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					                                      V O L U M E   2   J U N E   2 0 0 6


      M A G A Z I N E

                        CHANGE IS
                        IN THE AIR
                        COMPRESSED AIR,
                        INNOVATIVELY USED ACROSS
                        A SPECTRUM OF INDUSTRIES

                        21ST CENTURY CUTTING TOOL
                        INDUSTRY INSIGHTS

                              TIDES OF
                           FISHERMAN TRIBES
                           ON THE EAST
                           COAST OF INDIA
                           PRODUCT FOCUS
                                                                                     Send in your letters, faxes and e-mails to:
                                                                                     The Editor, ELGI MAGAZINE,
                                                                                     Corporate Communications
                                                                                     ELGI Equipments Ltd.,
                                                                                     Trichy Road, Singanallur,
                                                                                     Coimbatore – 641 005,
                                                                                     Ph:+91-422-2589555, Extn: 116,
                                                                                                                                                                            4        Life Today
                                                                                                                                                 4 Green Velvet Town
                                                                                     Should you require reprints of any of the                                                          Three rivers and exotic landscapes add to the abode
                                                                                     articles, please contact : Mr. Gopi Kannan,                                                        of tea and spices, making Munnar a perfect getaway.
                                                                                     Dy. Manager, Corporate Communications.
                                                                                                                                                                                      9 The Spirit of Independence
                                                                                     Volume 2 June 2006                                                                                 A tribute to our National Flag.

                                                                                    MANUSCRIPT AND ART
                                                                                    The Authors of the ELGI magazine belong
                                                                                                                                                      Munnar : Green Velvet Town
                                                                                                                                                                                     Industry Insights
                                                                                    to SPENTA MULTIMEDIA.
                                                                                                                                                                                     12 Bonded Glory
                                                                                                                                                                                        Find out how cement, a simple grey ash coloured powder,

                                                                                    The publisher assumes no responsibility                                                             has the potential to join the smallest cracks, to building
                                                                                    for return of unsolicited manuscripts, art,                                                         massive structures.
                                                                                    photos or negatives.                                                                             16 Tears of the Gods
                                                                                                                                                                                        The story behind the world’s largest diamond cutting and
                                                                                    The opinions expressed and conclusions                                                              polishing industry.
                                                                                    drawn by the authors do not necessarily                                                          20 Starry Eyed Surprise
                                                                                    reflect those of the editor or publisher of                                                         Demystifying the world of contact lenses.
                                                                                    ELGI Magazine.
                                                                                                                                                                                     23 Revisiting The Wonder Years
                                                                                    The author indemnifies the publisher                                                                The sight of a stuffed toy never fails to lift your spirits
                                                                                                                                                                                        bringing back nostalgic memories
                                                                                    against any violation of privacy, plagiarism
                                                                                    and copyright infringement of the written                                                        26 A Unique Package
                                                                                    content in the ELGI Magazine.                                                                       MasPack, a unique corporation, supplies a key product to
                                                                                                                                                                                        Indian defence.

                                                                                                                                        National Flag : The Spirit of Independence

EDITO R I A L N O T E                                                                                                                                                                Research & Innovation
                                                                                                                                                                       16            28 PLM@ELGI
Greetings to all, and welcome to Volume II of our annual corporate magazine – The ELGI magazine. The ELGI magazine is a                                                                 Product Lifecycle Management.

yearly publication devoted to the latest news and happenings in the compressor, automotive services and related industries.

Change is in the air. Considered a utility, along with electricity, gas and water, compressed air is used in every industry. Embedded                                                Business Spotlight
in this issue are the stories which centre on various industrial products, with applications that impact people’s lives everyday. The                                                31 Behind The Radiant Smile
stories are chosen based on their uniqueness, varying from diamond cutting and polishing to everyday use products that we take                                                          The evolution of toothbrush into a flourishing business in
                                                                                                                                                                                        the modern world.
for granted like cement and soft toys.

We look forward to bringing you the continuing edition of the ELGI Magazine in 2007.
                                                                                                                                                                                     Product Focus
                                                                                                                                                      Diamond : Tears of the Gods    34 Tides of Change
                                                                                                                                                                                        Peek into the lives of two extraordinary fishermen tribes
                                                                                                                                                                                        inhabiting the east coast of India.

                                                                                                                                                                                     38 Engineering Solutions
                                                                                                                                                                                        New products from ELGI.

 THE ELGI MAGAZINE                                                                                                                                                                                                                THE ELGI MAGAZINE 
                                                                                                                                                                               L I F E T O D AY

                                                                          Green Velvet Town
                                                                                 orming the craggy hills of           has the misty Palani Hills, and is home     supplies most of the machinery for use
                                                                                 the Western Ghats, Munnar            to beautiful plantations. The foggy         in tea factories at Munnar. Just 148
                 Three rivers and exotic landscapes add to the abode of          is a magical Indian tourist          skies and the moist earth are perfect       kilometres away, Munnar can also be
                                                                          destination with a perfect amalgam of       for growing coffee, tea and various         reached from Cochin, a bustling port
                 tea and spices, making Munnar a perfect getaway.         gorgeous greenery, lovely lakes, pristine   spices. Munnar, the region’s most           town in Kerala.
                                                                          valleys, dense forests and tea estates.     popular hill station, is located just 150       Set at an altitude of 6,000 feet MSL
                                                                          ‘Munnar’ literally means three rivers,      kilometres away from Coimbatore,            (Mean Sea Level), Munnar was the
                                                                          and true to its name it is located at the   Tamil Nadu.                                 favoured summer resort of the erstwhile
                                                                          confluence of three mountain streams            On a drive from Coimbatore to           British rulers in the colonial days.
                                                                          — the Muthirapuzha, Nallathanni and         Munnar, the roads wind through rolling      Munnar is better known as the ‘spice
                                                                          Kundala rivers.                             hills fringed by paddy fields, lovely       garden of India’. The Malabar pepper or
                                                                              To the south-west of the Deccan         lakes, dense forests and tea estates, all   black gold and cardamom brought the
                                                                          Plateau, separated from the state of        forming a part of the scenic landscape.     foreign traders to this tiny land crossing
                                                                          Kerala by the blue Nilgiri mountain         Having one of the largest clusters of       vast stretches of blue water in ancient
                                                                          range, lies the Coimbatore plateau. It      engineering units in India, Coimbatore      times.

 THE ELGI MAGAZINE                                                                                                                                                                     THE ELGI MAGAZINE 
                                                                                                                                                                                                                                              L I F E T O D AY

                                              sometimes referred to as the ‘Switzerland        In 1877, a local prince owing loyalty
The Cup that Cheers                           of India’ for its natural surroundings and   to the Maharajah of Travancore, leased
Munnar is essentially a tea town, where       old world architecture.                      out a tract that came to be known as the
tea is grown at an elevation of 7,200 ft.          The mountains known as the Kannan       Kannan Devan Concession Land. Later
Rajamalai – a frequent haunt of the           Devan Hills got their identity from a        on the concession area was purchased by
film units down south, beholds lush tea       former hill tribe zamindar (landlord)        Muir and Co., which soon after became
gardens that look as harmonised as if they    named Kannan Thevar, who ruled the           James Finlay & Co. Ltd.
were pruned and cut like bonsai. The          villages of Anchanadu around Munnar.               The name of the company was
harmony of the green carpet is speckled       It is said that travellers from Coimbatore   changed to Tata Tea Ltd., when Finlays
with women plucking ‘two leaves and a         to the West Coast passed through these       sold their remaining share holdings,
bud’ from the tea bushes.                     villages and named these hills after         including the considerable landholdings
    The fact that Munnar was opened           him. An entry in the diary of a Madras       and manufacturing facilities in north-
up out of virgin forests a century ago by     army lieutenant made in 1817 describes       eastern India. Tata Tea Ltd., the dominant
pioneering planters, adds to its charm.       a bullock cart road heading across the       player of tea in Munnar, justifiably claims
The British planters played a significant     Kannan Devan hills into Coimbatore.          to be the largest integrated tea company
role in developing the tea plantations             Vast expanses of tea plantations        in the world, with activities spanning the
at Munnar. They cleared vast tracks           were first cultivated by A. W. Turner        entire spectrum of the industry. Harissons
of forestland to cultivate tea, and the       near Devikulam Lake. The pioneering          Malayalam and Kulukkumala are the
people around the area were employed          planters tried many crops such as coffee,    other major tea producing companies
as labourers for the plantations. Most of     sisal and cardamom before discovering        owning the majority of the widespread
the apex positions were occupied by the       tea, the product best suited to the area.    tea estates in Munnar.
British though, proudly called ‘managers’     The first tea plant was planted by A. H.
in the region. A few bungalows were built     Sharp at Parvathi in Sevenmullay Estate,     Venturing Out
for them, which are still in use. Munnar is   a 50 acre clearing in an immense jungle.     Stopping at Peermade, the Pulluvora

                                                                                                                                         waterfall gorgeously tumbles down in       While driving down to the wildlife park      frolic in the lake and the place came to
                                                                                                                                         a frothy splendour. Lunch is a unique      on the zigzag metalled road through          be spoken about as ‘Devikulam’ (the
                                                                                                                                         experience here, with a magenta            the undulating grassland, the sight of       lake of the goddess) ever since. To this
                                                                                                                                         coloured liquid served in place of water   elephants grazing in the Shola forests       day the locals believe that a holy dip
                                                                                                                                         that smells strongly of clove and cumin    can be breathtaking.                         in this pristine lake can cure diseases.
                                                                                                                                         — a health tonic, reportedly good for          The Mattupetty dam nestles amidst        The lake is also an ideal place for trout
                                                                                                                                         digestion.                                 luxuriant tea gardens. Boating in the        fishing.
                                                                                                                                             Close to Rajamalai is the Eravikulum   mirror still waters of the lake with the         The exotic flora found in the forests
                                                                                                                                         National Park, home to the Nilgiri tahr.   cool breeze playing on your face is an       and grasslands here is all the more
                                                                                                                                         This endangered species of mountain        enthralling experience. The celebrated       fascinating due to the Neelakurinji. This
                                                                                                                                         goat is nearing extinction, and the        Indo-Swiss dairy farm is an exquisite        legendary flower blooms only once in
                                                                                                                                         present population is about 2,000 only.    example of nature’s harmony with             every 12 years. The Muduvar tribe, who
                                                                                                                                         The park covers an area of 97 sq km        human activities. Well-nourished cows        inhabit the mountain ranges around
                                                                                                                                         and is divided into three zones — core,    graze in the lime green valley set against   Valparai (Tamil Nadu) and Munnar,
                                                                                                                                         buffer and Rajamalai. Cars can reach       the backdrop of an aquamarine sky, a         calculate their age with blossoming of
                                                                                                                                         right up to the Rajamalai region, beyond   treat for the eyes indeed.                   the Kurinji. Neelakuriniji, which bathes
                                                                                                                                         which one can only trek through the            Devikulam (16 kilometres south-          the hill in the blue, is all set to bloom
                                                                                                                                         forested grassland.                        west of Munnar), another serene lake         this year during the months of August
                                                                                                                                             The green fertile tea gardens          hidden within the rolling hills, is yet      and September. The crisp and cool
                                                                                                                                         go right up to the rocky terrain of        another must-see. The old housewife’s        mountain air laden with the fragrance
                                                                                                                                         Anaimudi (Elephant Head), the highest      tale has it that once Sita Devi, the holy    of wild flowers and rare herbs is any
                                                                                                                                         mountain peak of the Western Ghats.        consort of Lord Rama, came down to           nature lover’s paradise.

