ENTERING INTO TEMPCORE BOX

The re-bar leaving the last stand of hot rolling passes through a special water cooling

section. The cooling is such that a surface layer of the bar is quenched into

martensite, the core remaining austenitic. The quenching treatment is stopped when

a determined thickness of martensite has been formed under the skin. The re-bar

leaves the drastic cooling section, the temperature gradient established in its cross

section causes heat to flow from the centre to the surface. This results in self

tempering of martensite. Finally, during the slow cooling of the re-bar on the cooling

bed, austentic core transforms into ferrite and pearlite.

Peekay TMT is produced by the world's most advanced technology licensed from

Centre de RecherchesMetallurgiques (CRM), Belguim, inventors of this process.

Tempcore bars are being successfully used in most parts of the developed world. TMT

are produced in two grades: TMT 415 and TMT 500. The numbers indicate the proof

stress. Because of the unique manufacturing process, TMT bars exhibit an excellent

combination of strength and ductility that far exceeds the minimum limits specified

by IS: 1786. Typical values for yield strength are as high as 465 N/mm2 for TMT (as
against IS standards, 415 N/mm2). Ductility as measured by elongation is 21% min (as

against standards 14.5% min). Thus, you get product which offers you higher safety

margins.

DESCRIPTION OF THE TOPIC SELECTED

!
After going thorough study and analysis of the process, LMMM is being followed one of

the important bottlenecks for smooth production appears to be binding machines.

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!
The problems with binding machines are as follows

Poor Packeting

Loose ties

Breakage of ties

Missing of identification of tags

Therefore the group felt, it is wroth while study the feasibility on strapping machines,

Which were being used in LMMM since 2009.

The scope of the study and recommendations will be as follows:

(a) Study on strapping machines.

(b) Technical specifications of strapping machines

(c) Major components of strapping machines.

(d) Sequence of operations.

(e) Advantages of steel strapping over tying wire rod coils.

!
!
SEQUENCE OF OPERATIONS OF BINDING
MACHINE
 !
Bundle is held by bundle former

Machine is kept in auto/remote mode.

Machine start pulse is given from pulpit by operator.

Machine moves to binding position until the sensing arm touches the

bundles.

Top guide track closes.

Wire feeding starts and wire enters the twist head.

Wire feeding stops and one end of the wire is held by clamping tool.

Wire stretching starts till the wire touches the bundle.

Wire breaks and both end are twisted tightly.

Binding unit lowers and bending down device moves forward to bend the

twisted towards the bundle and goes backwards.

Binding unit again moves upwards.

Next cycle starts.

Cycle continuous as per the no. of bindings selection.

After completion of all bindings guide track opens.

Machine moves off the binding position and stops at auto/remote position.

!
!
!
ADVANTAGES AND DISADVANTAGES
OF
 BINDING MACHINE
!
ADVANTAGES:

1. Easy availability of binding wire:

The binding wire is used for tying the bundle. This wire is brought from the

wire rod mill which is an on house product.

2. Overall cost/tie:

As the wire is obtained in house, the cost or tie is also less for this system than

other system.

3. Familiarity:

As the working men are experienced with the existing binding machine, the

operations become simpler.

!
DISADVANTAGESe

1. Poor packing:

Wirebindings are not compact and uniform over the length of the bundle,

Due to inconsistency in quality of wire.mostly caused by heat treatment and pickling of wire.

The heat treatment of wire is mainly annealing which results in softness in the wire. When

additional pressure is applied through binding machine and also while lifting the bundles by

magnetic cranes, there is a tendency elongation of wire due to softness. This is the main reason

for poor compacting and poorpacking.

2. Looseness and breakage:

 As the bundle is to handled by magnetic cranes wire gets elongated and tie becomes loose.

Further handling at stockyard loosens the tie and causes wire breakage.

3. Missing of identification tags:

At present identification of bundles of bundles is done through hand written tags

attached to binding/straps, which may lead to human error and mixing up of different categories

of material, which is highly incompatible with ISO standards and customers requirements.

