costix automation engineering company profile
TRANSCRIPT
Global service, sourcing, and manufacturing. Industry-leading engineers.
Value-added assemblies and solutions. Designed to required specifications.
A one-stop, full-service, globally competitive supplier... ……….Costix
COSTIX ENGINEERING Pvt Ltd
ELECTRICAL AND INDUSTRIAL AUTOMATION ENGINEERS
SOUTH AFRICAN HEAD OFFICES A INDUSTRIAL 90 ALBATROSS DRIVE FOURWAYS JOHANNESBURG, SOUTH AFRICA
Call Thando@+27836273321Tel. +27 11 705 1231 Fax +27 11 705 1231
VISIONVISION
To provide total exhibition of industrial technology envisaged in one innovative and confident engineering company driven by a true passion to provide intelligent factory answers
MISSIONMISSIONCostix Engineering intent to deliver comprehensive solutions and services to the manufacturing industries, cotton ginneries, plastic manufacturers, foodservice, food and beverage processing,
hospitality, healthcare, government and education, retail, textile care, commercial facilities, and automotive industries.
BUSINESS OPERATIONSBUSINESS OPERATIONSCostix Engineering is committed to assisting customers country wide with their unique needs by providing them with comprehensive, value-added solutions and professional personal service. With more experienced sales-and service experts, Costix Engineering employs the industry's largest and best-trained direct sales-and-service force, which advises and assists customers in meeting a full range of manufacturing and processing service needs.
Costix Engineering Head Offices are located South Africa and trade as SA Industrial, headed by local Zimbabwean Entrepreneurs. Costix Engineering has roots in Harare and an operational branch in South Africa .In the quest to provide quality service to the industrial world, Costix aspires to spread it’s wings in the southern region. Costix Engineering has several divisions namely:
Industrial Automation and Control Engineering Division Sales and Marketing Division Energy Management Division Electronics Repairs and Services Division Electro-Mechanical Engineering Division
We believe in constant refinement of our quality service to our valued customers with exhilaration to be better in technological advancement on the global village.
As an overview the Industrial Automation and Control Engineering offers services and projects in the field of PLC programming , Drive servicing and installations, Process Controllers servicing , sensors and Actuators. The Sales and Marketing Division does the daily marketing services offered by all divisions. The Energy Management Division offers services in Energy Auditing, designing Energy Management System and installation of Energy Controllers. The Electronics Repairs and Services Division is responsible for repairing of all control cards, power supply units and drives. The Electro-Mechanical Engineering Division does plant maintenance and machine overhaul for furnaces, injection molders, bailing machines, hydraulic machines, pneumatics and projects.
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INTRODUCTION
Costix Engineers in the field of Process Control are capable designing different control system to customize for your industrial application for example:
Temperature control e.g. furnaces and boilers Pressure control system e.g. for boilers and furnaces Humidity and moisture control system e.g. in Cotton Ginning
Some of our services include the following:
o PLC programming and servicingo Drive installation , programming, repairs and servicingo System Integrationo Service contractso SCADA softwareo Instrument Calibration and servicingo Thermographyo Panel boards
Costix engineering solutions are suitable for a wide array of basic and complex applications; our custom engineered solutions offer enhanced precision, repeatability, and ruggedness. We offer domain knowledge and technology resources, along with a close working relationship, to develop and deliver cost-effective, individually tailored solutions. Whether clean slate development or simple modifications to an existing design are needed, our expertly engineered solutions help to meet the most stringent requirements with world class product designs, technology integration, and customer-specific manufacturing.
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INDUSTRIAL AUTOMATION AND CONTROL ENGINEERINGINDUSTRIAL AUTOMATION AND CONTROL ENGINEERING
We have a well equipped electronics workshop which specializes in repairs of the following:
o Calibrationo control cardso power supply unitso Variable Speed Drives of any modelo electronic cardso electrical machineso Industrial troubleshooting including Root-Cause-Analysis. o We also focus on designing electronic circuits to suit your application.