 THE ELGI MAGAZINE                                                                                                                                                                                                                                    THE ELGI MAGAZINE 
                      THE SPIRIT OF
                      It was at the stroke of midnight on August , 
                      that we attained the greatest and most cherished
                      gift, our independence. Perhaps, if there is one
                      visual symbol that sums up the endless and selfless
                      struggle that went into it and what we stand for
                      now, it is the National Flag — standing proud with
                      its familiar horizontal tricolour of orange, white ,
                      and green with a blue Ashoka Chakra at the centre.
 THE ELGI MAGAZINE                                                          THE ELGI MAGAZINE 
                                                                                                                                                                                                                                                           L I F E T O D AY

         flag is the symbol of faith in a      whole of India, until the first uprising.      the first Indian to have raised an Indian
         country, and not a mere piece of      Under British rule there existed over          flag abroad, declaring to the world our
         cloth attached to a pole. From        565 princely states, with each having          political fight with the British.
time immemorial people have laid down          their own flags and royal emblems. The             In 1916, Pinglay Venkayya, an Andhra
their lives for their flag. Totem poles and    British used this to propagate the divide      youth, designed a flag and tried to get
flagpoles have been an important part          and rule policy, which made it easy for        Gandhiji interested in it. Gandhiji refused
of life since the days of early man, as        them to rule India as one nation under         to accept this design but later asked
shown by anthropological studies. The          one flag, the Union Jack.                      Venkayya to design a flag with a charkha                                                         1916
Indian flag is called the Dhvaja, and finds        At the turn of the century the quest for   (a spinning wheel). This was to be a
mention in the Puranas and in the other        a national flag assumed greater urgency,       bicolour flag with the charkha on a red
epics.                                         and its design goes to the credit of Sister    background denoting Hindus and green
    We might be inclined to take the           Nivedita, an Irish disciple of Swami           for Muslims. This was then changed to
sight of our National Flag for granted,        Vivekananda. The flag designed by her          the tricolour with the inclusion of the
but little has anyone wondered about its       failed to catch the imagination of the         white band, denoting the much hoped           1906                                                                                               1917
significance and evolution. There is an        people. Then came Lord Curzon and the          for unity and peace.
interesting story behind our National          Partition Movement of Bengal, (1905-               Deshabhimani of Guntur compared
Flag, a long winding one that takes you        1906) wherein ‘Vande Mataram’ became           the spinning wheel to the Sudharshana
many years back in time.                       the national song of Bengal and, Sister        Chakra, which destroys the bad, in this
    The history of our National Flag           Nivedita’s flag was adopted with some          case the bad qualities of the people,                                                                                                           1947
begins in 1599 when the British came to        modifications and hoisted on August            and teaches them self-help at the same
India as traders and turned into rulers.       7, 1906 to protest against the partition.      time.
Many small revolutions took place in an        The flag displays eight lotuses, which             In 1917 the Home Rule League
effort to put an end to their authority, but   represent the then eight provinces.            became popular and Bal Gangadhar Tilak
none of these led to any conclusion till           In 1907, the flag then reached the         and Dr. Annie Besant designed a new                        “It will be necessary for us Indians, Muslims, Christians,
almost the middle of the 20th century.         hands of Madame Bhikaji Rustom                 flag. It had 5 red and 4 green horizontal                Jews, Parsis, and all others to whom India is their home
    A rather remarkable verity is that         Cama in Germany, where she made                stripes arranged alternately with 7 stars                 — to recognise a common flag to live and to die for.”
there was no single ‘national’ flag for the    slight changes and unfurled it. She was        denoting the Saptarishi Configuration.

                                                                                                                                                   During her internment in July 1917           Government had decided to free India.
                                                                                                                                                   in Ollcott Cottage in Coimbatore,            An ad hoc committee was formed to
                                                                                                                                                   Dr Annie Besant had hoisted this flag        suggest a flag for ‘Free India’ that would
                                                                                                                                                   and saluted it as a symbol of India’s        be acceptable to all the parties and
                                                                                                                                                   freedom. The inclusion of the Union          communities in India.
                                                                                                                                                   Jack expressed Political compromise as           A few changes were made, the major       that the first flag to fly over this August
                                                                                                                                                   the goal of the Home Rule Movement           one being the replacement of the charkha     House should be a gift from the women
                                                                                                                                                   was Dominion Status and not Complete         with the Ashoka Chakra, the ‘wheel of        of India.” And the Indian Tricolour
                                                                                                                                                   Independence. And this was the reason        law’ (dharma) of the third century BC        went up for the first time amidst a
                                                                                                                                                   why this flag did not become popular         Mauryan emperor Ashoka. This was             31-gun-salute on the Council House.
                                                                                                                                                       The year 1923 was the year of the        done mainly because the symbol on one        The National Flag has the rare honour
                                                                                                                                                   flag Satyagraha. The tricolour flag was      side of the flag should be exactly the       of being hoisted seven times on Mt.
                                                                                                                                                   carried out in big processions. In 1927      same as on the other side, which could       Everest , in space on board the Apollo
                                                                                                                                                   came the Simon Commission, which             not be the case with the charkha.            15 and at the South Pole in Antarctica.
                                                                                                                                                   was greeted with tricolour flags, black          According to Dr. S. Radhakrishnan,           A lot has changed in the cultural,
                                                                                                                                                   flag demonstrations and slogans of           the saffron colour of the ‘Tiranga’          political, and historical landscapes of
                                                                                                                                                   ‘Simon Go Back!’.                            denotes renunciation and shows that the      India, but if there is one thing that stands
                                                                                                                                                       By 1930 the tricolour gained             leaders must be indifferent to material      tall against all, and still reminds us of
                                                                                                                                                   popularity all over India, but a few         gains and dedicate themselves to work.       our proud heritage and patriotism, it is
                                                                                                                                                   objected to the communal interpretation      The white in the centre is light, the        our tricolour flag. So while we unfurl
                                                                                                                                                   of the colours. Some wanted saffron          path of truth to guide our conduct. The      the flag again in this land of myriad
                                                                                                                                                   while others did not want white. The         green shows our relation to the soil and     cultures, let us remember the inspiring
                                                                                                                                                   Sikhs wanted the inclusion of yellow.        plant life.                                  words once said by Mahatma Gandhi,
                                                                                                                                                   Hence a seven member flag committee              At midnight on August 15, 1947 the       the Father of the Nation-
                                                                                                                                                   was formed which chose the complete          Constituent Assembly assumed power               “It will be necessary for us Indians,
                                                                                                                                                   saffron flag.                                from the British, and Shrimati Hansa         Muslims, Christians, Jews, Parsis, and
                                                                                                                                                       Finally, after a number of trials and    Mehta presented the new National Flag        all others to whom India is their home
                                                                                                                                                   tribulations came Lord Mountbatten’s         to the President Dr. Rajendra Prasad.        — to recognise a common flag to live
                                                                                                                                                   announcement in 1947 that the British        She said, “It is in the fitness of things    and to die for.”
0 THE ELGI MAGAZINE                                                                                                                                                                                                                                              THE ELGI MAGAZINE 
                                                                             I N D U S T RY INSIGHTS

                       “No two buildings have the same purpose. The
                       purpose, the site, the material determine the
                       shape… a building is alive, like a man”. These are
                       the immortal words from Ayn Rand’s novel ‘The
                       Fountainhead’, spoken by Howard Roark.

                       O          ften we hear that someone is
                                  coming up with a ‘concrete
                                  solution’, or is ‘cementing his or
                       her relationship’. These phrases indicate
                       the actual meaning behind ‘cement’, for
                                                                       product used to make homes, but little
                                                                       does he know about its versatility or
                                                                       about the various types of cement with
                                                                       diverse properties that can be obtained
                                                                       by varying the proportions and types of

  Bonded Glory
                       cement glues a mixture together and             its ingredients.
                       concrete provides the end product.
                           How this unimpressive looking grey          What Lies Beneath?
                       powder creates massive structures such          In general, ‘cement’ (from the Latin
                       as buildings and flyovers may seem              word caementum) is any material with
                       like an incredible mystery of its own.          adhesive properties. It is a finely ground,
                       We live our entire lives in our homes,          usually grey coloured mineral powder.
                       taking their safety and shelter for             When cement is mixed with water,
                       granted, without ever wondering how a           the silicates and aluminates undergo
                       magnificent construction is created on          a chemical reaction, and the resulting
                       the ground. One could say that cement           hardened mass is impervious to water.
                       is to buildings what salt is to food.           Cement may also be mixed with water
                           Cement — a grey ash-like powder,            to bind together the crushed stone,
                       can be used to fill the smallest cracks         sand, and gravel to form concrete, the
                       or to build enormous structures. To             most widely used construction material
                       a common man it is just cement — a              in the world.
 THE ELGI MAGAZINE                                                                        THE ELGI MAGAZINE 
                                                                                                                                                                                                                     I N D U S T RY INSIGHTS