!
!
4. High maintenance cost:

Shares used in the machine in general are important in nature. Hence procurements

lead time and cost of the spares are very high.

!
5. Difficulty in maintenance:

The existing machine operation consists of tying the wire in three loops ,cutting the

wire, tying knot which again consists of three loop and finally bending the ends. Each of these

operations are controlled through PLC and much complicated in nature and hence difficulty in

maintaining the machines.

!
6. High cycle time:
In the present machines each cycle takes 187 seconds which ishigh and incompatible
to the rolling rate of the mill which is 145tones/hour average and which causes shutdown in
production.
!
7. Loss in production:
 As the present machines are maintenance intensive downtime of the machine leads to huge
production loss to VSP.
!
!
!
To overcome these disadvantages, a new machine called STRAPPING MACHINE
can be installed. The idea got generated from the existing strapping of bundles manual
strapping where the machine the machine can strap the bundles automatically and
mechanically.
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!
STUDY ON STRAPPING MACHINES

!
!

! !
! !!
! !
! !
! !
! !
! !
! !
! SEALING OR NOTCHING: The process of
INTRODUCTION
! forming notches in the strap seal
This manual contains operation, safety, tocomplete the joint.
and
maintenance details for the Signode !
Model PRE-FEED OR FEED: The process of
M410-N Power Strapping Head. Because pushing strap into the head and driving
the it
head will become part of an application through the strap chute, around the
machine, details regarding the machine package,
into and back to the head. In most of the
which this head will be placed can be applications, strap is partially in the
found chute
in that particular manual. The M410-N when the strapping cycle begins.
Head Because
 !
!
!
!
!
SPECIFICATIONS
!
ELECTRICAL REQUIREMENTS: Refer to machine application manual for
!! Specificrequirements.
!Filtered, compressed air, 90 SCFM @ 70 to 90
PNEUMATIC REQUIREMENTS:
!HIGH SPEED FEED OR TAKE UP: psi.
!55 to 79 in/sec.
!LOW SPEED FEED OR TAKE-UP: !2 to 3 in/sec.
!TENSION FORCE: !3500 to 4400 lbs.
!STRAP TYPE AND SIZE: !Magnus, 1-1/4 .025 to .044
!SEAL MAGAZINE CAPACITY: !170 pieces
!HEAD WEIGHT: !478 lbs.
!
PNEUMATIC CONNECTION TO
MOTOR
There are four pneumatic ports on the Note: Changing transmission from low to
drive motor. The air inlet port to the air high (or high to low ) speed will reverse
motor can the
be either port "A" or "B" . When one is output shaft direction. Therefore the same
used direction of rotation is maintained by
as the inlet the other becomes the outlet. reversing the air flow (ports A + B) to the
A silencer is usually installed on the air motor itself.
exhaust/outlet port. !
! The following diagram shows the direction
For shifting from high to low on the of
transmission use the ports labeled H the transmission shaft by air supplied at
andL. When one is the inlet the other ports "A" and "B" or H and L.
becomes the outlet.
 "
!
1. MAJOR COMPONENTS ! .
2. AIR MOTOR-The sir motor powers the
transmission and strap tension is
!!
controlled by regulating air pressure to the
air motor. For specific adjustment
!
a. GATE CYLINDER-The gate cylinder
instructions, refer to the application manual is mounted behind the gate.
for recommended air pressure levels. Duringthe strap feed phase, it holds
! the gateclosed to contain the strap
2. TRANSMISSION-The transmission within the jaw area. Just prior to
drivesThetraction wheel.Feed take-up and tension, the cylinder
occurs when the transmission extends to open the gate.
outputshaft runs in The forward
direction. Take-up and tension
!
b. SEAL EJECT CYLINDER-Seal eject
occurs when the transmission cylinder is mounted on the right
output shaft runs in the reverse side of the seal magazine, ejects
direction. The traction wheel is seals into the jaw stack.
turned at high speed for feed and
take-up.During tension, the
!
c. TWO-IN-ONE CYLINDER, SMALL-The
transmission shifts into low speed small cylinder, mounted withinthe
to allow a higher level of tension to larger cylinder, advances the jawsto
be drawn. grip and hold the lead end of strap.
! !
3. TRACTION WHEEL-The traction wheel is d. TWO-IN-ONE CYLINDER, LARGE-The
driven by the transmission, and contacts large cylinder moves the jaws to
the strapdirectly. It performs three notch the overlapped strap, seal
functions of the strapping cycle; feed, take- the strap, and cut off the supply
up, and tension. of strap.
!
 ! !!
4. AIR CYLINDERS-TheM410-N-114 Head
hasthree external cylinders: one cylinder to
control the gate, another to eject seals, a
two-in-one cylinder for gripping, notching,
and cutting the strap.
!
5. JAW STACK-The jaw stack is composedof
moving and a stationary cutter forcutting,
grip jaws for securely holding thelead end
of the strap, and thenotchersfor sealing.
!
6. STRAP STRAIGHTENER- The strap
straightener removes natural curl in the
strap that, if left in, would adversely
affectstrap feed reliability.

