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“Customised Solutions” is our Forte
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Introduction
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80,000 Sq.Ft. of Manufacturing space, Centrally Air-Conditioned Tool Room
Complete set up of Design, Manufacturing and Testing facilities under one roof meeting global standards
Designed and Manufactured over 2000 high precision 101 class moulds
Capable of handling multiple clients simultaneously in seam less manner
A Dayanand Reddy
About Founder & MD
Vasantha Tool Crafts, is the brain child of Technocrat Founder & Managing Director A Dayanand Reddy, a post graduate Mechanical engineer in Tool Design & Manufacturing has rich design and Manufacturing experience Recognitions: Outstanding new generation entrepreneur -- Indian Plastic Institute (IPI) Special contribution award towards tooling development– Salcomp. India Manufacturing Excellence Awards - Silver Certificate for the year 2015 Recognition from Plasticon in excellence for Innovative Dies & Moulds year 2015 Firsts First to set up state of the art ultra modern robotic cell in entire South East Asia First in India to build Turn Table Rotary Mould and Cube Moulds First in India to have Direct Metal Laser Sintering technology in house for Conformal
Cooling
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Major Milestones
1989 Established
1992 First Un Screwing
Mould
2002 Fully Hot Runner Mould
& Moulding Facilities started
2010 First Bi
Injection Mould
2012 Set up of
Fully Automated Machining
Cell
2013 First Stack Mould &
Rotary Bi-injection
Mould
2014 First Cube
Mould 2014
In House Laser
Sintering (DMLS) &
Vacuum heat treatment
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Business Statistics FMCG 70.0%
Electrical & Engineering
10.0%
Health Care 5.0%
Others 15.0%
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12 14
16 19
21
0
5
10
15
20
25
2011-12 2012-13 2013-14 2014-15 2015-16
AVERAGE SALES GROWTH OF 15% YOY LAST FIVE YEARS MORE THAN 50 % OF EXPORTS SHARE
IN USD Millions
Tools
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Personal & Beauty Care, 956
Home Care 350
Food
& Beverage
250
Health Care
190
Others 500
Personal & Beauty Care Home Care Food & Beverage Health Care Others
Total – 2246 Moulds Nos.
Sr.No. Description Qty.
1 Total Tools 2246
2 Total Cavitation 35000
3 Hot Runner Moulds 1200
4 Bi – Colour Moulds 35
5 Stack moulds 06
6 Unscrewing moulds 450
7 Flip top cap moulds without IMC 185
8 Flip top cap moulds with IMC 120
Cavitation 96 128 144 64+64
No of Moulds
13 06 01 02
High Cavitation moulds Description Cavity
Nos Cycle time
Sec
Bi colour 32 14
Unscrewing 144 07
Flip top with IMC 96 12
Stack 64+64 07
High Cavitation faster cycle time moulds
High Lights
Services and Capabilities
Services
Mould Design
Mould Flow Analysis
Prototyping
Mould Manufacturing
Project Management
Capabilities Flip top cap moulds
– Vertical and Horizontal In Mould Closing Unscrewing Moulds
– Hydro motor – Rack & Pinion – Servo Drive
Bi Colour / Two Shot Injection Moulds – Punch Back – Over Moulding – Rotary – Cube
Stack Moulds Spray Through Cap and Dispenser Moulds Mould Testing and Qualification Direct Metal Laser Sintering for Conformal
Cooling channels in Metal Inserts 7
Design & Engineering
A Well equipped and established design & engineering department
Infrastructure to support designing of 300 Moulds 6000 Stacks annually
25 Work Stations , 10 ~ 15 Years Experienced designers Design for Manufacturability (DFM) – Value addition in terms of Product Design
CAD / CAM
• Pro-Engineer • UniGraphics
• AutoCAD
• Mould flow Analysis software
• MoldEx Mould Flow Software
• DelCam
• IGES (Surface & Wireframe)
• STEP
• DXF
• Para solid
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Manufacturing facility – High end CNC machines to support high precision and high speed machining needs 18 CNC Milling- 4 High Speed CNC + 14 CNC 15 CNC EDMs 4 wire EDMs 45 Conventional Machines In house grinding and polishing facility EROWA Holders
Integration by Chameleon Handling Systems - Robotic Cell 2 Yasda High Speed Milling 1 Makino V55 Graphite Milling 2 Zimmer & Kriem Sparking 1 Zeiss CMM Transclean
Advantages: Minimum Human Involvement, Precision Machining, High Productivity, Consistency & Repeatability, cavity to cavity and mould to mould Interchangeability
Manufacturing
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Quality Assurance