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Installation of Variable Speed Drive
ELECTRONICS REPAIRS WORKSHOP
Industrial Automation is the automatic processes done by machines with minimum to no human
interference. As the name indicates, it is not a full control system, but rather focuses on the supervisory
level. As such it is a purely software package that is positioned on top of hardware to which it is
interfaced, via PLCs. The system collects data from various sensors in the plant and then sends this data
to a central computer that then manages and controls the data. The plant control logic resides in the PLC
and it does all the logic decisions.
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INDUSTRIAL AUTOMATIONAUTOMATION SYSTEM AND GENERAL CONTROL ENGINEERING
Insert are pictures of Costix Automation Engineers designing a SCADA System for advanced computerized production system at a local manufacturing plant. Costix Engineers are capable coming up with customized product to suit your plant.
Our Service Engineers are capable of performing Root-Cause-Analysis on all complex control systems. At Costix Engineering we believe every processing plant can easily be optimized for better performance and increased rate of production.
PROGRAMMED SCADA INTERFACE
Service Engineer performing Maintenance on a Drive
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A cotton gin’s profit depends on the number of bales it can produce per week. Moisture control increases this number and protects fiber
quality at the same time
Cotton gins benefit from fiber moisture control by producing more bales per week of a higher quality and turnout than is possible without it.
When a cotton gin can increase the number of bales it gins in a given week, the revenue generated by “extra” bales shows up as profit, after recurring expenses like bagging and ties are deducted. For this reason, gins must concentrate on production for their economic survival. The number one problem in maintaining consistent production in a cotton gin is the weather and the unpredictable conditions that result from it. A powerful drying system that responds quickly to changing cotton conditions is a key tool in compensating for unpredictable cotton. If the system is slow to respond to fast changing conditions, chokes occur and downtime from clearing chokes limits gin profit. Ginners know this and, too often, the solution is to operate with high temperatures to compensate for unpredictable conditions. This harms staple, strength, and other fiber properties for the ginneries, and increases the drying fuel expense for the gin. No one profits when this strategy is used to maintain production.
Costix Engineering has some of the world’s most experienced Service Engineers trained by Samuel Jackson the manufacturers of Humidaire (Burner) Units.
Costix Engineers had been servicing Burner units for the past decade and all projects were focused on improving the moisture
content within the gin stands and in the bale.
COTTON GINNINGCOTTON GINNING
There are a lot of technical explanations for why drying in a cotton gin matters, but it all comes down to one thing, Money . Careful investing in your gin’s drying system can yield huge returns for you and
people you do business with. Money for the gin. A powerful drying system allows a gin to maintain higher production rates in challenging cotton. Consistent bales per week are the surest path to a profitable season and a solid drying system is needed to get you there. But drying isn’t all about muscle, it’s also about energy efficiency. A well-planned drying system that adjusts based on the needs of the incoming cotton can not only keep up production, but can also offer substantial fuel and electrical savings.
Costix Engineers………………………the moisture people
Samuel Jackson Certified Engineers
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MOISTURE RESTORATION IN THE BALE AND WITHIN THE GIN STANDS
PREVENTATIVE MAINTENANCE
Costix Automation is a solution oriented company focused in applying the following technologies;
Infrared Thermography Oil Analysis Vibration Analysis Laser Alignment
Whilst these technologies have traditionally been used in Condition Based Maintenance, Security, and Equipment Protection, and form Costix Automation’s core business, we are also actively pursuing applications in Quality Assurance and Process Automation.
We believe that by carefully choosing and aligning our company with leading global companies, we are able to contribute and offer unmatched value-based solutions within the Sub-Sahara Africa region. We have a relentless pursuit of distinguished performance that results in repeat business and customer referrals.
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RELIABILITY PLANT MAINTENANCE MANAGEMENTRELIABILITY PLANT MAINTENANCE MANAGEMENT
Costix Service Technician configuring a weigh-feeder at one of the local process plants, this is one of the preventative maintenance we are capable of doing for your organization.
Costix Service Engineer commissioning a VersaMax PLC which has more than 1012 signals at a local manufacturing plant. Our Service Engineers are capable installing, commissioning and servicing any model of PLC such as Siemens, Omron, VersaMax and Logic Direct to name but a few.
