2. 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?
3.
4. 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
7. 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. 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. 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. 10
Front & Rear Bumper Assembly
Automotive Exterior Systems
Fuel Tank – 220 L
Hydraulic Reservoir
12. 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”.
13. 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
14. 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).
16. 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
17. Kalol
Inland Truck
Mundra
Sea transit
Port of Norfolk
TOFC
Chicago Rail Yard
Inland Truck
Warehousing at Gillett
Sintex + SWC = Happy Customer
Leveraging manufacturing cost advantage & Logistics management
19. 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
25. Gelcoat Spray on Mould
Moulded Part
Gelcoat Finish
Initial Products..
26. Initial Products..
2K PU Painting in conveyor paint shop
No extra efforts for Surface Preparation
27. Safety, Health & Control
PPEs for everybody Eye Wash
Quick Relief
Entry for authorized
personnel only
28. • 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
31. * Construction & Mining Equipments * Agricultural tractors and other machines
* Off road vehicles * Mass transit – Rail and Road * Medical Equipments
Where LRTM is used?