!
!
TYPICAL PRINCIPLES OF
OPERATION
!
GENERAL Theleading strap end trips the strap
Various applications will have different fee
electricaland pneumatic sequences and d
the proximity switch as it reenters the
starting point of a strapping cycle may he
also ad.
vary. For specific operation sequences, !
refer 1. This proximity switch signals a timer to
to the application manual. begin
! timing and at this time air flow to
The six-phases of mechanical operations; the air motor is metered down to feed
strap feed, grip, take-up, tension, punch strap at a reduced speed.
and !
cut-off are described below. 5. The timer times out and sends a signal
! to
STRAP FEED CYCLE stop air to the air motor. At this time
1. A strapping cycle is begun by an the
external lead strap end overlaps the supply
signal. strap
! in the jaw stack area by an amount
2. Air is sent to the air motor. determined by the length of time that
the
3. The air motor and transmission run to
air motor ran after starting the timer.
drive the traction wheel in the feed
Air
direction at high speed. The traction
 !
!
!
GRIP CYCLE
1. Air is evacuated from the rod end of
the
large 2 in 1 cylinder.
!
2. The constantly pressurized cap end of
the small 2 in 1 cylinder partially
advances the piston rod, moving the
jaws
into the grip position and tripping the
central proximity switch, (#2). Grip
jaws hold the outer strap, (the strap
closest to the package), against the
grip side of the stationary cutter.
!
3. The valve that controls gate cylinder
extension receives a control signal.
!
 !
!
!
TYPICAL PRINCIPLES OF
! !
OPERATION, Continued
! !
TAKE-UP CYCLE
!
3. After taking up strap at high speed
1. Air is sent to the cap end of the gate
forapredetermined interval of time,
cylinder and the rod end is evacuated air flow to
at
the air motor is metered down to
a metered flow rate. The gate cylinder
complete the take-up strap at a
extends, opening the gate away from
reduced rate of speed.
the
jaw stack area for final strap cycle
phases.
!
2. Then the air motor reverses and air flows
unmetered, turning the traction wheel in
the tension direction at high speed,
 !
TENSION CYCLE !
1. Another proximity switch, mounted near The transmission shiftsand continues to
the traction shaft, or as determined by draw tension on the strap.When the
the application, signals a change in air desired
direction at the two speed transmission.
tension level has beenreached, as
Air is redirected to the shaft end of the
indicated
transmission and is evacuated from the
by a stall at the airmotor, another
opposite end. Note that the rotational
switch, determined by theapplication,
direction of the air motor is changed
is tripped. Air
because the rotational direction of the
transmission reverses when it shifts flow to the airmotor is continued to
machine constant straptension until cut-
betweenhigh and low speed.
off occurs.

!
!
 GATE IS OPENED BY GATE
CYLINDER, NOT SHOWN
THIS VIEW

PACKAGE

EXCESS STRAP IS
TAKE-UP CYCLE
 !

