1. ACE Presentation

2. Associated Consulting Engineers
Consulting – Plant Engineering, project management
Technik – Start up and service support, diagnostic
Services – Retainer ship, training, documentation
Associated consulting Engineers, 21, Saibaba park New civil road, Valsad India

3. The Company
We are group of professionally qualified engineers with more than 9 decades of cumulative experience in industry
We are into providing engineering services and automation solutions for polymer compounding industry for the last 20 years
Authorized service partners for Krauss Maffei Berstorff, Elin motoren, (BKG Under Water Pelletizer, Kreyenborg group, Promixon mixer – currently not active)

4. Business Philosophy Quality- Tools & Training are our key investments
Commitment, Transparency & Integrity as basis of business
To deliver our collective skill & knowledge to our customer and society at large
Profit is a by product of hard work & essential to continued hard work
Compete with cooperation

5. ACE – Current Focus Consultancy – Technik
Selective projects in india
Strategic tie ups with European experts for services outside india. This is now in initial phase of joint approach to project.
Technik
Acquire More principles from Europe
Offer off site services
Focus on spares / sourcing
While maintaining focus on plastics, expand in
Related area like food & pharma
Develop generic capabilities – mechanical – alignment, precision repairs – gear box
Services – to continue more as sustaining measure to support of development of above plans
Retainership
Training / documentation

6. Business scope
Inspection, Overhaul & Repair of AC/DC motors & Gear boxes & other key up & downstream equipments for twin screw extruders
On site diagnostic services, inspection and installation of up and down stream equipments for compounding plant following proper SOP’s

7. Our workshop
Approx Sq ft floor area

9. Our service approach within 1 day
300 km
200 km
100 km

10. Instruments Make : SPX Powerteam Hydraulic puller
Model : PH103C & RPS1010
Capacity : 10T
Spread : 432mm
Stroke : 381mm
Pump capacity : 700 bar
Make : Enerpac Hydraulic cylinders & pumps
Model : RC-102 & P-392
Capacity : 5T, 10T
Pump capacity : 700 bar

11. Make : SKF vibration meter
Model : CMAS 100 SL
Velocity range: 0.7 to 65mm/s
Acceleration range: 0.2 to 50 gE
Temp range: -20 to 200°C
Make : Easy Laser shaft alignment tool
Model : XT-440
Shaft Diameter range: 20mm to 500mm
Accuracy: 0.001mm

12. Make : TPI Vibration analyser kit
Model : 9080 plus
Frequency range – 2 Hz to 1K Hz (ISO) 1 kHz to 10 kHz (BOU)
Max frequency resolution lines FFT setting
Measure – Acceleration in g Velocity in mm/s (or inch/s) Bearing noise in BOU (bearing damage units) Displacement (mm, microns, inch)
Smart trend meter with recording facility
VibTrend PC software

13. Make : Bosch Endoscope with image and video recording facility
Model : GOS 10.8 V-LI
Camera cable length = 1.2m
Display size = 2.7”
Make : Megger Insulation Tester 10KV
Model : MIT 1025
Digital display
Software generated report

14. Make : Easytherm Bearing Induction Heater
Model : 3.5
Diameter 15mm to 420mm
Max weight: 70 kg
Max temp: 240°C
Make : RSK Presicion level guage (accuracy 0.02mm /m)
Model :
Length : 150mm & 300mm

15. Make : Mitutoyo digital outside micrometer
Range: 0 to 300 mm
Make : Mitutoyo Bore guage with expansion rodes
Model : Series 511
Range: 18mm to 250mm
Length of measurement : 3m

16. Make : SKF Thermal camera Model : TKTI 10
Large colour display
Storage upto 1 GB data
Software generated report
with thermal & digital image
Make : Circutor System analyser Model : C-80
Measure in true RMS
Measurement of harmonic
distortion in current & voltage
Automatic data recording in internal
memory

