Composite Business Unit

To discuss….

• Sintex Group

• Bright Autoplast (BAPL)

• Sintex Wausaukee Composites Inc (SWC)

• Synergy – Customers to serve Globally

• Success Stories – Happy Customers

• LRTM in Pune

• Unique Features

• Operational Strategy

• Why, When & Where LRTM?

Sintex Group - Active Thinking

The world of Sintex is one that is driven by ideas;

it is the key to the Group’s growth over 8 decades.

This spirit is encapsulated in the motto, ‘Active

Thinking’; which is the practice of translating ideas

and thoughts into actions with an objective of creating

meaningful innovations and solutions.

Over the years the Group has added depth and width

in its offerings to serve range of industries from

automotive, aerospace, electrical, energy to

medical and defence.

It has focused on mastering cutting edge

technologies, innovations and has built state-of-the-

art infrastructure to meet its clienteles constantly

evolving requirements.

Company is listed on “Bombay Stock Exchange”

“At Sintex, change is the only permanent feature”– Mr Dinesh Patel, Chairman

Plants |35

Countries |9

Continents | 4

Solutions Engineered across the globe 5

Global Manufacturing Bases

6

7

BAPL Foot prints

Strategically located in the automotive corridors

of India, offering a range of mfg capabilities for

Thermoplastic & Thermoset parts

Sohna | Indore | Pune | Nasik | Chennai 1| Chennai 2 | Chennai 3

Passenger Vehicles

Passenger cars

Sports Utility Vehicle

Multi Utility Vehicle

Scooters & Motorcycles

Commercial Vehicles

Micro & Light Trucks

Heavy Trucks

Passenger Buses & Coaches

Goods Carriers

8

▶ BODY-AIR CLEANER,UPPER

▶ ELEMENT -AIR CLEANET

▶ PACKING-ELEMENT

▶ BODY-AIR CLEANER,LOWER

▶ LOWER CASE DIFFUSER, UPPER

▶ LOWER CASE DIFFUSER, LOWER

▶ NECK RESONATOR (INLET PIPE)

▶ BODY-AIR CLEANER,LOWER

▶ RESONATOR, UPPER

▶ RESONATOR, LOWER

▶ DUCT A-AIR,INLET UPPER

▶ DUCT A-AIR,INLET LOWER

Technologies in Use

• Injection molding

• Blow molding

• Rotomolding

• Vacuum Forming

• Rubber injection molding

• Fabric insert molding

• Vibration welding

• Assembly and Testing

• Painting

Functional Auto Parts- Air Induction System

9

Defroster Grill Gap HiderRadio Centre

Stack Bezel

MFD Cover

Pull Handle

Shifter Bezel

Assembly

Climate Control

Head Bezel

Rear Décor

Strip

Chute Channel

Assembly

Glove Box

Assembly

Shifter Trim

Plate

Shifter Ring

Front Décor

Strip

Automotive Interior Systems

10

Front & Rear Bumper Assembly

Automotive Exterior Systems

Fuel Tank – 220 L

Hydraulic Reservoir

11

Technologies in Use

• LRTM Light Resin Transfer Molding

• RTM Resin Transfer Molding

• HLU Hand Lay / Open Molding

• LCM Liquid Compression Molding

• RIM Soft Touch Urethane

• SMC Sheet Molding Compound Moulding

• DMC Dough Moulding Compound Moulding

Composite Manufacturing Processes

Conversion to Composites

Mfg Tech

Mould Mfg Mould Design

Complete Solution

Sintex Wausaukee Composites is a premier provider of highly-engineered Composites,

Urethane and Structural Plastic component solutions worldwide.

• Producing more than 100,000 components for more than 35 OEMs annually.

• Experienced workforce including more than 40 ACMA certified “Composite Technicians”.

LRTM

• Vacuum to close mould and inject resin

• Two-sided finish with lower tooling cost.

• Consistent dimensional tolerances and resin/glass ratio

• Moderate production rates (500-5,000 parts/year).

1

2 3

13

Soft Touch & Compression Moulding

14

• Soft Touch Interior Parts

• Semi structural strength

• Superior Finish

• Production rate 1,000 – 50,000 parts / year

• Structural & Semi structural parts

• For Interior and Exterior application

• Excellent Mechanical & Electrical properties

• Production rates (5000-50,000 parts/year).

Product Range

Synergy – Customers to Serve Globally

Initiative of Sintex divisions

Sintex-Wausaukee, Sintex-Nief, Sintex India, and Bright Autoplast

Objective: Exchange of technological expertise, Leveraging manufacturing cost advantages,

Engineering support, Part supply & Logistic management to service Global Customers - Globally

16

KalolInland Truck

Mundra

Sea transitPort of Norfolk

TOFC

Chicago Rail YardInland Truck

Warehousing at Gillett

Sintex + SWC = Happy Customer

Leveraging manufacturing cost advantage & Logistics management

Nief Plastic + BAPL = Happy Customer

Exchange of Technological expertise & Locational Advantage

Moulding Area: 9000 Sq Ft

Capacity: 18000 parts per year

with parts up to 5 sq. met. Area

Painting: Connected with existing conveyor paint shop

SWC + BAPL = Now Ready….

Arial View of LRTM Cell in the Pune Factory

Plant Layout

Designed for Process Control & Productivity

Mould Path Material Path

Mixing of Resin, Additives, Promoter,

Filler etc

Gelcoat by Spray; Positive pressure

booth, Unidirectional door movement,

Plant Infrastructure..

1 2

Reinforcement cutting section

Carbon, Glass etc

Resin Injection & Moulding Area

4 Moulds can be used at a time

Plant Infrastructure..

3 4

Inside View Trimming Booth, Floor &

Cutting tools with Vacuum suction,

Adhesive dispensing for Metal –

Composite – Composite bonding

Plant Infrastructure..

65

Plant Infrastructure..

Maturation Booth

Ensuring Complete Curing

Inside View

87

Gelcoat Spray on Mould

Moulded Part

Gelcoat Finish

Initial Products..

Initial Products..

2K PU Painting in conveyor paint shop

No extra efforts for Surface Preparation

Safety, Health & Control

PPEs for everybody Eye Wash

Quick Relief

Entry for authorized

personnel only

• Integrated facility: RM testing to assembly of Product. Under One Roof.

• Gelcoat by spray; Good for finish & consistency.

• Automatic Injection Machine with RFID sensor on each mould for program selection.

• Vacuum assisted tools and booth for trimming. EHS is utmost important

• Structural adhesive dispenser, pre-programmable with variable ratio for Metal to FRP or

FRP to FRP assembly

• On line painting in Conveyor Paint Shop

• All the Process Parameters are Centrally Controlled and Monitored using SCADA based

system. This can be remotely accessed for control and troubleshooting

Unique Features of Plant

Operational Strategy

Product Quality Globally Same

1 Tech by SWC-USA

2 People Training by SWC

3 RM Localization

by BAPL

4 Product Engineering

by SWC

5 Mould & Process

Design by SWC

6 Prod & Supply by

BAPL

Why & When LRTM?

30

* Construction & Mining Equipments * Agricultural tractors and other machines

* Off road vehicles * Mass transit – Rail and Road * Medical Equipments

Where LRTM is used?

Thank you