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The Alpha range of cast iron self priming water pumps rank among the best in the world in terms of reliability performance and price. Manufactured in Europe and sold in Zimbabwe for many years. They are supplied in standard Monoblock or Bare shaft options and are renowned for their excellent self priming and solids handling capabilities.
The Ebara are one of the largest and most respected water pump manufacturers in the world. We at Costix Engineering carry in stock their range of monoblock water pumps and dewatering water pumps in cast iron and stainless steel construction.
The CM range of centrifugal Ebara water pumps starts from 0.37kW upwards and are available in 220v/1 (where applicable) and 380v/3 phase supply.
The PRA range of peripheral water pumps are available from 0.37kW to 1.5kW and are useful when water flows required are small but with high pressure. For example a Boiler feed application.
The AGA range of Jet water pumps range between 0.75kW to 2.2kW and have excellent self priming qualities.
The CDA ranges are two stage twin impeller water pumps and are suitable for high pressure with lower flows.
Foras have been manufacturing water pumps in the heart of the world’s water pump industry for more than 20 years. The Foras MN range of water pumps is manufactured according to the EN 733 standard (former DIN 24255).
The MN range of water pumps have flanged connections varying from suctions of 50mm to 65 and 80mm. The MN range of flanged water pumps come in sizes ranging from 2.2kW to 22kW.
They are used on agricultural, industrial and domestic applications. The Foras MN range is successfully used on pressure boosting applications too. In addition to the MN water pump range we also stock the Foras Plus Vertical Multistage pumps.
The Foras Plus Vertical Multistage range comes in 1.5.kW, 2.2kW, 3.0kW, 3.3kW and 4kW. These water pumps have steep performance curves making them excellent pumps for pressure boosting and installations with large fluctuations in pressure demand.
PUMPSPUMPS
Three years ago when Costix Engineering introduced these fine Italian submersible water pumps we knew that they would be a resounding success. We have a large stock holding of the popular Leader submersible pumps for dewatering.
PondThe Leader Superpond submersible pump range is available in two motor sizes 0.28-0.75kW. This pond pump is made out of plastic and comes with a 10m cable. The Superpond is able to pump vertically or horizontally (lie flat in pond), it has an adjustable filter for solids handling.
Dewatering, Drainage and emptyingThe Leader Ecosub and Supersub dewatering, drainage and emptying (clean water) range has three versions, the Supersub 450A, Supersub 460A and Supersub460 HP. Each pump is automatic, fitted with a float switch and 10m cable.
The Leader Vertigo 300 is another great little submersible water pump for drainage. It has an automatic or manual control. The Vertigo 300 is a compact pump (20cm X 20cm) able to operate is confined holes
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WATER PUMPSWATER PUMPS
as the float switch is encased within the pump. The Vertigo 300 is a 0.3kW pump and is capable of draining down to very low levels (2mm- on manual and 10mm on automatic)
Dirty Water PumpThe Leader Ecovort and Leader BVP Submersible Dirty Water Pumps are specifically designed for dewatering, drainage and emptying of dirty water. The Ecovort (0.75kW) has a vortex impeller which enables pumping of suspended particles up to 30mm in diameter. The BVP submersible water pump is specifically designed for heavier duty, higher heads, and larger flows. The Leader BVP (1kW) is reliably used in many dirty water dewatering, drainage and emptying applications. The Leader BVP has solids handling abilities of up to 50mm max particle size diameter.
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PNEUMATICS
Pneumatics is that branch of technology, which deals with the study and application of use of pressurized gas to affect mechanical motion. Costix Engineers has a specialized branch which deals with pneumatic systems. Our Technicians under the guidance of well experienced Service Technicians are capable of designing, maintenance and service any pneumatic circuit and compressors.
Pneumatic power is used in industry, where factory machines are commonly plumbed for compressed air; other compressed inert gases can also be used. Pneumatics also has applications in processing plants, plastic industry, construction, mining, and other areas.