17. Make : Allosun Electronic stethoscope
Model : EM410
Frequency range – 100 Hz to
10K Hz
Ambient noise permitted – 100 dB
Make : Lutron Digital anemometer Model : AM-4201
Accuracy – 99.9 %
Measure in m/s, km/h, ft/min
Data hold function

18. Model : High pressure pump
Capacity : 0 to 2000 bar

19. Diagnostic tools Vibration analysis (TPI)
Industrial endoscope with image recording (Bosch)
Thermal imaging (SKF)
Laser alignment tool (Easy Laser)
Bore measurement (Mitutoyo)
Insulation tester (Megger UK)
Oil analysis (out sourced)

20. Typical compounding plant

21. Feeders: Capabilities
We have wide experience with different type Loss-In-Weight feeders.
We have handled following type of feeders -
K-Tron : 100+
Brabender : 25+
Sonner : 10+
Schenck : 10+

22. Feeders: Services Sr No Services 1 Screw wear measurement 2
Load cell, Card, Cable Integrity check 3
Mechanical ( Gearbox & bearings)

23. Motors: Capabilities
We are handling following types of motor of rating 5 to 1500 KW -
Water cooled motor
Air cooled motor
Major motors that we have handled till now are of make -
Elin motoren
Siemens
Baumuller

24. Motor: Services Sr No Services Tools used 1 Vibration analysis
Vibration analyser kit (TPI – 9080 plus) 2
Bearing change
Hydraulic puller (Enerpac), induction heater 3
Water cooling jacket descaling
GWK descaling unit PGDU-200 4
Re-winding & Vacuum pressure impregnation 5
Insulation (IR) test
Megger MIT-1025 (UK) 6
Winding resistance measurement (low ohm resistance) 7
Shaft repair- surface rebuilding
ESAB consumables 8
Rotor balancing
Outsourced 9
Rotor cylindricity correction 10
Alignment with gear box
Laser alignment tool (Easy laser XT-440)

25. Example Elin motor
Tunnel boring machine motor complete overhaul with rewinding

26. Motor Inspection sample report

27. Motor IR test sample report

28. Laser alignment using easy laser alignment kit (XT-440)

29. Laser alignment sample report

30. Diagnostic package examples
Vibration analysis by TPI vibration analyser kit

31. Gear box thermal image by SKF thermal camera
Electrical parts thermal image by SKF thermal camera

32. Gear box: Capabilities
This is one of the major service we provide. We have attended following makes of gear boxes till now -
Siemens/ Flender
Zambello
SEW
PIV
Other German make

33. Gear Box: Services Sr No Services Tools used 1 Vibration analysis
Vibration analyser kit (TPI – 9080 plus) 2
Overhaul: Bearing, seals & gears replacement
Hydraulic puller (Enerpac), induction heater 3
Oil analysis
Outsourced 4
Thermography
SKF thermal camera 5
Shaft repair
ESAB consumables 6
Physical inspection
Endoscope (Bosch) 7
Gear measurement 8
Shaft balancing 9
Alignment with motor
Laser alignment tool (Easy laser XT-440)

34. Example Gear box overhaul
Make – German GB
Bearings & seals worn replaced
Replaced in 5 days

35. Example Gear box overhaul
Make – German GB
Problem: Bearings & seals worn
Replaced in 6 days

36. Barrel & Screw: Services
Sr No
Services
Tools used 1
Bore measurement of barrels
Mitutoyo Bore Guage 2
Barrel cooling channel descaling
GWK descaling unit PGDU-200 3
Screw wear measurement 4
Element wear out measurement 5
Control system for barrel cooling unit 6
Barrel liner replacement
Hydraulic press, Shrink fitting operation 7
Thermography to check hot spots
SKF thermal camera TKTI-10

37. Melt pump: Services Sr No Services Tools used 1
Cooling jacket Descaling
GWK descaling unit PGDU-200 2
GB overhaul
Typical as used eariler 3
Shaft, Bearings, Polymer channel bore measurement
Mitutoyo 4
Thermography
SKF Thermal camera TKTI-10