!
!
!
!!
!
!
!
!
!
 "
!
TYPICAL PRINCIPLES OF
OPERATION, Continued
NOTCH AND CUT-OFF CYCLE
!
1. The valve that controls the large 2 in 1 1. The moving cutter is advanced at
cylinder receives a signal. the
! same timeas the laws and notchers
2. Air is sent to the cap end of the engage the strap, the strap is cut
largecylinder. from the
! supply. The leading end of the
3. The large piston advances. The jaws strap is
hold the strap and seal securely as the
drawn back through the strap
notchers are driven into the overlapped
strap and seal. straightener.
2. The uppermost proximity switch, #3
is
tripped to signal a full notch
!
NOTCH AND CUT-OFF CYCLE
!

!
!
!
!
!
!
!
!
!
HOME POSITION !
! !
1. Air is momentarily admitted into both 1. Air is sent to the opposite end of the
ports of the air motor. After a short transmission and it shifts from low
tohigh
delay, all air is stopped. The air motor,
the transmission, and the traction wheel speed for the next strap
applicationcycle.
stop turning.
! The output shaft of the transmission
will simultaneously changedirection
2. The valve that directs air to the upper of
side of the large piston receives a signal rotation when changing from low to
and air is sentto the rod end of the large high
2 in 1 cylinder. speed.
! !
3. The large and small pistons return to 2. The valve that controls gate cylinder
home position, thus retracting jaws and retraction receives a signal and air
notchers. is sent
! to the rod end of the gate cylinder.
4. The lowermost proximity switch,(#1),
was
!
3. The gate cylinder retracts and
tripped when the 2 in 1 cylinder was closes the
retracted.
gate. Back pressure on the cap side
of
the cylinder is maintained. At the
same
time the seal ejector cylinder is
activated
to place a new seal in the jaw stack.
!
!
 GATE CLOSES

PACKAGE

COMPLETED
TIE
PRESSURIZED

AIR EVACUATED FROM

BENEATH PISTONS

PRESSURIZED
STRAP IS SECURELY TIED
AROUND PACKAGE

HOME POSITION
 !

!
!
!
!
OPERATING INSTRUCTIONS
!
LOADING STRAP LOADING SEALS
To load strap in the head, proceed as To insert a stack of seals in head proceed
follows: as
! Follows:
a. Push down the release handle. This
will raise the back-up wheel from the !
traction wheel, allowing the strap to a. Pull back seal pad until it locks.
pass freely between the two. !
! b. Slide seal cover away from magazine
channel.
b. Insert the lead-end of the strap into
!
!
!
!
!
!
!
MAINTENANCE !
GENERAL PROLONGED SHUT DOWN
Under severe operating conditions, such If the M410-N-114 Power Strapping
as high cycle rate and extreme dust Head is
and dirt, frequent cleaning and to be shut down and remain out of
inspection of the strapping head will
service
be required in addition to the
minimum service requirements listed for a prolonged period of time a
below: definite
! procedure must be followed in order
TWICE WEEKLY to
1. Remove the jaw stack. Clean, inspect assure a trouble free return to
and lubricate all parts with SAE #30 service.
machine oil. Refer to the Parts
Removal an Replacement
!
Section for details. UP TO TWO WEEKS
! For a shut down of up to two weeks
2. Remove the traction wheel and check duration, the procedure is as
the follows:
teeth. Clean, if necessary, with a wire
brush.
!
1. Follow the twice weekly
! maintenanceprocedure, taking
3. Grease all lubrication fittings. See care to lubricate all
Lubrication Chart. parts thoroughly.
! !
! 2. Disconnect all air hoses from the
WEEKLY air
Make several sample joints, approximating cylinder ports and place
the package size in use, and examine approximately 1
them for the following concerns: ounce of air cylinder oil in each
! cylinder
1. Check for grip slippage marks. If there port. Reconnect air hoses to
is slippage, replace the stationary prevent contamination.
cutter,
check grip.
jaws, or both, and re- !
3. Prior to return to service,repeat
!
MAJOR COMPONENTS OF STRAPPING MACHINES
The proposed strapping machine model M410N-114 CHM INDIA

LIMITED is made of ITW SIGNODE INDIA LTD.