Many modern installations in automated process control applications require the use of electronic controllers to provide electrical signal to position the final control element in the proportionate manner. In the closed loop system the positioner is usually located in between controller and final control element. Generally the final control element is normally a pneumatically driven power device e.g. control valve
Both pneumatics and hydraulics are applications of fluid power. Pneumatics uses an easily compressible gas such as air or a suitable pure gas, while Hydraulics uses relatively incompressible liquid media such as oil. Most industrial pneumatic applications use pressures of about 80 to 100 pounds per square inch (550 to 690 KPa). Hydraulics applications commonly use from 1,000 to 5,000 psi (6.9 to 34 MPa), but specialized applications may exceed 10,000 psi (69 MPa).
Advantages of pneumatics
Simplicity of Design And Control
o Machines are easily designed using standard cylinders & other components. Control is as easy as it is simple ON - OFF type control.
Reliability
o Pneumatic systems tend to have long operating lives and require very little maintenance.
o Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of
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We supply hydraulic fittings, valves and pumps .Costix Service Engineers and Technicians are experienced in designing hydraulic circuits that will suit your industrial application. The service team is also capable of setting hydraulic system on Cotton Ginning Power Packs and Baling Machines for scrape metal.
The basic idea behind any hydraulic system is very simple: Force that is applied at one point is transmitted to another point using an incompressible fluid. The fluid is almost always an oil of some sort. The force is almost always multiplied in the process. The picture below shows the simplest possible hydraulic system.
Advantages of hydraulics
Liquid (as a gas is also a 'fluid') does not absorb any of the supplied energy.
Capable of moving much higher loads and providing much higher forces due to the incompressibility.
The hydraulic working fluid is basically incompressible, leading to a minimum of spring action. When hydraulic fluid flow is stopped, the slightest motion of the load releases the pressure on the load; there is no need to "bleed off" pressurized air to release the pressure on the load.
Hydraulic logic is a reliable and functional control method for industrial processes. In recent years, these systems have largely been replaced by electrical control systems, due to the smaller size and lower cost of electrical components. Hydraulic devices are still used in processes where fluid is the only energy source available or upgrade cost, safety, and other considerations outweigh the advantage of modern digital control.
A hydraulic or hydrostatic drive system or hydraulic power transmission is a drive or transmission system that uses hydraulic fluid under pressure to drive machinery. The term hydrostatic refers to the transfer of energy from flow
HYDRAULICS
Pneumatics is that branch of technology, which deals with the study and application of use of pressurized gas to affect mechanical motion. Costix Engineers has a specialized branch which deals with pneumatic systems. Our Technicians under the guidance of well experienced Service Technicians are capable of designing, maintenance and service any pneumatic circuit and compressors.
Pneumatic power is used in industry, where factory machines are commonly plumbed for compressed air; other compressed inert gases can also be used. Pneumatics also has applications in processing plants, plastic industry, construction, mining, and other areas.
Many modern installations in automated process control applications require the use of electronic controllers to provide electrical signal to position the final control element in the proportionate manner. In the closed loop system the positioner is usually located in between controller and final control element. Generally the final control element is normally a pneumatically driven power device e.g. control valve
Both pneumatics and hydraulics are applications of fluid power. Pneumatics uses an easily compressible gas such as air or a suitable pure gas, while Hydraulics uses relatively incompressible liquid media such as oil. Most industrial pneumatic applications use pressures of about 80 to 100 pounds per square inch (550 to 690 KPa). Hydraulics applications commonly use from 1,000 to 5,000 psi (6.9 to 34 MPa), but specialized applications may exceed 10,000 psi (69 MPa).
Advantages of pneumatics
Simplicity of Design And Control
o Machines are easily designed using standard cylinders & other components. Control is as easy as it is simple ON - OFF type control.
Reliability
o Pneumatic systems tend to have long operating lives and require very little maintenance.
o Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of
In the field of process automation, Costix Engineering offers an extensive range of weighing products. In today‘s competitive environment, reliable, accurate, and dependable weighing and feeding equipment from Costix Engineering helps your profitability. Whether your application is crushed stone, ore, cement, coal, food processing, or chemicals, you can profit from our field-proven conveyor belt scales, weigh-feeders, solids flow-meters, and integrators. Standard and custom models are available to suit your requirements. Our products are rugged – built for tough operating conditions in the aggregate, cement, and mining industries.
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We supply hydraulic fittings, valves and pumps .Costix Service Engineers and Technicians are experienced in designing hydraulic circuits that will suit your industrial application. The service team is also capable of setting hydraulic system on Cotton Ginning Power Packs and Baling Machines for scrape metal.