                                                                                                                   form. Cooled clinker is combined                                                            to almost any form, allowing architects
                                                                                                                   with gypsum and ground into a fine             A SNAPSHOT OF THE CEMENT                     to be truly creative in their designs.
                                                                                                                   powder.                                            INDUSTRY IN INDIA                        Imagination becomes architectural
                                                                                                                       Compressors are indispensable to                                                        reality with white cement.
                                                                                                                   the cement industry. They are used              The Indian cement industry
                                                                                                                   at every stage, from the initial water          dates back to  — the                    The Right Mix
                                                                                                                   spraying to the transportation of fly ash         first unit was set up at                  Concrete is another creative offspring
                                                                                                                   to storage silos, and the final packaging.                                                  of cement. In construction, concrete
                                                                                                                   Compressed air is used to provide the
                                                                                                                                                                  Porbandar with a capacity of                 is a composite building material made
                                                                                                                   initial agitation needed to mix the raw                 ,000 tonnes.                       from the combination of aggregates and
                                                                                                                   materials to form uniform slurry. The                                                       a cement binder. Contrary to common
                                                                                                                   slurry is usually blended in elevated             Currently, India is ranked                belief, concrete does not solidify upon
                                                                                                                   silos. Silos are vented to allow air to         second in the world with an                 drying after mixing and placement.
                                                                                                                   escape through filters, so controlling           installed capacity of .                Instead, the cement undergoes
                                                                                                                   dust emission. Compressed air is                                                            hydration, gluing the other components
                                                                                                                   blown into the slurry at the base of the
                                                                                                                                                                           million tonnes.                     together to form a stone-like mass
                                                                                                                   silo to improve the mixing. Further,                                                        known as concrete.
                                                                                                                   compressed air can be used to remove               The current per capita                       The key to achieving strong and
                                                                                                                   the dust and smoke particles collected            consumption is  kg, as                  durable concrete rests on the careful
                                                                                                                   on the filter bags while packing. A jet of        against the world figure                  proportioning and mixing of the
                                                                                                                   compressed air is directed through the                   of  kg.                         ingredients. A concrete mixture that
                                                                                                                   centre of each bag to remove the dust.                                                      does not have enough paste to fill all
                                                                                                                                                                                                               the voids between the aggregates will be
                                                                                                                   Creative Use                                                                                difficult to place, and will produce rough
                                                                                                                   Cement is used basically to build, but        taking on a wide range of finishes, and       concrete. A mixture with an excess of
                                                                                                                   there are ways of using it creatively         therefore architects appreciate its ability   cement paste will be easy to place and
                                                                                                                   too. Cement plaster or ‘stucco’ as it         to combine aesthetic versatility and a        will produce a smooth surface.
                                                                                                                   is commonly known, is a popular               cost effective construction method.               Within this process lies the key to a
                                                                                                                   exterior finish for buildings. It gives an        White cement concrete is again a          remarkable trait of concrete: it is plastic
                                                                                                                   economical hard surface that is rot, rust,    brilliant architectural material. Whether     and malleable when newly mixed,
                       In the Making                                    The first step in the Portland cement      and fire resistant, and can be coloured       plain or pigmented, it agrees to a broad      strong and durable when hardened.
                       Historically, cement can be traced back to   manufacturing process consists of              and finished in a wide range of textures to   spectrum of colours — from bright             These qualities explain why one
                       the early Roman Empire. Cement made          obtaining raw materials. Generally, raw        adorn any architectural style. A popular      whites and pastels to saturated colours.      material, concrete, is the right mix for
                       by grinding together lime and volcanic       materials consisting of combinations of        cladding material, stucco is capable of       It can be textured, patterned, or shaped      nearly everything we build.
                       products found at Pozzuoli on the Bay        limestone, shells or chalk, shale, clay,
                       of Naples, was used in ancient Roman         sand, and iron ore are mined from a
                       construction works.                          quarry near the plant. At the screening
                           It was Joseph Aspdin, a British          plant, the raw materials are reduced to
                       stonemason, who invented Portland            the desired size by the crushers.
                       cement in the 19th century. The inventor     Once the raw materials reach the cement
                       heated a mixture of finely ground            plant, they are ground to form slurry
                       limestone and clay in his kitchen stove,     and blended using the ‘chemist’s secret
                       and ground the mixture into a powder         mixture’. Two methods, dry and wet, are
                       to create ‘hydraulic cement’ — one           used to manufacture Portland cement.
                       that hardens with the addition of water.     In the dry process, dry raw materials
                       Aspdin named the product Portland            are proportioned, ground to a powder,
                       cement because it resembled a stone          blended together and fed to the kiln in
                       quarried on the Isle of Portland off the     a dry state. In the wet process, adding
                       British coast. With this invention, Aspdin   water to the properly proportioned raw
                       laid the foundation for today’s Portland     materials forms slurry.
                       cement industry, which annually                  The slurry is then transported to
                       processes mountains of limestone, clay,      the rotary kiln for heat processing. The
                       rock, and other materials into a powder      discharge from the kiln is called ‘clinker’,
                       so fine that it will pass through a sieve    and resembles small rocks or the residue
                       capable of holding water (half a kilogram    from a blast furnace. The clinker is
                       of cement contains 150 billion grains).      nothing but the cement in a ‘lump’

 THE ELGI MAGAZINE                                                                                                                                                                                                                THE ELGI MAGAZINE 
                                                                                                                                                                                           I N D U S T RY INSIGHTS

                                                                                                                                        the pressures and temperatures under         operate at very high temperatures are
                                                                                                                                        which diamonds are thought to form           some of the promised applications of
                                                                                                                                        naturally. In HPHT synthesis, graphite       diamond films.
                                                                                                                                        and a metallic catalyst are placed in
                                                                                                                                        a hydraulic press to form diamond            What You ‘C’ is What
                                                                                                                                        crystals. These diamonds are usually         You Get
                                                                                                                                        a few millimetres in size and this           A diamond’s beauty and value centres
                                                                                                                                        limits their use as gemstones, but they      around four key factors (the four Cs)
                                                                                                                                        are extremely useful for industrial          — namely clarity, colour, carat, and cut.
                                                                                                     From myths about                   applications. Tiny synthetic diamonds            A diamond’s clarity refers to
                                                                                                                                        are used in saw blades for cutting asphalt   the presence of flaws such as cracks
                                                                                                     valleys of diamonds                and marble, and in drill bits for oil and    and chips, on and within the stone.
                                                                                                     protected by snakes,               gas drilling.                                Diamonds with no or few flaws are
                                                                                                                                            Diamond films are manmade replicas       more highly valued than those with less
                                                                                                     to the production                  of the natural diamonds. A process called    clarity, since they are rarer.
                                                                                                                                        ‘Chemical Vapour Deposition’ (CVD)               The clarity of diamonds ranges from
                                                                                                     of millions of carats              may be used to produce diamonds in           flawless to the three included grades.
                                                                                                     in rough diamonds                  the form of coatings or wafers. CVD,         Diamonds with VVS and VS grades are
                                                                                                                                        as its name implies, involves a gas phase    excellent choices for both value and
                                                                                                     each year, the                     chemical reaction occurring above a solid    appearance.
                                                                                                     history of diamonds                surface, which causes deposition upon            Colour in a diamond ranges from
                                                                                                                                        that surface. CVD diamond is usually         colourless to yellow, up to the rare pinks,
                                                                                                     is one of mystical                 produced by energising mixtures of           blues, and greens known as ‘fancies’.
                                                                                                                                        hydrogen and hydrocarbon gases with          The true colour of a diamond can only
                                                                                                     power, beauty                      heat or electrical energy in a deposition    be determined by using a set of master
                                                                                                     and commercial

    Tears of the
                                                                                                                                        reactor. A region of plasma drives           diamonds certified by the American
                                                                                                                                        the complex chemistry, which causes          Gem Society. The whiter a diamond’s
                                                                                                     expertise.                         diamond coatings to grow on objects          colour, the greater is its value.
                                                                                                                                        placed in the reactor. Unbreakable               Carat is the weight of the diamond.
                                                                                                                                        coatings and computer chips that can         One carat is equal to 0.2 grams.

        he word ‘diamond’ has its roots       luck and success.                             the magma cooled, it solidified into blue
        in the word ‘adamant’, which,             There are few substances in the world     ground, or kimberlite, where precious
        in Greek literally means, ‘not        today that have so fascinating a story        rough diamonds are still found today.
conquered’. Quite apt, considering that a     behind them, or substances that can boast     Rated 10 on the Mohs scale of hardness,
diamond’s beauty is eternal, ethereal and     of being half the age of the planet itself.   diamonds are the hardest substance on
can never be tarnished by the ravages of      Such is the truth behind diamonds.            earth. (Mohs scale measures a mineral’s
time. The ancient Greeks and Romans                                                         hardness)
believed diamonds to be tears of the gods     The Source of the Rough
and splinters from falling stars, and the     Natural diamonds were formed about            Indulge in Variety
value of such mythical beliefs exists even    billions of years ago at a depth of 300        Diamonds are of various types - natural,
today.                                        km within the earth’s crust. Under            synthetic industrial, and film diamonds.
    Plato wrote about diamonds as living      immense pressure and temperatures,            Synthetic industrial diamonds are
beings, personifying celestial spirits. For   carbon atoms combined to crystallise          lab-grown using the process of ‘High
as long as man has known about these          and grow as diamonds within rocks. The        Pressure High Temperature (HPHT)
gems, they have been associated with          diamond-bearing ore was brought to the        Synthesis’. Synthetic industrial diamonds
astrology and have been believed to bring     surface through volcanic eruption. After      are grown under conditions that mimic
 THE ELGI MAGAZINE                                                                                                                                                                                      THE ELGI MAGAZINE 
                                                                                                                                                                                                                                       I N D U S T RY INSIGHTS

The value of a diamond increases                                                           stone. A facet is a tiny plane that traps the
exponentially in relation to carat weight,
since larger diamonds are both rare and
                                                                                           light and makes a diamond sparkle. The
                                                                                           facets are applied to the diamond on a
                                                                                                                                                                                       GRADES FOR CLARITY
more desirable for use as gemstones.                                                       turntable, which is coated with diamond
    Diamond cut is perhaps the most                                                        dust and oil. The diamond is set into a                  F                      VVS-VVS                     VS-VS                       I-I-I
important of the four Cs. It refers to the                                                 holder and held against the turntable as it
finish and symmetry of the diamond.                                                        revolves at a very high speed. It requires              Flawless: No           Very Very Slightly             Very Slightly Included        Included (three grades).
The most popular style of cut is the         India, where artisans discovered that they    anywhere between a few hours to several                 internal or            Included (two                  (two grades). Minute          Inclusions visible under
brilliant cut, a round stone with 58         could make a diamond sparkle simply by        months for the process of cutting and                   external flaws.        grades) with minute            inclusions seen only          0x magnification as
facets. Any style of diamond cutting         rubbing one diamond against the other.        polishing a diamond, during which                       Extremely rare.        inclusions, which              with difficulty under         well as to the human eye.
other than the brilliant cut is called a         A diamond must first be meticulously      it loses half its original weight on an                                        cannot be detected             0x magnification lens.       Buying diamonds from
fancy cut; important fancy cuts include      studied and then marked for cutting,          average.                                                                       even by a trained                                            any of these grades is not
the marquise, emerald, oval, heart shape,    as each stone is different. The rough             The traditional diamond cutting
                                                                                                                                                                          gemologist.                                                  recommended.
pear shape, kite, and triangle. A well-      diamond is divided into two parts by          tools have now been replaced by modern
cut, well-proportioned stone displays        sawing or cleaving. Most stones are sawn      machinery, which uses lasers. The desired
maximum brilliance.                          across the ‘grain’ (visible evidence of the   cut is pre-programmed into a computer
                                             diamond’s crystal structure). The stones      linked to the platform; the platform then
Secret Behind the Sparkle                    that are marked for cleaving are split        moves the diamond through the beam in
Modern mining as we know it today            along the grain by a single blow from a       a back-and-forth motion as determined
began in South Africa in the late 19th       steel blade.                                  by the system operator. In contrast to
century. However, the art of diamond             The polishing of the diamond begins;      conventional cutting methods, in which
polishing and cutting has its origin in      one by one, facets are ground on to the       the saw as well as the stone being cut

                                                                                                                                           move, the beam in laser sawing remains       diamonds and jewellery to the most       would become diamond dust due to
                                                                                                                                           stationary. Once the beam reaches the        exacting international standards.        the continual abrasive action of non-
                                                                                                                                           stone and the platform begins to move,               .
                                                                                                                                                                                            K.P Sanghvi & Sons increased         laser cutting.
                                                                                                                                           the sawing starts.                           the level of automation in diamond           Many diamonds with distorted
                                                                                                                                               Only 20 per cent of the diamonds         manufacturing by introducing laser       growth, such as graining, are impossible
                                                                                                                                           mined are suitable for polishing, and the    facilities for cutting diamonds. Laser   to cut by conventional means because
                                                                                                                                           remaining 80 per cent are of industrial      cutting technology provides the          of the changes in sawing planes they
                                                                                                                                           quality. There are many industrial           manufacturer with higher accuracy        contain. A stone such as this can now
                                                                                                                                           applications for laser-cut diamonds,         in diamond cutting. In addition, it      be sawed by laser without regard for
                                                                                                                                           which includes wire dies, surgical           gives maximum utilisation of the         the grain. At the point where the laser
                                                                                                                                           instruments, heat sinks, and many            rough stone. Non-laser cutting tools     strikes the diamond, the temperature is
                                                                                                                                           more in the electronics and aerospace        lack this weighty advantage, for the     very high. The heat generated during
                                                                                                                                           industries.                                  volumes cut off from the diamond         the process is cooled by directing
                                                                                                                                                                                                                                 compressed air on the cutting surface
                                                                                                                                           The Indian Tale                                                                       of the diamond. Apart from this
                                                                                                                                           Surat is the nerve centre of diamond                                                  application, compressed air is used to
                                                                                                                                           cutting and polishing industry in India,                                              hold uncut diamonds using pneumatic
                                                                                                                                           famed for its handmade jewellery. More                                                valves. Downstream accessories such as
                                                                                                                                           than half of the world’s export of cut                                                dryers and filters are used so that the
                                                                                                                                           and polished diamond is from India. So                                                compressed air in these applications is
                                                                                                                                           whether you live in France or the U.S.,                                               free of moisture and oil.
                                                                                                                                           if you buy an engagement ring, there’s                                                    The use of advanced technologies
                                                                                                                                           a good chance you’ll be taking home a                                                 has been established in the diamond
                                                                                                                                           diamond crafted in India.                                                             industry, where smaller stones are often
                                                                                                                                               Since their beginning in 1965, K.P                                                cut and polished using laser equipment.
                                                                                                                                           Sanghvi & Sons’ quest for the perfect                                                 With laser facilities the potential for rare
                                                                                                                                           diamond has been endless. A leading                                                   fancy cuts is limitless, although how
                                                                                                                                           client of the Diamond Trading Company                                                 some of the special diamond cuts are
                                                                                                                                           (DTC), they manufacture and market                                                    made remains mysterious.