Each machine consists of

1. power strapping head

2. Bed& slide

3. Strap chute system

4. Carriage and mainframe

5. Continues Ink Jet printer

6. Pneumatic components

7. Electrical control system

1. Model Signode: M410N-114 power strapping head:

The M410N-114 strapping head is mounted on the vertical bed. The air powered

M410N-114 strapping head is designed for heavy-duty applications. Strap tension is

adjustable up to 20,000 N. The working components for the head are easily accessible for

inspection and the replacement. The sealing mechanism is protected by a face gate, which

exposes the sealing jaws only during the tensioning cycle. Strapping head feeds the strap

around the bundle (strap gets guided in the chute), grips the leading end, pulls the extra

length of the strap, provides the set tension and seals the joint in that position. All these

operations are done automatically in the sequence with the help of electro-pneumatic

valves and controls.

 The strapping head houses a seal magazine to hold a maximum of 170 seals. The

seal magazine enables automatic insertion of the seals during the strapping operation. The

seal magazine is built in with the head. It's got a seal ejector at the top. This seal ejector

ejects the seal in the jaws of the head at the beginning of every strapping cycle. Jaws hold

seal lightly till the extra length of the strap is taken up and tensioned. After this the

notching of the seal and cutting of the strap takes place. The head is also inbuilt with a

provision to mount the Inkjet Printing head, which has an interfacing with the PLC for

the printing subject as per the instruction from the Computer. The Strap path is designed

specially for maintaining the gap between the UP head and the strap to enable the correct

printing characters on the strap.

2. Bed& slide:

The M410N-114 head is mounted on the slide that is fabricated of heavy gauge steel

plates and machined. The slide with head is guided on hardened & ground guide ways that are in

turn mounted on fabricated and machined bed. The keeper plates retain the slide with head and it

is moved front & back by a Hydraulic cylinder / electric motor with suitable transmission

mechanism to match the sealing position with product centre line of various sizes. The whole

assembly is mounted vertically on the machine carriage.

3.Strap chute system:

The strap chute system is made in two parts, one is pivoted and the pivoted bracket is

mounted on the movable slide on top of the head. The other part of the strap chute is mounted to

the bottom face of the head. The part pivoted on the slide is connected to a Pneumatic cylinder.

When this chute segment swings, a loop path is formed over the drcurnference of the bundle. In
open (swing back) position strap chute clears the bundle on the conveyor. The strap chute is

fabricated out of steel plates and sections. Raps around the entire chute confine the strap, but

permit a controlled release during take-up& tensioning. Provision is made to open a part of the

fixed strap guide, by a pneumatic cylinder, to print on the strap.

!
!
4. Carriage and mainframe:

The existing machine mainframe and carriage of the wire-tying machine is

retained for the strapping machine. The bed & slide with strapping head, strap chute assembly,

cylinders for head & strap chute movement are mounted on the carriage which is guided in the

main frame and it is driven by an electric motor. The main frame is guided on existing track.

ITW will decide on receipt of the Order, whether to use a new Main ' frame or continue with the

old Main frame based on the detailed design of the strapping m/c.

5. Track for the machine:

The existing track provided for the movement of the wire-tying machine for

applying multiple wire tie will be used. Now it is proposed three machines stationary in fixed

position in each .bay and one stand by machine will be positioned in between the two bays and it

moves either side on the existing tracks depending on the requirement. The existing track is

retained for this purpose.