The basic idea behind any hydraulic system is very simple: Force that is applied at one point is transmitted to another point using an incompressible fluid. The fluid is almost always an oil of some sort. The force is almost always multiplied in the process. The picture below shows the simplest possible hydraulic system.
Advantages of hydraulics
Liquid (as a gas is also a 'fluid') does not absorb any of the supplied energy.
Capable of moving much higher loads and providing much higher forces due to the incompressibility.
The hydraulic working fluid is basically incompressible, leading to a minimum of spring action. When hydraulic fluid flow is stopped, the slightest motion of the load releases the pressure on the load; there is no need to "bleed off" pressurized air to release the pressure on the load.
Hydraulic logic is a reliable and functional control method for industrial processes. In recent years, these systems have largely been replaced by electrical control systems, due to the smaller size and lower cost of electrical components. Hydraulic devices are still used in processes where fluid is the only energy source available or upgrade cost, safety, and other considerations outweigh the advantage of modern digital control.
A hydraulic or hydrostatic drive system or hydraulic power transmission is a drive or transmission system that uses hydraulic fluid under pressure to drive machinery. The term hydrostatic refers to the transfer of energy from flow
PROCESS WEIGHINGPROCESS WEIGHING
Our continuous process weighing systems are easy to install and to maintain, and expert technical support is there when you need it.
Choosing the best belt scale for your application depends on the type of material weighed, conveyor design, rate range, space limitations, and accuracy required. All Costix Engineering belt scales require very little maintenance and are fast and easy to install and calibrate. They have no moving parts, include corrosion-resistant load cells, and are designed for 150% of rated capacity and 300% of ultimate load cell capacity. Siemens representatives are with you every step of the way to ensure the best fit for your application.
Whilst our historically low electricity price has contributed towards a competitive position, it has also meant that there has been little incentive to save electricity. At the same time consumers of energy also need to perceive the cost-benefits they can derive from energy efficiency measures and it is here that demonstrations are essential. The cost of Energy Bills from ZESA had just increased and this had negative impact on production cost. Costix Energy Experts are capable deriving methods of reducing energy consumption at your organization thereby reducing the Energy Cost.
Costix Energy Experts follow the following necessary steps to reduce the energy consumption:
Assessment and Gap Analysis Energy Audit Energy Management System Policy Implementation of Energy Controllers
The Industrial and Mining Sectors are the heaviest users of energy, accounting for more than two-thirds of our national electricity usage. Here lies the potential for the largest savings by replacing old technologies with new, and by employing best energy management practices.
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ENERGY MANAGEMENT SOLLUTIONSCostix Energy Division is led by the Energy Expert Mr. E. Mungofa ( B. Eng. Renewable Energy, Msc Renewable Energy-UZ). Mr. Mungofa managed to lead a Team of Energy Experts on several successful projects across the country. The Energy Team also comprises of Mechatronics and Fuel Technology Engineers who has in-depth knowledge of Energy Management Systems.
In Zimbabwe we take energy for granted, with the consequence that our energy consumption is higher than it should be. Indeed, our country’s economy is largely based on minerals extraction and processing which is by its nature very energy intensive.
Perhaps the most neglected area for implementation is the promotion of public awareness about the costs and benefits of energy efficiency. Major energy savings can only be achieved through changes in people’s behavior, and that depends on informing them about what options exist.This Energy Saving Strategy by Costix Engineers allows for the immediate implementation of low-cost and no-cost interventions, as well as those higher-cost measures with short payback periods. These will be followed by medium-term and longer-term investment opportunities in energy efficiency. The Strategy acknowledges that there exists significant potential for energy efficiency improvements across all sectors of our national economy.
Energy efficiency projects can result in numerous benefits. By using energy more efficiently an organization. Vulnerability to energy prices is reduced, while its cost effectiveness is improved, and the environmental impacts of electricity production are avoided. Frequently entities must choose between investing in energy efficiency or energy supply. There are numerous issues surrounding these decisions.
Why spending much of your profits on paying electricity bills when you can prevent it…………….call Costix
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