State of the Art Metrology Equipment: Host of Standard Quality Equipment with software Minitab for generating CP and CPK reports 7 CMMs of various measuring ranges, and an Optical Inspect CMM for inspecting critical plastic parts all of them
from Zeiss Max. Measuring Range of 1000mmx1200mmx600mm Accuracy of (1.9+L/300) µm Min. Measuring Range of 500mmx500mmx500mm
Accuracy of (2.4+L/300) µm O–Inspect Measuring Range 400 mm x 400mm x 200mm Accuracy (1.7+L /250) µm
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High-end design capabilities Design for manufacturability (DFM) –Value addition in terms of product design, optimum mould
design and optimum cycle times Mould flow analysis 3D mould design using PROE Strong mould design concepts
World class infrastructure
High end CNC machines, Automated machining cell In-house vacuum heat treatment (2014 ) In-house laser sintering machine (conformal cooling) Precision finishing, excellent polishing capabilities ( SPI – A1, A2) Effective documentation procedures from design to mould qualification with traceability capabilities State- of- the- art all electric injection moulding machines for mould trials and moulding
Why Vasantha
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State of the art metrology equipment's CMMs from Zeiss O - Inspect from Zeiss
Measurement capability Dimensional guidelines Gauge R&R In-house Jigs and Fixture manufacturing and qualifying capability
Project management Knowledge to interpret quality reports Facilitates from DFM to mould commissioning Weekly reviews (internal and customer), updates with photographs of mould progress
Why Vasantha
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Mould qualification 4 hours of dry run, 8 hours mould qualification run (MQR) for parts Observe for foreign particles Disassemble and check mould for any scoring / wear tear Ability to align for cleanroom moulding- coatings, graphite impregnated guide bushes, servo
electric technologies, etc. Parts qualification
Scientific injection moulding (SIM) Optimized cycle time Cp, cpk study using minitab software
Mould commissioning & service support Mould commissioned by trained personnel Preventive maintenance training Exclusive team for mould service and spares support
Why Vasantha
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Sr. No. Injection moulding machine Model Type Capacity Qty.
1 FERROMATIC MILACRON HYDRON 450 with all electric bi- injection unit
Hydraulic 450 T 1
2 HUSKY HYLECTRIC Hybrid 400 T 1
3 FANUC ROBOSHOT S-2000 I 300B
Electric 300 T 1
4 L&T DEMAG Aswa 250 Hydraulic 250 T 2
5 FANUC ROBOSHOT α- S 150 i A
Electric 150 T 2
6 FANUC ROBOSHOT α – S 100 i A
Electric 100 T 1
7 Larsen & Toubro DTS 100 LNC5 Hydraulic 100 T 1
8 FANUC ROBOSHOT α – S 50 I A
Electric 50 T 1
Sampling Capabilities
Injection Moulding Machines
Sampling Capabilities
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Make Capacity Qty.
Mold Masters - emulti
0 to 20 g 03
Plasdan 0 to 10 g 01
Plasdan 0 to 50 g 01
Ferromatic 0 to 200 g 01
Bi colour injection units for 50 T to 150 T IMM m/c and 300 T to 450 T IMM m/c
Backed up with all requisite support of ancillary equipment such as, dehumidifiers, chillers and mould sweat protector to validate and qualify the moulds to global standards
Component testing laboratory consisting, vacuum leakage tester, universal testing m/c (UTM), profile projector, height master, torque tester, conditioning chamber
High Precision and High Cavitation Moulds
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High Precision and High Cavitation Moulds
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High Precision and High Cavitation Moulds
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Major Customers Domestic and International
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Russia
China
India
Bangladesh
South Africa
Congo Tanzania
Brazil
Major Global Supplies
USA
Sri Lanka
France Germany
Poland
Vietnam
Indonesia
Belgium
Egypt Saudi Arabia
Philippines Thailand
Mexico
UK
Italy
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Australia
Kenya
Turkey
Canada
Products Covered
Bi Color Caps
Pumps /Dispensers
Water Bottle Cap
Flip Top Caps
Tamper Evident
Spray Thro’ Cap
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Conical
Spout and Cap
Shoulders
Products Covered
Standup Cap
CRC
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Medical
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Electrical & Switchgear
Products Covered
Automotive & Engineering
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Automotive & Engineering
Products Covered
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