6. Strap Dispenser DPAM 1000:

 Strap coil held in the dispenser, which releases the strap as requires by the head

during feeding and takes the extra length of the strap back during take-up and tension. The strap

is routed through a hopper, which moves vertically on guide rods. Sufficient length of strap is

fed, such that the hopper remains in the bottom most position, at the beginning of the cycle. As

the strap is fed, the hopper going up compensates it. The hopper moves down under gravity

during take-up and tensioning. An electric motor feeds the strap to fill the hopper. The dispenser

is mounted on an idler conveyor attached to the machine carriage and moves integral with the

machine main frame for the case of stand by machine. For stationary machines it is proposed to

mount on the floor near the machine.

!
7. Continues Ink Jet printer:

The required data to identify the coil is printed on one of the straps applied on the bundle.

A non - contact form of high speed ink jet printer is mounted on the fixed part of the strap guide

system which is designed inbuilt with the strapping head and is programmed to print

automatically on the strap, receiving the data to print from the PC where in operator can

manually enter the data to be printed or else VSP PC should give the soft data to ITW server for

necessary printing operation. The printer head is mounted in the strap guide path. The printer

works by propelling a continuous stream of ink through a nozzle. The stream is broken down

into identical droplets at a rate of up to 120000 per second. These droplets are selectively

charged and deflected to print dot matrix characters. Undeflected characters are re-circulated.

Machine at each bay and stand by machine is provided with the above printer assembly.
 However to provide uninterrupted on line printing of data, the stand by machine

which has printer assembly shall be positioned at the strapping area, hence we are not providing

any facility in our machine for automatic insertion of tags.

The ink jet printer has programming facilities for batch coding and sequential

numbering. It has a memory to storage capacity to store 5 messages and 5 logos. Red colour ink

shall be used for printing hence the strap colour shall be preferably Black, yellow or zinc for

better visibility of printed matter.

!
!
8.Electrical control system:

New electrical control system will be provided for the operation of the strapping

machine. To operate various hydraulic & pneumatic cylinders, motors and other accessories in

desired logic and sequence, an electric control panel is provided with a programmable logic

controller with necessary control and interlocking elements between the MILL PLC and ITW

PLC. This has various contactors, timer relays and other electrical accessories. Control desk has

various push buttons for manual and automatic operations. By considering the smooth and less

breakdown time we are considering two independent PLC for the two strapping bays.

The ATM 80 up gradation of required hardware and soft ware would be made by

VSP. However, ITW will try to match the strapping machine with the existing mill

requirements and will extend necessary support for the modifications required in the

existing line. For this VSP should provide the PLC software softcopy and the development
software, PC - PLC communication cable for VSP PLC and related manuals to ITW in

advance.

Cabling between the electrical cabinet and the pulpit closer to the strapping machines

shall be in scope of ITW. However, VSP should assist ITW in wire routing and trench details.

ITW PLC control panels will be located near the strapping m/c [ a new Control room

should be built by VSP for this with AC facility]. The horizontal movement of the Strapping m/c

on the track is done thru PB station by the supervisor and once the location of the strapping m/c

is frozen, the same will remain unchanged until it is moved again. The strapping m/c location

should be determined such that it does not foul with the roller conveyor elements and bear

huggers and lowering arms.

9.Pneumatic components:

As described above, the strapping head is operated by various pneumatic elements like

pneumatic cylinders, motors etc., through various pneumatic solenoid valves. The minimum

pressure of air required is 6 Bars. The non- availability of this pressure may lead to insufficient

strap tension and possible malfunctioning during the notching and strap cutting process. The

machine is fitted with a pressure switch, which automatically stops the machine as soon as the

pressure drops below 5 Bar. Each machine is provided with complete set pneumatic control

valves to operate the strapping head.

10. Compressor and drier:

 As the performance of the machine depends on the minimum pressure available and the

presently available pressure is 3 bar or less than 3 bar, we are recommending two numbers stand

alone dedicated compressors of 525 cfm-7 bar working pressure capacity along with a filter and

drier and receiver at LMMM. Each compressor can serve three fully automatic M410N - 114

power strapping machines.

The drier provided is of the refrigerated type. The advantage of this type'of a drier is that

there is no air loss involved during the drying process. The structure is very compact and the

drier maintains a constant dew point at all times.

