Transformer manufacturers are well aware that the domestic and export market has turned highly competitive. Customers want the best at the lowest possible cost. And you as a company know that quality cannot be compromised. The transformer casting process is an area where challenges have existed for long. The casting process, for transformer manufacturers, is a key cost center and also holds the key to the quality of products.
You know that the casting process has to be done with complete precision and accuracy. Whether it’s weighing the materials, maintaining exact temperature control or ensuring the accuracy of the mixing ratios, each step in the casting process demands a specific requirement.
With this, the casting process is prone to several challenges including material wastage, poor process control, sub-optimal productivity and more. While automation of the casting process is the go-to-solution, the initial investments and operational costs of the current solutions could be highly prohibitive.
The Challenge Today
Typically, the current method for large-scale manufacturing of Transformer uses a “fixed” setup for the material preparation and casting process. This often involves separate and fixed stations where resin and hardener are prepared and mixed to be carried using fixed pipes until the clamping stations. One of the reasons for high initial investment is due to the higher complexity of the fixed set-up which requires the piping and material handling, preparation, mixing and dispensing/casting stations to be laid out in a very specific manner for efficient operations.
The use of fixed stations and pipelines to transfer materials lead to several disadvantages:
- High upfront investment owing to design complexities, equipment costs, and a layout that demands more space
- Very high installation costs due to a long drawn out process of installation, and commissioning efforts, often running into months
- Severe limitations on modification of the layout
- Relatively higher cost of cleaning and maintenance owing to the fixed design
- Much higher operational costs due to the need to continuously run the process as necessitated by its design
While the fixed layout has its benefits, clearly, there is huge room for improvement to reduce the investments and operational costs.
The Innovative Solution
We have come up with a simple solution. Our Epoxy casting plant can be used successfully in the manufacturing of Open Cast components or can be easily attached to clamping stations in the APG (Automatic Pressure Gelation). Our innovative, portable system for APG helps companies achieve efficiency using optimised process economics. With this system, preparation and dispensing processes can be performed simultaneously and also independent of each other. There is no need to run the entire plant continuously. This is a plug-to-use system, is movable and can be operated by a single, skilled operator.
It has a Hopper sieve to collect the pre-heated silica and a magnetic vibratory separator that removes the metallic and foreign particles from the fillers. Its screw conveyor carries the fine particles to the resin and the hardener tank separately. It has an intake data display that is displayed on the HMI which maintains all the production data record and is logged in for all future references. The portable meter mix dosing system is mounted on a portable trolley that can be easily moved between the clamping stations. The shrinkage compensation cylinder in the system ensures that there is no material loss inside the mould by providing the necessary gelation pressure.
Some of the most complex problems sometimes have the simplest of solutions. Our solution has a small footprint and makes sure that our clients are able to create high-quality products that meet global standards. It offers them the flexibility they need because of the system’s portable nature and also gives them the benefits of a low operational cost and yet high-quality set-up.
Our solutions are designed in Germany and manufactured in India using the best quality products and have been used by customers across 15 countries to improve the productivity, quality, and cost-effectiveness of their mixing and dispensing process.
Connect with us at firstname.lastname@example.org – we may have a similarly innovative solution for you too!
The use of Composite pipes in oil and gas, water treatment – especially for treatment of seawater has been growing rapidly over the last decade. It is estimated that corrosion of metal piping itself costs approximately $20 billion each year. As composite pipes get ready to take a bigger role, Twin’s mixing and dispensing technology is used by the world’s leading players to manufacture composite pipes up to 1000 mm. in diameter.
Composite pipes demand very unique requirements – from high dispensing volumes ranging up to 500 Kg/shift, highly accurate mixing ratios to smart machine layout for high productivity and ease of maintenance. Twin’s machines, particularly, have enabled material savings (ranging in excess of 30%) for composite pipe manufacturers. As a partner to some of the world’s leading composite pipe manufacturers, Twin’s machines have enabled several new possibilities.
Deep process insights, like never before
With advanced data logging, Twin’s machines have enabled previously unavailable process insights for manufactures. Considering the high costs of materials, the production managers are now able to accurately track material costs and productivity per unit of the pipe. More importantly, the manufacturers are able to establish co-relations and often improve the mixing and dispensing efficiency by a multi-fold.
Complex processes and productivity goals achieved with modular and flexible layouts
Seamless integration of the mixing and dispensing machine into the production line layout has a lasting impact on product quality and profitability. With a modular and flexible machine design, Twin has offered smart customised layouts for dispensing. Often, this means an integrated system that takes automates transferring the materials to be mixed from bulk containers, carrying the mixed materials over long distances without affecting its flow and properties and ensuring efficiency in dispensing using advanced automation. Leveraging these and other innovations, Twin’s machines are redefining the productivity benchmarks in composite pipe manufacturing.
Instant support for global customers
Quick support is critical, especially in high volume production environments. With an innovative mobile App, Twin puts the power to seek support and provide feedback to the first point of contact – the Operator of the machine. The mobile App enables the Operator to instantly connect with Twin’s support team and track the progress of resolution of his/her query in run-time. The App takes away the geographical distance with the Twin’s team while ensuring no delay, whatsoever on the time to respond.
Twin’s Adhesive Pumps are the preferred choice for 7 of the top 10 Laminator Manufacturers in India and some of the leading packaging companies around the world. Twin Engineers offers advanced Pumps for dispensing of Mono-component and 2K Adhesives in solventless lamination packaging.
Twin’s Intelligent Pump for solventless packaging features next-generation meter mix system with highly advanced automation in 2k adhesive dispensing. Equipped with several intelligent features, the 2K Pump helps to improve productivity while delivering consistent quality. Customers using Intelligent Pump have experienced a seamless process in mixing and dispensing that requires almost no human intervention.
Twin’s newly designed mono-component pump is suitable for lamination of Paper to Polyester and Paper to Metalised Foil Lamination. The Mono-component Pump is an ideal choice for accurate dispensing of single part adhesive that is used in case of Paper and Polyester (LDE).
Both the Pumps feature industry’s most advanced technology and come with an unmatched warranty, near-zero maintenance, and long operational life. The Pumps also feature remote diagnostics facility, a mobile app for operators and videos of key maintenance procedures accessible through the HMI. Trusted by the world’s largest Laminator manufacturers and packaging units, the dispensing Pumps are trendsetters in the industry.
One of the major highlights at the Twin Engineer’s booth at CWIEME is the newly upgraded Combo System for electrical casting based on the Intellomix platform. It has never been so easier to quickly start your casting process. This innovative machine combines silica preparation, transfer, mixing and dispensing into a single unit and does not require any manual intervention in the process. With an option for seamless integration for APG clamping stations or Vacuum Chambers, the Intellomix Combo Systems can be used for the large-scale production of CT/PTs, Instrument Transformers, Dry Type Transformers to reduce throughput time and improve productivity.
For void-free casting of components that require relatively higher volumes and vacuum casting, Twin Engineers offers a new machine aided with automated dispensing and a range of vacuum chambers, as per the size of the components to be cast. These advanced Intellomix Combo Machines, one of Twin’s innovations, ensure seamless integration of all the processes in casting, enabling higher volumes, better quality and lower wastage of material in production.
With an expanded range of vacuum chambers, the systems can now cater to components of multiple sizes, requiring casting mix of 3 Kg to 30 Kg per piece. The high-quality and low-maintenance vacuum chambers designed by Twin are very easy to operate with dispensing conveniently controlled via a joystick-based system. On request, tackles and trays can be made available for automated loading and unloading of components into the vacuum chamber.
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