 THE ELGI MAGAZINE                                                                                                                                                                                                                                  THE ELGI MAGAZINE 
                                                                                                                                                                                                           I N D U S T RY INSIGHTS

                 STARRY EYED

                                                                 pectacles provoke ridiculous nicknames,       green is added to a lens to help you see        easier to spot.
                                                                 and according to some people they bestow      it better during insertion and removal.             Colour lenses can drastically change
                                                                 a sense of inferiority. It is thus time to    Optionally these contacts are given an          the way you look, and give you a total
                                                                 junk those spectacles that made you the       enhanced tint, which can alter your eye         makeover, but it is necessary to remember
                                                                 butt of all the jokes soaring around.         colours for a beautiful natural look.           that the colour of your lenses should not
                                                                                                                   The most commonly adorned                   clash with your skin and hair colour. It
                                                      Demystifying Lenses                                      contacts are the ones with colour tints,        should otherwise blend with the way
                                                      Contact lenses are thin, finely crafted plastic discs    and they are all the rage. Hazel, blue,         you look. Also, people who apply eye
                                                      designed to fit over the cornea of the eye, usually to   green, grey, you see it and you can sport it.   make-up should be careful that it does
                                                      correct vision problems caused by refractive errors.     There are the two-in-one lenses available       not overshadow the colour of the lenses,
                                                      They are held in place by adhering to the tear film      in the market for people who like to keep       and should in fact augment the colour.
                                                      that covers the front of the eye. In addition to their   their options open. So now you can                  Various other factors should be
                                                      obvious cosmetic advantages over eyeglasses, contact     have two of your favourite colours in           kept in mind while buying lenses. For
    A fashion statement or a convenient option?       lenses provide better peripheral vision and virtually    one lens. With the advent of colour lens,       instance, if you plan to wear the lenses
                                                      eliminate the image distortion sometimes caused by       youngsters are also given an option of          for more than 18 hours for the purpose
     With rapid industrialisation and growth, the     spectacles.                                              wearing theatrical contact lens to make         of eye colour change, then you should
    world is moving at a swift pace with ‘beauty                                                               the eye appear unnatural. Whether it was        opt for soft lenses. Both hard and soft
     equates to confidence’ as the mantra of the      Colour Me Right                                          Ellen Burstyn (Regan) in the Exorcist           lenses are used for vision correction as
                                                      Our eyes are like an ocean, vast and deep. They          or one of those ghastly things on horror        prescribed by your doctor. The most
      current generation. The rising popularity of    speak volumes, and are an outlet to the world.           shows, one can add some shock and thrill        important thing while picking contact
                                                      Blessed are we that we can experience infinite           to one’s life with just a pair of costume or    lenses comes down to quality, for it
     all the light-eyed Hollywood and Bollywood       colourful moments because of them. Have you ever         theatrical lenses.                              involves the health of your eyes.
             celebrities has popularised the use of   wondered how you would feel if your eyes were                Another option available is lenses
         contact lenses among the young brigade       gifted with colour? Colour lenses provide just that      with light filtering tints, which sharpen       At Your Disposal
                                                      experience; one does not require vision correction       objects and are usually worn by athletes        Disposable contacts are a breakthrough
         rapidly. A lot has changed since the days    to wear these.                                           and sports stars. They are designed such        in the field of eye care products.
                                                          Most contact lens comes with visibility tints that   that they sharpen certain colours – a           Recommended by most practitioners,
     when frameless glasses were considered an        relieve you from the tension of scurrying around in      tennis ball, for example, will stand out        disposables are not only convenient,
          indicator of the attractiveness quotient.   case you drop your lenses. Usually a light blue or       more against the background and will be         but also very healthy. Your tears contain

0 THE ELGI MAGAZINE                                                                                                                                                                                                    THE ELGI MAGAZINE 
                                                                                                                                                                                                                                       I N D U S T RY INSIGHTS

                                                                                                                                                                                                                      The sight of a stuffed toy
                                                                                                                                                                                                                      never fails to lift your spirits,
                                                                                                                                                                                                                      bringing back nostalgic
                                                                                                                                                                                                                      memories. Age has never been
                                                                                                                                                                                                                      a factor in collecting soft toys
                                                                                                                                                                                                                      and filling homes and cars. A
                                                                                                                                                                                                                      soft toy can fit in any barren
                                                                                                                                                                                                                      corner, giving the surrounding
                                                                                                                                                                                                                      a bubbly and lived-in aura.
                                                                                                                                                                                                                      Soft toys are one of the best
                                                                                                                                                                                                                      relaxing agents that help
                                                                                                                                                                                                                      unwind from a stressful day.
                                                                                                                                                                                                                      Kids may just be your excuse
                                                                                                                                                                                                                      to get hold of these
                                                                                                                                                                                                                      cute add-ons.

                                                                                                                                            REVISITING THE
substances such as proteins, calcium,          high quality lenses in greater volumes.    Compressed air is used as an air bearing
and lipids. These are deposited on             With prices slashed, lenses are becoming   system – the spindle is suspended in the
your contact lenses, making them less          more affordable and replaceable, which     air and a natural diamond tool is used for
comfortable. The deposits can also             is how disposable contacts came into       cutting the lens. The air-bearing system

                                                                                                                                            WONDER YEARS
make your eyes more prone to infection         existence.                                 needs a clean, dry air supply, free from
as they accumulate on your lenses.                                                        solid, liquid, and gaseous impurities.
Disposables overcome the hassle of             Untainted Appeal                               A CNC lathe and a CNC mill are
cleaning with a solution, which is rather      AI Optics Ltd. Chennai manufactures        required to cut an IOL. These operations
time-consuming. Disposables seem to            intraocular lenses (IOLs). IOL is a        need to be performed in moisture and
be the best option, as they do not need        medical device with optic and haptic       oil-free air. AI Optics utilises both
to be cleansed daily, and there is less risk   components, intended for surgical          refrigerated and heatless dryers for
of infection or swelling when one falls        implantation inside the anterior or        condensing the moisture. Compressed           A Fascinating Beginning                       19th century, sock monkeys remain a        President failed to make a kill, and so

asleep with the lens on.Their expiry           posterior chamber of the eye for visual    air is vital to the production process, and                                                 popular toy to this day, although not as   his hosts caught and tethered a bear,
periods range form 24 hours to forty five      correction of aphakia (cataract). The      the compressors run round the clock,                   s early as the 1930s the plush toy   prevalent as teddy bears.                  presenting it to the President as a sitting
days.                                          lenses are cut on lathes from PMMA         seven days a week at AI Optics.                        or ‘stuffed animal’ was stuffed         The cuddly children’s toy – quite       target. Naturally, the President refused,
       Before the development of               (Polymethyl methacrylate) or HEMA (            Since the time the contact lenses were             with straw, beans, cotton, etc.      unlike a real bear – was invented almost   uttering the immortal words, “Spare the
disposables, regular lens replacement          hydroxyethyl methacrylate) blanks with     first described and sketched by Leonardo      Of the two most popular types of stuffed      simultaneously in the United States        bear! I will not shoot a tethered animal”.
was recommended, which was very                UV absorbing properties.                   Da Vinci in the early 1500s, they have        animals, the teddy bear enjoys favour         and Germany, but the United States         Clifford Berryman drew a cartoon of
expensive. Hence, cleaning solutions that          The manufacture of IOLs involves       come a long way, offering an array of         over the sock monkey. A sock monkey           unquestionably gave it its name. In        the scene, which was published in the
extend the lens’ life came in. Technology      a 25-stage process, which includes         choices and opening a completely new          is a type of stuffed toy fashioned in the     November 1902 Theodore Roosevelt,          Washington Post. That same month
has however come up with cheaper               the     preparation,   characterisation    perspective to the world, literally!          likeness of a monkey. Originally made         26th President of the United States,       Brooklyn shopkeepers Morris and
modes of production, which produce             and fabrication of intraocular lenses.                                                   from discarded workmen’s socks in the         was hunting in Mississippi. The            Rose Michtom made a soft bear toy,

 THE ELGI MAGAZINE                                                                                                                                                                                                                                  THE ELGI MAGAZINE 
                                                                                                                                            I N D U S T RY INSIGHTS