The air filter is of the compressed air type. This filter is designed to remove solid

particles up to 5 microns and moisture and oil droplets. It incorporates a cleanable filtering media

of porous ceramic cylinders, complete with automatic drain tap. The ceramic media retains on its

surface the piping dirt and rust. The water and oil condense to drops while passing through the

pores of the filter media, which is periodically drained through automatic condensate discharge

valve. These filters are effective for air temperature of 45 deg. C.

!
!
!
 TECHINICAL SPECIFICATIONS
MACHINE OVER ALL DIMENSIONS (APX.):

HEIGHT : 4185MM

WIDTH : 1650MM

LENGTH : 8100MM

STRAPPING HEAD:

MODEL : M400N-114

MODE OF OPERATION : PNEUMATIC

STRAP FEET &TAKE UP RATE : 1500-2000 MM/SEC

STRAP TENSION : 20,000 N MAX.

JOINT TYPE : DOUBLE NOTCHED

SEAL MAGAZINE CAPACITY : 150 PIECES

SEAL TYPE : 114M (NESTACK)

SEAL APPLICATION : Automatic

Strap Details:

Type : Magnus grade painted & wax coated

Width : 31.75mm
Thickness : 0.89mm (min)

Material : IS -5872 GRADE-1

Zinc coating & corrosion : Is-9844

Resistance test.

Strap Dispenser

Model : DPAM1000

Mode : Electrical

Max strap coil wt : 500kg.

Ink jet printer

Lines of print : Two

Speed : 1.5m/s max

Ink type : MEK Dye based blank ink

Max no. of characters /min : 1000

Character height range : 1-11mm

Display : 4line x 40 character LCD display

Electrical Connections

Mains voltage : 415V, 3Ph, 50Hz

Control voltage : 24VDC

Power CONSUPTIONS : 9Kva Aprx.

Pneumatic Connections

Air pressure : min. 5 Bar; working pr=7bar

Air consumption : 120 CFM per Machine

Pipe connections : 2

Compressor & Drier

Dew point : const.5Deg.cat inlet temp of 40deg c

Free Air delivery : 495cfm

Motor rating : 75KW

Dimensions : As per the details enclosed

!
Man power required

One person (semi-skilled) would be required for all the five strapping Machine at LMMM, to

load strap coils on to dispenser and seal stack on the seal magazine as and when seal magazine

is exhausted and also one More person is reqd to enter the date to be printed on the printed key

board.
!
SEQUENCE OF OPERATIONS OF STRAPPING
MACHINE
!
!
!
Auto cycle steps

The sequence of the operation is as follows:

Carriage starts moving from Home position to Strap feed position in high speed.

When the carriage reaches the strap feed position speed change limit switch (L,S1 -4), the

carriage speed is changed to slow speed (through VFD).

When the carriage reaches the strap feed position (LS1 -5), carriage is stopped.

When the carriage reaches the strap feed position, bayonet starts closing(S13).

Once the bayonet is closed (PRX 7) , Face gate starts closing(S9) (only if it is in open

position).

When both bayonet and face gate are in closed position (PRX7 and RS2), fast strap

feeding takes place( S3 will ON).

Once the strap re-enters into the head and sensed by strap switch sensor (PRX1), strap

feeding shifts to slow feeding (both S3 and S5 will ON).

 Slow strap feeding time will be controlled by a timer in the program for required overlap

of strap..

Once the overlap time (in program) is completed, strap feeding stops.

After some delay, gripping takes place(S7), this action holds both edges of the strap along

with the signal( PRX 6) is ON, face gate opens (S8).

When the face gate open signal (RS1) is ON, then the carriage moves towards the bundle

in slow speed.

When the head at bundle limit switch (LS2) is ON, carriage movement stops.

Once the head reaches the bundle, fast strap take up (S2 and S4) takes place

During take up cycle, once the Do-Notch cut signal is either continuously ON or OFF for

2 sec, take up cycle ends and the high tension (S1 AND S10) cycle start. First S10 (Switch

tension) will ON and after a delay of500 milliseconds.