38. Screen Changer & PDV: Services (as required)
Sr No
Service
Tools used 1
Visual inspection for groove & scratches 2
Control syncing with extruder

39. Pelletizer: Services Sr No Service 1 Overhaul 2
Control syncing with extruder

40. Descaling of cooling channel
Why descaling??
Even when not blocked a relatively thin layer of scale or corrosion can act as an insulator and have a huge impact on the efficiency of your circuit
GWK make pump unit with online temp and pH measurement
Capable to remove all types of scales formed inside the cooling channels
Equipped with 4 way valve to reverse flow to ensure quick & complete removal of scales
Separate tanks for both chemical and water flushing
Drain tank for neutralize descalant and then dispose off

41. Descaling process flow
Flushing system with DM water
Add descaling agent till pH goes below 1
Circulate Descaling agent till the pH is constant about 2
Reverse the flow of the descaling agent
Add Neutralising agent till the pH is above 12
Circulate neutralising agent for 2 hours

42. Descaling sample report

43. Thermography Instrument – SKF TKTI 10
The SKF TKTI 10 is a digital camera with advanced thermal imaging capabilities. It is ideal for use as a Predictive Maintenance (PdM) tool. Thermography is a non-invasive technique and is well suited for mechanical and electrical inspections, energy conservation and plant safety activities.

44. Thermography applications:
It has a large backlight 3 ½” colour screen which gives clear & sharp resolution.
Special features –
It is designed for easy operation
Temperature range : -10 deg C to +350 deg C
Multiple temperature measurement
Difference between temperature measured
20° x 20° field of view and 47 x 47 pixel detector
Image storage : radiometric data & digital image
Thermography applications:
Overheated connections for high & low voltage installations, cable insulation
Mechanical issues like hot bearings, overheated motors
Mould inspection

45. Thermography sample report

46. IT enabled services ( proposed) Mobile application , external to customer ERP,
Customer interface
Service call login , status update, time sheet , report, critical data logging like vibration enabled.
Service engineer
Calender with Schedule appointment, movement,
Support data base
Additional support like manuals, technical details
ACE data base Customer / Equipment
Updated history cards and repairs log with spares
ACE Control Room
Assigning jobs, movement support , logistics and hotel, tools

47. Services - Looking only for high end services – if and when required .
Now have place to offer shop services.
Ready to invest in tools and training as required.
Can work as front end – make all preparation at site for KMB technician to take over – possibility of a overall saving in time
A joint services has potential of addressing cost sensitive Indian market for services – quote possible that most European share in services in India is disproportionately low compared to population of equipment.
Can actively assist in spares sourcing in India
Can also support in ME / Iran / Far east when required.

48. ACE focus on services Mechanical
Twin screw gear box
Kneader gear box
Specialised mixers
De scaling barrels / jackets/ moulds
Laser alignment
Thermography
Electrical ( partly with strategic tie ups)
AMC for control system – PLC / FC
Feeders ( Loss in weight systems)

49. Approach & Schedule
Form a new company with majority shareholding by Kaushik – 3 /4 quarter – mostly closely held private limited liability company.
Actively search for European partner – This will accelerate growth in multiple ways
Creditability in india and Europe
Acquiring more principles
Additional fund to accelerate tools acquisition
Add staff & train Adequate for present

50. Our team Mr. Kaushik D Naik Mr. Bharat D Patel
Proprietor of the company
ME (Prod.) GDMM, DBM
Chartered Engineer
Mr. Bharat D Patel
Senior associates
Mechanical

51. Mr. Ankit B Fruitwala Mr. Nitant R Vyas Mr. Manish N Patel
Project & Service engineer (Electrical & Instrumentation)
BE Electrical
Mr. Nitant R Vyas
Project & Service engineer (Mechanical)
BE Mechanical
Mr. Manish N Patel
D’man Mechanical

52. Thank you for your attention