                                                                                            same manner as other industries.
                                                                                                 The soft toy involves an eight-
                                                                                            stage production process that includes
                                                                                            designing, pattern cutting, cutting of
                                                                                            synthetic fur/plush fabrics to design,
                                                                                            fixing things like glass eyes, nose,
                                                                                            buttons, joints, etc., mechanical stitching
                                                                                            with stitching machines, stuffing with
                                                                                            sponge, cotton or manmade polyester
                                                                                            fibre fill, closing, and packing.
                                                                                                 Compressors form a vital part, and are
                                                                                            inevitable for a toy-filling machine. The
                                                                                            toy-filling machine comprises polyester
                                                                                            fibre held by a horizontally mounted
                                                                                            hopper-fed drum, with nozzles that are
                                                                                            used for toy filling. Filling is carried out
                                                                                            by operating an actuator valve that causes
                                                                                            compressed air to drive polyester fibre
                                                                                            into the toy through the nozzle. The
                                                                                            same process can be used for a variety
                                                                                            of textile fillings, including down and
                                                                                            crumb. During the process of stitching,
                                                                                            the fur is held in place on the surface of
                                                                                            the sewing machine using compressed
                                                                                            air. Compressed air is also blown into the
which they named ‘Teddy’s Bear’ and              Their brands Muskan (economy               stuffed toys to fluff up the fur.
displayed in their window with a copy        range for small outlets), Play-Pets (for the        Hanung offers myriad varieties of
of the cartoon. America went bear-           upwardly mobile) and Play-Pets Premium         soft stuffed toys made of acrylic plush
mad almost overnight, the Michtoms           (for high-end buyers) dominate almost          fabric in pleasing colours and designs.
went on to make their fortune with the       every store and city mall. With an immense     These toys are stuffed with polyester
‘Ideal Novelty and Toy Company’, and         factory and an in-house designing unit,        staple fibre (PSF) that has a tube-like
President Roosevelt had found a highly       Hanung has a product range of over 7,000       structure. The dimensions and material
effective political mascot.                  designs and a production capacity of           of the PSF are so chosen that the toy
    On the other side of the Atlantic,       30,000 pieces a day.                           retains its shape for a very long period.
Margarete Steiff, a disabled German                                                         Meticulously manufactured from the
seamstress founded the Steiff Company,       Yielding Upshot                                finest soft materials, artists and designers
the first commercial concern to create       Earlier toys were hand-made by parents         have innovatively reproduced animals,
stuffed toys. It is reported that in 1907    or in limited quantities by artisans. Later,   celestial toys, flowers, fruits and veggies,
Steiff made around 9,75,000 bears (with      19th century industrial toy production         sporty toys…the list is endless.
their trademark button in the left ear), a   benefited from technological advances in            Hanung is well supported by designers
record that has not been equalled since.     tools and dies, ceramics, and paper in the     from India’s premier fashion institutes.
                                                                                                    Some, who have been trained by
Closer Home                                                                                          Koreans and have over ten years’
Set up in technical collaboration                                                                    experience in the field are involved
with Hanung Toys in South Korea,                                                                     in developing designs. Hanung
Hanung Toys (India) Ltd. has                                                                         has a lot more to offer other than
evolved as one of India’s largest                                                                    toys. It also manufactures bed
manufacturers and exporters of                                                                       linen, hotel linen, bedspreads,
soft toys, decorative cushions                                                                       filled pillows, pillow covers,
and children’s room furnishings.                                                                     blankets/quilt covers, table covers
Based in Noida, Uttar Pradesh,                                                                       and table napkins for passionate
Hanung has an annual turnover                                                                        homemakers. Nevertheless, their
of US$ 15 million, and exports                                                                       most affable offering remains the
toys to leading retailers in                                                                         cuddly soft toys that have become
Sweden, Germany, the US and                                                                          a vital part of our children’s daily
other countries.                                                                                     lives.

 THE ELGI MAGAZINE                                                                                                                                     THE ELGI MAGAZINE 
                                                                                                                                                                                                                    I N D U S T RY INSIGHTS

                       A UNIQUE                                                                                                                                                 The cartridge case is the
                                                                                                                                                                            single most difficult part to
                                                                                                                                                                                                              Development Organisation) and INTIB
                                                                                                                                                                                                              (Energy and Environment Information)

                       PA CKAGE
                                                                                                                                                                            manufacture in ammunition,        in technology transfer for developing
                                                                                                                                                                            and is both expensive and         countries.
                                                                                                                                                                            heavy. This is why there are
                                                                                                                                                                            very few companies today          Foraying Out
                                                                                                                                                                            with the pluck and capability     The turning point in Shri Thampan’s
The invention of the cartridge case           Mechanism Reloaded                                                                                                            to manufacture this mission-      life came in the early 1990’s when the
has completely revolutionised the             A cartridge is a container, usually cylindrical in shape, which                                                               critical product.                 Defence Research and Development
                                              holds a bullet, gunpowder and primer (a chemical substance)                                                                                                     Organisation (DRDO) approached
knack of gun making, which has been           together in a single metallic case. Of the complete cartridge                                                                                                   him with the idea to manufacture and
successfully applied to all descriptions of   package, the case is the key element.                                                                                         Leadership with a                 supply combustible cartridge cases for
firearms and has given rise to cartridge          The cartridge case is the one re-usable component of                                                                      Difference                        the Indian army. Shri. Thampan took
                                              the cartridge that makes the practice of ‘reloading’ feasible.                                                                                                  up this challenge to design and produce
manufacturing—a crucial industry.             Reloading is a process where the combustible material can                                                                      MasPack India Ltd. is one        such a mission critical element in the
                                              be re-loaded into the once-used cartridges.                                                                                    of the leading solution          ammunition that was being imported
                                                  Firing a cartridge is a physical and chemical chain reaction                                                               providers of combustible         until then.
                                              that takes place in a split second. The chain reaction starts                                                                  cartridge cases for the Indian       The cartridge cases imported earlier
                                              with pulling of the trigger, which releases the firing pin.                                                                    Army. MasPack also takes         were made of brass, which was heavy,
                                              The firing pin strikes the primer, igniting it. The flame then                                                                 pride in being a pioneer to      expensive and also non-flammable.
                                              ignites the gunpowder, which swiftly burns a high volume                                                                       design and supply paper          So, DRDO supplied MasPack an
                                              of gas. Burning gases under very high pressure seek the path                                                                   pulp moulding plants. They       inflammable raw material, which was
                                              of least resistance, down the bore to the muzzle, which is         powder when a gun is fired, causes the         supplied the first 100 percent indigenous     designed indigenously, to manufacture
                                              the open end of the gun. The gas pushes the bullet along           case to expand slightly, tightly sealing the   Egg Tray Plant, using wastepaper as the       and supply combustible cartridge cases
                                              as it travels to the muzzle. Thus, the cartridge case not only     chamber and preventing the blowback            main raw material, in 1981.                   for the Indian army.
                                              holds the combustible material together, but also forms a          of gas towards the shooter.                        MasPack’s most interesting product            MasPack can produce a minimum
                                              gas seal crucial to the shooter’s comfort, and contributes to          The original cartridge for military        is the Combustible Cartridge Case             of 250 cartridge cases per day. ELGI
                                              safety when the arm is fired. The high pressure generated          firearms dates back to 1586, which             (CCC) used in tanks and artillery             compressors play a vital role in the
                                              by the expanding gases which is released by the burning            consisted of gun powder and a bullet in        guns. MasPack has been successful             complex production process followed
                                                                                                                 a paper tube. The lack of technology was       in supplying cartridge cases to meet          to convert the cotton pulp into the
                                                                                                                 very evident, as the cartridge cases used      specific ammunition needs for India’s         combustible cartridge case. As a first
                                                                                                                 were wreaked with various drawbacks.           main battle tank ‘Arjun’ and many of the      step, the cotton pulp is put in the mould
                                                                                                                 The conventional cartridge added               Russian guns.                                 and is squeezed with a pneumatically
                                                                                                                 certain problems to the firearm. The               If we were to look behind the scenes      pressurised plastic bulb. This is done
                                                                                                                 firearm had to have an ejection port to        we would see a face that established and      mainly for two objectives: to squeeze
                                                                                                                 eliminate the spent cartridge case. This       nurtured MasPack against all hardships.,      out the water from the pulp, and to
                                                                                                                 meant that dirt and fluid could enter the      After serving 20 years in the Indian          from a homogeneous cotton wall. The
                                                                                                                 gun through the ejection port, which           Navy and the Department of Atomic             combustible material is then squeezed
                                                                                                                 increased the possibility of the firearm       Energy, Shri R. V. Thampan ventured           into the cotton shell with a pneumatic
                                                                                                                 locking. Moreover, the primer and the          into the industry to start a small-scale      press to get the final product.
                                                                                                                 associated firing pin added some delay         light engineering unit in the backward            These cotton capsules produced for
                                                                                                                 between the time the trigger was pressed       districts of Allepey, Kerala.                 ‘Arjun’ battle tanks are unique in their
                                                                                                                 and the time the bullet left the barrel.           Though not an engineer by                 design; they do not leave any debris
                                                                                                                 However, the cartridge has overcome            education, Shri Thampan became                behind after explosion. Arjun is a main
                                                                                                                 these difficulties in recent times with the    immensely successful in perfecting            battle tank indigenously developed by
                                                                                                                 invention of modern cartridge cases.           the design and development of more            DRDO for the Indian Army. It is named
                                                                                                                     These days, cartridge cases are made       than 20 high tech equipments for the          after Arjuna (famed for his excellence
                                                                                                                 from paper of various qualities with           production of combustible cartridge           in archery), one of the heroes in the
                                                                                                                 brass bases or entirely of thin brass.         cases. He was a technical consultant for      Hindu epic the Mahabharata, for its
                                                                                                                 Combustible cartridge cases used in            the Defence Ministry’s combustible            ability to provide accurate firepower.
                                                                                                                 battle tanks have cylindrical walls            cartridge case production plan, a pioneer     Combat proven combustible cartridge
                                                                                                                 formed of combustible material. The            project in India. Shri Thampan has            cases are thus an integral part of modern
                                                                                                                 walls comprise one or more wraps or            won the National Award for Research           tank ammunition. These re-loadable
                                                                                                                 windings of textile fibres, which are          and Development from NRDC. He                 cartridge cases act as the backbone of
                                                                                                                 bound together with bonding agents             has also been selected to the panel for       Indian defence in providing solutions
                                                                                                                 having propellant charge characteristics.      UNIDO (United Nations Industrial              for critical applications.
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                                                                                                                                                                                                        R E S E A R C H & I N N OVAT I O N

                                                                                                                                     but also a process that will help capture the right         At ELGI, the task of design creation, shared
                                                                                                                                     information to manufacture a product, operate           information, and general coordination for
                                                                                                                                     it in the field, and dispose or decommission it         efficiency is an ever-increasing challenge.
                                                                                                                                     at the end of its useful life. Manufacturing and        Currently, we have implemented Program
                                                                                                                                     operational process plans form an inherent part         Central and Engineering Central modules to
                                                                                                                                     of PLM. It has emerged as the primary means to          create a competitive edge.
                                                                                                                                     improve product development processes across
                                                                                                                                     the value chain to deliver the most business            Program Central
                                                                                                                                     value. The pre-requisites for a successful              The program central module in PLM allows
                                                                                                                                     product lifecycle in the current dynamic business       ELGI to tag live product information to internal
                                                                                                                                     environment are planning, greater flexibility,          processes, and eliminates the need for manual
                                                                                                                                     better communications and more effective                input when product tasks are finished. Our
                                                                                                                                     business processes.                                     project teams can easily create, share and manage
                                                                                                                                          A strong need for PLM had been identified          project information globally, ensuring consistent
                                                                                                                                     by ELGI mainly, because of its constant efforts         approaches and informed collaborative decisions.
                                                                                                                                     geared towards enhanced innovation, along with              ELGI’s Product Development Process, NPD
                                                                                                                                     improved manufacturing capability, quality, cost-       (New Product Development) has been mapped
                                                                                                                                     efficiency, and consequent productivity. A PLM          under program central. The NPD is a business
                                                                                                                                     system in place will enable us to capture and re-       process that enables us to consistently deliver
                                                                                                                                     use knowledge about our products, processes,            compelling consumer solutions, drive predictable
                                                                                                                                     resources, suppliers and customers so that we           financial results, and win in the market place.
                                                                                                                                     can increase the value of our product portfolio.            The NPD-DFSS (Designed for Six Sigma)
                                                                                                                                     It will minimise our lifecycle costs and maximise       life cycle go through several phases. The formal
                                                                                                                                     the revenue generated by individual product             development effort may come under the product
                                                                                                                                     offerings.                                              conceptualisation, design input, development
                                                                                                                                     Product Lifecycle Management (PLM) offers               planning, design output, verification and finally
                                                                                                                                     different modules to manage the business                the product review and release phases.
                                                                                                                                     processes around product development and                    ELGI has implemented the NPD form for
                                                                                                                                     engineering changes. Some of the main modules           Standard Product development and the NSD
                                                                                                                                     in PLM are the following:                               form for Non-Standard Product development
                                                                                                                                     Product Central                                         phases. The availability of the form enables the
                                                                                                                                       This guides product managers and engineers            marketing to raise the relevant form based on field
                                                                                                                                     through the process of building the product             requirements, which then goes through a defined
                                                                                                                                     structure, which includes all the features and          workflow to secure the management acceptance.
                                                                                                                                     options for a product.                                  Approval hierarchies from members of the cross-
                                                                                                                                     Document Central – A knowledge management               functional team have been built in at various stages
                                                                                                                                     system that helps to store, share and search            facilitating information sharing and management
                                                                                                                                     technical information.                                  of the deliverables between various participating
                                                                                                                                     Team Central – helps you complete projects              departments within the organisation.
                                                                                                                                     faster and with more efficiency by linking you
                                                                                                                                     with other people, both inside and outside your         PLM Projects help manage NPI (New Product
                                                                                                                                     company, whose input is critical to completing          Initiative) activities from concept to retirement
                                                                                                                                     the project.                                            stages. With PLM projects, we have realised the
                                                                                                                                     Info Central – This helps to access all information     following benefits:
                                                                                                                                     stored in the repository. It is a collection of tools   n	 Increased rate of NPI