Tension time is controlled by a timer in PLC program( present tension time is 2 seconds).

Once the tension time is over, notch and cut (S6) operation takes place.

Once the notch cut OK signal ( PRX4) is ON, carriage starts to move in reverse to strap

feed positon.

During the same time strap take up is 0N for 2 seconds to straight the starp end and the air

blows (S11) will ON to clean the head.

 Once the carriage reaches the strap feed gate , face gate closes.

Bayonet opens (S12) will ON to open the bayonet.

Once the bayonet is opened( PRX8) , carriage reaches the home position speed change

limit switch(LS1 -3), the carriage speed changes to slow speed.

Once the carriage reaches the home position, carriage movement stops. And it gets ready

for next cycle.

!
Note: The strap is always applied on the circumference of the bundle.

!
STRAPPING MACHINE OVER BINDING MACHINE
Total Annual Cost in the case of Binding Machines

S.no Particulars Cost(Rs/-)

1 cost of wire : 630T *Rs 10,000 63,00,000.00
2 Cost of Picking and annealing : 630T 9,45,000.00

*Rs1500
3 Cost of contractual manpower / year 50,55,000.00

and, Cost of spares for maintaining

binding Machines and cost of labels / tags

4 Cost of straps ( Two straps / bundle) 70,00,000.00
TOTAL Rs.1,93,00,000.00
 !
TOTAL ANNUAL COST IN THE CASE OF STRAPPING MACHINES

S.no Particulars PRICE(Rs)

1 Total cost of straps /year 1,23,00,000.00
2 Total cost of Seals 18,00,000.00
3 Spares cost for maintenance 25,00,000.00
4 Printing ink 4,00,000.00
5 Contractual man power cost 3,00,000.00
TOTAL Rs.1,73,00,000.00

Additional intangible on account of charging to strapping machine = 1,93,00,000-1,73,00,000

=20,00,000/-

=Rs.20 Lakhs annually

Monetary benefits
Gain in production:

Production loss on account of non-availability of Binding machine.

= minimum 15 min/day

= 15x 24 min/month

= approx. 6 hours/ month

Considering only 500T/month

=6000T/year
 Contribution is Rs. 2000month

=6000xRs.2000

=Rs.1,20,00,000/-

Gain in mix up:

Out of total production of 9,00,000 approx 3000T are downgraded on account of mix up.

3000T x Rs.1000 = Rs. 30,00,000

Total tangible gain = 1,20,00,000 + 30,00,000

= Rs. 1,50,00,000

!
!
!
Intangible gain:

Good packing, generation of good will, products may command premium.

Gain every year = Rs. 150 Lakhs

Direct additional expenditure = Rs. 20 lakhs/year

Gain in one year = 150-20

= Rs. 130 lakhs.

Total investment = Rs.700 lakhs + (84*6) lakhs

 =Rs.1204 Lakhs.

Payback period = 1204/130 = 9.26

=9.26*12 (months)

= 111.12 months.

Total payback period is 111 months.

NEED FOR REPLACEMENT OF BINDING MACHINES

WITH STRAPPING MACHINES

!
Many complaints from customer regarding

1. Poor Packing

2. Looses ties

3. Breaking of ties

4. Missing of identification tags.

Difficulty in maintenance of existing machines.

1. Spares are generally important in nature.

2. The cycle time is more.

!
 !
CYCLE TIME:

Production [per year] :10,00,000TPA

Average bundle weight : 4000 Kg

No. of bundles/year[based on avgwt] :250000

No. of days of production per year : 325

No. of hours/day : 20

No. of bays :2

Hourly production/hour/bay : 19.2 bundles

Cycle time available per bundle in binding machine =187.2 seconds

Cycle time available per bundle in strapping machine =140 seconds

Therefore additional buffer time available is =187.2-140

=47.2

Therefore 25% of time is saved through strapping machine.

Hence the cycle time is reduced and the machines availability is increased,

For more production.

Reliability of straps is good over binding wire.