                                                                                                                                     that allow a company to effectively perform basic       n	 Improved communication and collaboration

                                                                                                                                     search functions, create and save queries and               with cross-functional teams in real time for
                                                                                                                                     collections.                                                reduced cycle time and new product ideas

     n a global economy defined by          like Gartner and Forrester Research have          Product Lifecycle Management helps         PLM system gives traceability to employees          n	 Product delivery within budget
     intense competition and ever-          identified Product Lifecycle Management       as a business approach in solving the      who come up with new product ideas that                 n	 Timeliness and quality of information.
     changing consumer preferences,         (PLM) as the necessary enterprise             problem of managing the complete set of    generate revenue. The system provides
nobody accepts status quo as a permanent    infrastructure to successfully address        product definition information spanning    accountability to employees who bring in design         Engineering Central
condition. The daunting task in a global    issues in managing products from idea         everything from the concept to end of      changes that improve customer satisfaction              The Engineering Central manages the
economy is to manage and maximize           through retirement. It is quintessential to   life of a product; it integrates people,   level. PLM will help us to better define, execute,      engineering changes made to all the parts used in
the value of a product throughout its       improve the effectiveness of the product      processes, business systems, as well as    measure, and manage key product-related                 various products manufactured by ELGI. These
lifecycle. Leading industry analyst firms   development process.                          information. PLM is not just a program     business processes.                                     parts could be manufactured parts, standard
 THE ELGI MAGAZINE                                                                                                                                                                                                      THE ELGI MAGAZINE 
                                                                                                                                                                                                                    B U S I N E S S S P OT L I G H T

                                                                                                                                                                BEHIND THE
                                                                                                                                                                RADIANT SMILE

                                                                                                                                                                         he toothbrush could be one            the tooth stick to enable the cleaning of
                                                                                                                                                                         invention that man can hardly         the rear teeth. Inspired by this practice,
                                                                                                                                                                         imagine a life without. This          William Addis, of Clerkenald, England,
                                                                                                                                                                innocuous tool of personal hygiene has a       created the world’s first modern
                                                                                                                                                                long and chequered history dating back         toothbrush in 1780. Addis, and later
                                                                                                                                                                thousands of years. Physically recorded        his descendants, manufactured the
                                                                                                                                                                evidence from well-preserved Egyptian          finest brushes, where the handles were
                                                                                                                                          Every morning, in     tombs suggests that ancient Egyptians          carved out of cattle bones, and the hairs
                                                                                                                                                                were conscious of their dental hygiene,        from the neck of a Siberian wild boar
                                                                                                                                           every household      and rudimentary teeth cleaning devices         were inserted into the holes made in
                                                                                                                                               from coast to    existed as early as 3500 BC.                   the bone.
parts (screws, bolts, nuts...etc), bought-     PLM to involve the approvals of various     in PLM, drawings are handed over by                                      Unlike today, when there are a                 The       boar-hair       toothbrush
out parts (ELGI designed and supplier          members of the CFT (Cross-Functional        R&D to the archivist and the users from        coast, the sounds     host of options available in terms of          continued to be used until the advent
designed), spare parts, etc.                   Team). Once approvals are sought, the       various teams can request a part drawing     of bristles whisking    toothbrushes, early man had hardly             of World War II. Ironically, it was in
    Each part has a specification attached     PLM system revises to release the product   electronically through the Document                                  any recourse to variety. What did exist        this period, with military insistence on
with drawings. With PLM framework,             accommodating the new specifications.       Management System. DMS mapped                      over teeth can    then was a ‘chew-stick’. This brush was        dental hygiene, that brushing of teeth
the R&D at ELGI can now store all the          The Engineering Central at ELGI thus        in PLM enables us to organise the                  be heard. This    made by mashing small twigs or tree            became a common everyday activity of
drawings related to their parts in a central   closely monitors ECR/ECO process in         documents in a structured manner at a                                roots until the fibres at one end became
repository. ELGI has a separate NAS            every stage.                                commonplace. The request for a drawing          daily routine is a   loose enough to form a rough brush.
storage with 700 GB of storage space at            Engineering Central is integrated       is routed through an approval process         necessary lifelong     Some native Indian and African people
each of our two factory locations for this     with the ERP initiative from BaaN that      before the archivist releases a drawing to                           living traditionally still clean their teeth
purpose.                                       handles production and inventory. The       the requestor.                                   commitment to       with chew sticks. There also existed a
    ELGI has defined an ECM                    part created or revised in PLM is always        The PLM solutions from Matrix                 maintain those     more primitive version of toothpicks,
(Engineering Change Management)                posted to BaaN for production purpose.      One have enabled ELGI to dramatically                                namely the tooth sticks. Originally,
process to handle product changes              In addition, appropriate actions like       accelerate innovation, time-to-market,              pearly whites    these tooth sticks were fashioned out
and ensure robustness of the product.          Scrap and Re-work are initiated on old      revenue and improved customer relations                              of porcupine quills, bird feathers, or
Any part that undergoes an ECR/ECO             revisions.                                  by collaboratively developing, building,                             wooden thorns.
process has a workflow pre-designed in             Once a part is revised or released      and managing products.                                                   History also points towards the
                                                                                                                                                                usage of a soft rag attached to the end of
0 THE ELGI MAGAZINE                                                                                                                                                                                                                THE ELGI MAGAZINE 
                                           toothbrush came to exist.                    and those who wear braces. Sometimes,
                                               Dr. Robert Hutson, a periodontist        it takes more time and effort to use an
                                           from San Jose, California, invented the      electric toothbrush because batteries
                                           first toothbrush with soft end-rounded       must be recharged after every use.
                                           nylon bristles. He named the product             Much goes into the manufacture of
                                           ‘Oral-B’. In 1969, the Oral-B classic        this ever-evolving toothbrush though.
                                           toothbrush went to the moon. Neil            Jewel Brushes Pvt. Ltd., one of the
                                           Armstrong used one a minute before his       largest manufacturers of toothbrushes
                                           historical moonwalk.                         in India, operates with state of the art,
                                               The basic design of plastic              fully automated plants. Jewel Brushes is
                                           toothbrush handles, mounted with             a certified and recommended supplier
                                           nylon bristles at one end, has remained      of toothbrushes for Unilever companies
                                           virtually unchanged since then. With         around the world, and is present in all the
                                           the passage of time and as technology        segments of toothbrushes - premium,
                                           progressed, the design evolved and           mid-price and mass-market. Since their
                                           improved. The first electric toothbrush      modest beginning in 1993, today they
                                           was developed in 1939 in Switzerland.        have reached a capacity of producing
                                           Electric toothbrushes generally work by      165 million toothbrushes per annum.
                                           using tufts of nylon bristles to stimulate   An ISO 9002 company, Jewel brushes
                                           gums and clean teeth in an oscillating or    exports to more than 25 countries across
                                           rotary motion. Some tufts are arranged       the world.
                                           in a circular pattern, while others have         Jewel Brushes is the only supplier in
                                           the traditional shape of several bristles    India that has been awarded the ‘Tynex’
personal cleanliness. Around this time,    lined up on arrow. Electric brushes are      logo from Du Pont for adhering to
a shortage of boar hair was experienced,   advantageous because they can cover          consistent quality of toothbrushes. Hence
and this led to the invention of nylon     more area faster. Electric toothbrushes      they use the best of technology available
bristles. Nylon filaments replaced boar-   are recommended for elderly people           in the toothbrush industry worldwide.
hair bristles, as these were less                                                               The thorough manufacturing
expensive in terms of production                                                                procedure includes the use
costs. It allowed manufacturers                                                                 of compressors for a critical
to shape the filament tip and also                                                              operation - for inserting nylon
vary the diameter according to the                                                              bristles onto the moulded
desired preferences. Boar hair on                                                               polypropylene handles. This
the other hand tended to fall more                                                              process takes place using special
easily, and since it took longer to                                                             machines called the bristling
dry it became a breeding ground                                                                 machines. Compressed air is also
for bacteria. Even so, boar hair                                                                used in the sealing machines for
bristles, today accounts for a 10 per                                                           the packaging of brushes. Jewel
cent share in the world market of                                                               Brushes, a valuable customer of
toothbrushes.                                                                                   ELGI for over 15 years, use ELGI’s
    Plastic handles gained popularity                                                           compressors for manufacturing
in the period between the two                                                                   toothbrushes.
world wars. Due to the increase in                                                                  Over the centuries, the
the nutritional demands of soldiers,                                                            toothbrush has seen many changes
bones that were earlier available in                                                            in configuration, material and
plenty came to be in short supply.                                                              geometry. Today’s toothbrushes
The resultant shortage called for a                                                             come in a large variety of
new toothbrush handle material.                                                                 shapes, styles, and colours, yet,
As a result, celluloid handles were                                                             despite this incredible selection,
created by injecting plastic into                                                               toothbrush geometry is not
moulds and then cooling them in                                                                 nearly as important to dental
the required shape. By 1920 a new                                                               health as brushing frequency and
method of drilling holes into the                                                               technique. Therefore, the brush
brush head to attach the bristles was                                                           that suits you best is the one you
developed. Therefore, the classic                                                               enjoy using.
 THE ELGI MAGAZINE                                                                                                                  THE ELGI MAGAZINE 
                                                                                                                                                                                PRODUCT FOCUS

                       TIDES OF
                       CHANGE                                                    A
                                                                                          long the picturesque Indian East
                                                                                          Coast, off the Bay of Bengal, lie
                                                                                          the states of Tamil Nadu and
                                                                                 Andhra Pradesh that are home to many
                                                                                 such fishermen tribes who may not
                                                                                 be renowned for their unique history
                                                                                                                              in the south. The Palli community
                                                                                                                              live in 35 villages of Prakasam district.
                                                                                                                              There are also 37 Pattapu villages here
                                                                                                                              called Pattapupalems. People of the
                                                                                                                              Pattapu community can be found from
                                                                                                                              Pandurangapuram in Guntur district to
                                                                                                                                                                          They are also known by the name
                                                                                                                                                                          Patnapu Rajulu since they hailed from
                                                                                                                                                                          the ‘Patnam’ (now known as Chennai).
                                                                                                                                                                              The word Palli is derived from the
                                                                                                                                                                          word Pallava. People of this community
                                                                                                                                                                          claim to be the descendants of the
                       An ocean, which is one of the most expansive              of traditions and beliefs, but are true      Tada in Nellore.                            Pallava dynasty, which once ruled most
                       features on this blue-green planet, is also probably      examples of the theory of survival of the
                                                                                 fittest. Two such communities are the        Tribal Fusion
                                                                                                                                                                          of south India during the 12th century.

                       the most intriguing. Just as intriguing and               Pattapu and the Palli community. With        Each of these tribes has its own set of     Kinship within Periphery
                       fascinating perhaps, is the life of marine fisher folk    their unique customs and traditions,
                                                                                 these communities add colour to the
                                                                                                                              customs and beliefs. The people of
                                                                                                                              the Pattapu community, known as the
                                                                                                                                                                          Traditionally, the Pattapu and Palli
                                                                                                                                                                          tribes are controlled by the kapu –
                       who live closest to the sea. Many a tale is woven         Indian cultural fabric.                      Pattinathar, have been fisher folks for     which means ‘protector of the village’.
                       around them, and innumerable stories come from                The long coastline of Andhra
                                                                                 Pradesh has fisher folk living in
                                                                                                                              thousands of years. The tribe migrated
                                                                                                                              to Andhra Pradesh some centuries ago
                                                                                                                                                                          Each village can have three different
                                                                                                                                                                          kapus, called Pedha Kapu, Nadu
                       them. This is especially true in India, which is a land   nine districts along the coast, from         and settled on the southern coastline,      Kapu and Chinna Kapu, who together
                       of countless tales that keep the Indian culture alive.    Srikakaulam in the north to Nellore          where marine fishing was convenient.        form the village committee. These

 THE ELGI MAGAZINE                                                                                                                                                                         THE ELGI MAGAZINE 
                                                                                                                                                                                             PRODUCT FOCUS

traditional leaders have administrative        climate and environment. Earlier, they          Traditions Galore
power and are responsible for social           lived in thatched, round-shaped huts            Though they are Hindus and follow
control, the economic affairs of the           called Gudisilu. Now the houses are             Hindu culture, their traditions differ
village, and conflict resolution. They are     constructed in a rectangular shape with         considerably from the widely accepted
indispensable in all religious ceremonies      low roofs to avoid being blown away             Hindu traditions.                               that the men avoid seeing women             sail made of cloth. Luckily, their lives
and festive occasions of the villages.         during a cyclone. These huts are called             The Pattapu and the Palli communities       before setting out to the sea. Seeing a     have been made much easier with
    The presence of women at these             Nittillu by the Palli community, and            have a blend of Hindu and Muslim                woman is considered as a bad omen.          the advent of technology. During the
kapu hearings is strictly prohibited. If       Moola by the Pattapu community. The             practices, though they are Hindus. The                                                      mid-1980s the marine diesel long tail
any woman passes the venue of the kapu         wood and the other material used for            patron saint of the Muslims, Nagore             Marine Livelihood                           outboard motor (OBM) concept was
meeting, even by chance, the meeting is        construction are obtained locally.              Meeran Valli, is the patron saint of the        A fisherman’s entire life depends           introduced and the fishermen started
cancelled. If a woman makes a mistake,             The daily lifestyle is still dramatically   sea; and every year they celebrate a festival   on the ocean. The standard of               venturing into the sea on motorboats
first her husband is called for the meeting,   conventional, and this can be observed          in his honour to ensure plentiful catches       living has advanced a lot for fishing       for fishing.
then she is called in for a hearing next.      in their attire and ornaments. Most of          at sea. Before starting the festivities,        communities in terms of the kind of             The diesel engines used in the
    The Grama Kantu (village area) is an       the fishermen wear a gochi (loin cloth).        they offer pooja (prayers) to the goddess       nets used and the boats, which have         boats are much more advanced now.
interesting concept followed by both the       The Pattapu community women love                Poleramma. Their important festivals            been mechanised now. However,               ELGI supplies advanced OBMs to the
communities. In the Palli community,           clothes in vibrant colours such as yellow,      are the Avvamma festival, Sri Rama              there is much ceremony and ritual           market. Only ELGI engines feature
nine stones are laid to mark the boundaries    green and red. Like other tribal women,         Navami, the Jalamma festival, Pongal,           attached to the usage of new nets.          a rust-free FRP air cowl over the
of the village. Eight stones are placed in     the fisherwomen like to wear jewellery          and Vinayaka Chathurdi. The main                    The      Pattapu       and      Palli   sheet metal to withstand corrosion
eight directions and the ninth is installed    made of gold, silver and bronze. The            festivals celebrated by the Pallikars are       communities use only theppas for            at sea. They also have stainless steel
in the centre of the village. An eminent,      expression of desire for ornaments is           Sankaranthi, Sri Rama Navami, Attla             fishing. Theppa in Telegu means             fasteners to prevent rust formation
skilled architect carves Sanskrit shlokas      found even in their folksongs.                  Tadhi and Jalamma Thiranala.                    anything that floats. It is also called a   and have a reduced engine weight for
(Vedic chants) on the centre stone. The            Tattooing is a common practice                  They worship Gangamma Thalli, the           ‘catamaran’, a word derived from the        easy portability. These engines give
Pattapu community places four stones in        amongst these tribes. Called paccha             goddess of the sea, before they go for          Tamil word kattumaram. It is a keel-        higher speeds, while using lesser fuel
the four directions, and the fifth one in      bottu, most of the men and women get            fishing. She is believed to wander in the       less raft formed by lashing together        and minimum start-up smoke.
the centre.                                    their bodies tattooed, particularly on          sea protecting the fisherman and blessing       four or five logs.                              The advent of diesel engines has
                                               the arms and forehead. Women prefer             them with a good catch. When casting                Way back in the 1970s the               simplified the fisherman’s life to a
Abode by the Sea                               to have tattoos on their foreheads, as          the net, pulling it in, and while returning     fishermen used to go fishing on             large extent, keeping the tradition
The structure of the houses of the             they believe it prevents headache and           home, the fishermen praise and worship          a traditional catamaran made of             alive, while incorporating new
fisher folk is greatly influenced by the       migraine.                                       Gangamma. Another peculiar custom is            Albhisia wood, with the help of a           technology.
 THE ELGI MAGAZINE                                                                                                                                                                                       THE ELGI MAGAZINE 
                                                                                                                                                                                                      PRODUCT FOCUS

               On The Tracks Of
               Customer Care

                                                                                                                                    The RR100101EC is an upgraded Expressor suitable for Alco
                                                                                                                                Locomotives manufactured by Diesel Locomotive Works (DLW),
                                                                                                                                Varanasi. The new product developed as replacement for the
                                                                                                                                existing Expressor Model 6 CD 3UC, features lower maintenance
                                                                                                                                interval to reduce maintenance cost, and enhance the reliability
                                                                                                                                of the product. The expressor is used to provide compressed air
                                                                                                                                to the braking system and its accessories has a discharge pressure
                                                                                                                                of 140 psi and a free air delivery rating of 200 cfm at 1100 rpm.
                                                                                                                                The upgared expressor model is developed in absolute compliance
                                                                                                                                to DFSS process and is being validated through functional and
                                                                                                                                environmental qualification tests as per RDSO ( Research Designs
                                                                                                                                and Standard Organization) specifications. In the last one year
                                                                                                                                five Expressors have been put for field validation at West Central
                                                                                                                                Railways- Jabalpur and is monitored under RDSO and DLW
                                                                                                                                guidelines. The performance reported greater satisfaction.

                                                                                                                                 COMPRESSOR-EMU APPLICATION
                                                                                                                                     Crossing yet another milestone in our association with the
                                                                                                                                 Indian railways, ELGI has developed a new compressor ‘RR15070’
                                                                                                                                 for the Indian railways. This compressor will be powering the
   WATER-COOLED COMPRESSOR                                                                                                       AC/DC EMU (Electric Multiple Unit) braking system and its
                                                                                                                                 accessories. The RR15070 is an air cooled two-stage reciprocating
    ELGI is the first and only Indian manufacturer chosen       compressors were validated for 3000 hours of continuous          “W” type compressor , with splash lubrication. The compressor has
by Indian Railways for development of indigenization            running and for a period of 50 hours running at an elevated      an operating pressure of 100 psi, delivering free air at 1200 lpm.
compressor Model RR 66101 W for General Motors                  temperature of 80 deg C as a part of the performance                 The compressor has been designed in compliance with the
Locomotives. The compressor developed for Indian                verification test. The Diesel Locomotive Works-Varanasi,         DFSS (Design For Six Sigma) process taking into consideration,
Railways as per General motor specifications. is the first      Indian railways has recently placed an order worth $0.67         the environmental severity of Mumbai where these compressors
ever water cooled compressor developed indigenously . The       million for the supply of water-cooled compressors. This         would be deployed . The prototype testing was conducted according
compressor has a discharge pressure of 140 psi and a free air   indegenisation has given significant advantages to the Indian    to RDSO specifications and the compressors are being validated in
delivery rating of 190 cfm at 900 rpm.                          Railways on cost reduction and on-time delivery. It has          the field at the EMU Car shed, Western Railway Mumbai for the
    The complete design and development was done in-            also helped the Indian Railways to save valuable foreign         last six months.
house as per DFSS (Design for Six Sigma) process. Three         exchange.
 THE ELGI MAGAZINE                                                                                                                                                                                          THE ELGI MAGAZINE 
                                                                                                                                                                                                                        PRODUCT FOCUS

                                                                                                                           INDIGENOUSLY DEVELOPED GAS ANALYSER
                                                                                                                               ELGI has indigenously developed ECOMATE, the latest and most advanced four gas analyzer in the market today.
                                                                                                                           The new device has been approved by Automotive Research Association of India (ARAI), a Ministry of Road Transport &
                                                                                                                           Highway Government of India’s authorized certification agency. The product was developed as an upgrade to the existing
                                                                                                                           two gas analyzer in the market and will be used to test vehicles running on petrol. ELGI ECOMATE gas analyzers are
   COMPRESSORS THAT CAN COMMUNICATE!                                                                                       setting new standards of functionality in vehicle exhaust gas monitoring. These exhaust gas analyzers measure the levels
                                                                                                                           of pollutant gases by NDIR (Non-Dispersive Infra Red) Technology. The outstanding feature of this instrument is its
                                                                                                                           ease of operation. All it requires is the insertion of the probes into the exhaust pipe of the vehicle to be analyzed and
       In keeping pace with the industry’s focus on high-      systems allow centralized personnel to perform remote
                                                                                                                           readings appear on a LCD screen. The new smoke meter for testing diesel vehicles is under development and will be
   tech advancements, ELGI has developed the Neuron            monitoring and control of widely dispersed equipment.
                                                                                                                           introduced in the market shortly.
   controller with in-house engineering to control             This controller by interfacing with the DCS (Distributed
   medium to large size rotary compressors. This dedicated     Control System) can monitor the operations easily
   micro controller accurately monitors the compressor         and warnings regarding any failure are conveyed to
   and ensures precise capacity regulation. It also allows     the plant personnel immediately through the use of
   communication capability.
       ELGI Neuron is the first ever compressor controller
                                                               networked computers. These automation systems are
                                                               capable of controlling multiple compressors and enables
                                                                                                                                                                                        ELECTRONIC OIL / LUBE METER
   to feature an in-built Mimic. The Mimic panel is a          communication across the compressors through DCS
   pictorial representation of various components of a         control stations.                                                                                                                ELGI offers the most affordable and accurate
   compressor. It enables semi-skilled personnel to easily         The integrated automated system of Neuron has                                                                            meters for dispensing and metering lubricants in
   detect the trouble allowing them a higher degree of         revolutionized the compressor unit operation by                                                                              demanding environments. This newly developed oil/
   control over the compressor’s operation. The LED            providing Remote Analysis. Service and maintenance                                                                           lube meter is approved by Ministry of Weights and
   indicators below each component provide a visual            information is built into the controller for enhanced                                                                        Measures Department. The Electronic oil/lube meter
   indication of the fault status of a particular component    accuracy and convenience. The RS 485 communication                                                                           is specifically designed to dispense all types of synthetic
   at the detector location. The indicator flashes red light   port allows for communication and remote monitoring.                                                                         oil and anti freeze. An easy-to-read digital display shows
   when the parameter is close to maintenance schedule or      No matter where the compressor unit is, the remote                                                                           the exact amount of fluid dispensed and the unique
   of abnormal function. The Neuron automated process          diagnostic software can send e-mail reports to the                                                                           beep signal allows the operator to stop filling when
   control system thus eliminates human errors and gives       central supervisory station of the ELGI customer care                                                                        the desired amount of fluid is dispensed. With the use
   early warning of fault indications through continuous       centre pinpointing the faults and failures in compressors                                                                    of the electronic oil/ lube meter in garages, oil filling
   monitoring of pressure and temperature.                     from the customer site itself. Without traveling to the                                                                      and lubrication becomes easy and highly accurate. The
       The Neuron control system of the compressors is         compressor location, the service engineers at ELGI can                                                                       electronic accuracy will save time and money. The meter
   widely used in various industries using DCS/SCADA.          conduct diagnosis, detect malfunctioning components                                                                          can measure in liters, gallons and pints, as required by
   SCADA (Supervisory Control and Data Acquisition)            and evaluate unit performance.                                                                                               the customer. It features a rigid extension with a non-
                                                                                                                                                                                            drip tip and has a comfortable grip.

0 THE ELGI MAGAZINE                                                                                                                                                                                                                  THE ELGI MAGAZINE 

    ELGI has been innovating and creating new
products on a regular basis, thereby keeping ahead
of the competition. The latest addition to their ever-
growing product line is the Wheels Free Scissor
Lift. The scissor-like structure makes the lift rigid,
sturdy and stable under stressful conditions. This
hydroelectric lift can lift up to an impressive 3000
kg, and is powered by a three phase 1440 RPM, 2
HP motor. The lift provides for effortless loading
and unloading using a drive-up ramp, and is rugged
and durable. The entire equipment is easily portable
and requires no expensive or time-consuming
installation procedures. It can be deployed for
various operations like pre-delivery inspection,
under chassis repair, etc. And enhancing this
complete solution is a pneumatic lock, provided
with the equipment for safety.

                                                         TROLLEY MOUNTED EPSAC

                                                              Building on the success of portable diesel powered
                                                          compressor unit, ELGI has extended its range of
                                                          compressors with the recent launch of the innovative
                                                          E45 trolley mounted oil injected electric powered
                                                          screw air compressor, widely used in the plant hire,
                                                          construction, quarrying and general industry segments.
                                                          This new single axle portable compressor is powered by
                                                          a three phase, TEFC squirrel cage motor with ‘F’ class
                                                              The new compressor features an integrated electric-
                                                          driven motor, resulting in increased motor performance,
                                                          reduced power consumption, lower maintenance costs
                                                          and fewer emissions. Compact in design, the E45 model
                                                          gives a unique solution for applications near urban
                                                          areas where electric power is readily available, and
                                                          environmental impact is a concern.
                                                              The EPSAC model in this new family of compressors
                                                          is dedicated to economising fuel expenses, offering
                                                          higher ROI (Returns on Investments) for the customer.
                                                          Embedded with cutting-edge technology, it has a free air
                                                          delivery range of 294 cfm at working pressure of 7 bar g.
                                                          The high performance two-stage air intake filters prevent
                                                          dust and dirt particles from entering the compressor.
                                                              Overall, the E45 portable motor-driven compressor
                                                          has all the desired features. Its high motor efficiency
                                                          provides quiet operation, high reliability and durability
                                                          required for operating rock drills, chipping hammers,
                                                          breakers, pneumatic pumps and surface finish
                                                          applications like sand blasting.
 THE ELGI MAGAZINE                                                                    THE ELGL MAGAZINE           THE ELGI MAGAZINE 
Contact us
Branch Offices
                                                                                                                                                            Think Long Run
AHMEDABAD	             	           “ELGI	HOUSE”	2,	Mill	Officer’s	Colony,	Behind	La-Gajjar	Chambers,	(Old	Reserve	Bank)
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	    	                 	           Ph:	91-79-26583736,26581274	Fax:91-79-	26587683	E-mail:

BANGALORE	             	           15,16	Richmond	Road,	Bangalore	-	560	025.
	     	                	           Ph:	91-80-22240674,	22220296	Fax:91-80-	22293274	E-mail:

BHOPAL	                	           	        M-1,	“Purjor	House”,	Block	No.32,	Indira	Press	Complex,	Zone	1,	M.P,	Nagar,	Bhopal	-	462	011
	     	                	           Ph:	91-755-2578281,	2578317,	5273317	Fax:91-755-	2578289	E-mail:

BHUVANESWAR	 	                     374,	Goutam	Nagar,	Vivekanand	Marg,	Near	Bhubaneswar	Municipal	corporation	office,	Bhubaneswar-	751	014
	     	      	                     Ph:	91-674-2432552	Fax:	91-674-243558	E-mail:

CHENNAI	               	           52,	Second	Floor,	“Amar	Sindur”	43,	Pantheon	Road,	Egmore,	Chennai	-	600	008.
	     	                	           Ph:	91-44-28586699,	28555199,	28553599	Fax:	91-44-28586499	E-mail:

COIMBATORE	            	           Singanallur,	Coimbatore	-	641005	.	Ph:	91-422-2589555	Fax:	91-422-2573697	E-mail:

HYDERABAD	             	           1-8-611,	Airport	Plaza,	Third	Floor	B,	Opp.	Airport,	Begumpet	Road,	Hyderabad	-	500	016
	     	                	           Ph:	91-40-27768326,	27768226	Fax:	91-40-27768327	E-mail:

JAIPUR	 	              	           T-13,	3rd	Floor,		Jeevan	Vihar,	4	New	Colony,	Jayanthi	Market,	Jaipur	-	302	001.
	       	              	           Ph:	91-141-2375595	Fax:	91-141-2377100	Email:

KOCHI	 	               	           39/3973,	Pallimukku,	M.G.	Road,	Kochi	-	682016.
	      	               	           Ph:	91-484-2360155	Fax:	91-484-2351904	E-mail:

KOLKATTA	              	           II	Floor,	Parijat	Building,	24	A	Shakespeare	Sarani,	Kolkatta	-	700	017
	     	                	           Ph:	91-33-22834270,	22834271	Fax:	91-33-22834272	E-mail:

MUMBAI	                	           Marcol	Co-op	Industrial	Estate	Ltd.	Plot	No.48,		J.B.	Nagar	Post,	Mathurdas	Vassanji	Road,	Andheri(East),		
	     	                	           Mumbai	-	400	059Ph:	91-22-28591905,	28501682	Fax:	91-22-28591601	E-mail:
NEW	DELHI	             	           23,	Shivaji	Marg,	New	Delhi	-	110	015.
	     	                	           Ph:	91-11-25153644,	25928095,	25939283		Fax:	91-11-25459375	E-mail:

PUNE	      	           	           White	House,	2nd	Floor,	388-A,	1/2240,	Mumbai-Pune	Road,	Opp.	Sandvik(Asia),	Dapodi,	Pune	-	411	002
	          	           	           Ph:	91-20-27145288,	27148892	Fax:	91-20-27145289	E-mail:

TIRUCHENGODE	                      4/2,	Nandhini	Complex,	1st	Floor,	Velur	Road,	Tiruchengode	-	637	211		Ph:	91-4288-25713
	     	     	                      	Email	:				

Foreign	Offices	
BANGLADESH	 	                      C/o	IFAD	Enterprises	Limited,Sonartori	Tower	(15th	and	16th	Floor),	No.	12,	Biponon	C/A,	Sonargaon	
	     	     	                      Road,	Dhaka	-	1000.Ph:	880-9671453-57	Fax:	880-2-8616148	E-mail	:

CHINA	 	               	           Elgi	Equipments	Ltd.,	899,	Lingling	Road,	6/F	Cross	Region	Plaza,	Shanghai,	PRC-200030
	      	               	           Ph:	0086-21-54892879	Fax:	0086-21-64686999	E-mail:

INDONESIA	             	           C/o	Pt	Esa	Bina	Utama,	JI,	Pangeran	Jayakarta,	No.117/B	43,	Jakarta	10730,
	     	                	           Ph:	+62-21-6282067,	6590383	Fax:	+62-21-6007066

MALAYSIA	              	           Lee	Engineering	Trading	Sdn	Bhd,	#11,11A,	Jalan	IPS	11/9,	Bandar	Sunway,	46150	Petaling	Jaya,	Selangor.
	     	                	           Ph:	00-605-56328488	Fax:	00-603-56328630	E-mail:

MIDDLE	EAST	 	                     C/o.	Tech	International	LLC,	P.O.	Box:	3390,	Dubai,	UAE.
	     	      	                     Ph:	+971-4-263-1744	Fax:	+971-4-261-1073	E-mail:

NEPAL	 	               	           2nd	Floor,	Jog	Kumari	Bhawan,	Naya	Bazar	-	Balaji	Road,	Kathmandu.
	      	               	           Ph:	+977-1-4380592,	2020059	Fax:	+977-1-4288842	Email:

SRILANKA	              	           																				S.G.	Arcade,	2nd	Floor,	No.441,	Sri	Sangaraja	Mawatha,	Colombo	-	10,
	     	                	           Tele	fax:	00-94-11-2392425,	E-mail:

THAILAND	              	            .P
                                   P .Parts	Co.	Ltd.,	114,	Moo	3,	Soi	Watcharapol,	Ram	Inthra	Road,	Taraeng,	Bangkaen,	Bangkok	-	10220
	     	                	           Ph:	+662-9482941-4	Fax:	+662-9482940	E-mail:

SOUTH	AFRICA	 		                                   Nysamco,	Nr.	1	CC,	4,	Van	Dyk	Road,	Nestadt	Industrial	Site,	Benoni	R.S.A.	Ph:	+27-11-9142271		
																																																												Fax:	+21-11-9145380	Email:

                                                        ELGI Equipments Limited
               Singanallur,	Coimbatore	-	641005,	India,	Tel	:	+	91-422-2589555	Fax	:	+	91-	422	-	2573697	E-mail	:	Visit	us	at	:
                                                  International	Division	:	Fax	:	+	91-	422	-	2576849			E-mail	:
     	            	           	           																																Toll	Free	Customer	Care	Number	(India)	:	1800	-	425	-	3544	

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