Bony Polymers Private Limited

Bony Group of Companies

Metallic

Flexible HosesExtrusion Division

Compounding

Business Segments

- Rubber

- Non Asbestos Friction Material

- O Rings

- Rubber Moulded Parts

- Rubber to Metal Bonded Parts

- Brake Blocks (Rail)

- Turbo Charges Hoses

- Air Clean, Radiator & Coolant Hoses - Fuel Hoses

- Brake Hoses

- Press Work - Fabrication

Moulding Division

LED

Division

Bus Aggregate

Division

Sheet Metal

- Cross Over Piping

- Convolutions

- Sign Boards

- Street Lights

- Coach Lights

- Air Conditions

- Rear View Cameras

- Fleet Mgt.

Prime India Polymix (P) Ltd.

Bony Polymers (P) Ltd. Saket Fabs (P) Ltd. Bony Systems &

Technologies Ltd.

Bony Polymers (P) Ltd. is a reputed name in the field of Manufacturing Rubber Moulded Parts, Rubber to Metal Bonded Parts, Non Asbestos Friction Materials, Hoses, Hose Assemblies & Fuel Tubes for automotive and non automotive sectors. Bony Polymers (P) Ltd. was established in the year 1981 & our specialised products have been utilised by renowned OEM’s.

The aim is, to make the Bony Polymers (P) Ltd. and its products a benchmark at all levels of International Standards.

Introduction

Technical Collaboration between Becorit GmbH (Germany) and Bony Polymers (P) Ltd. for

manufacture of Non Asbestos Friction Materials

Bony Polymers (P) Ltd.Becorit GmbH

K Type Brake BlockK Type Brake Block L Type Brake BlockL Type Brake Block

Agreement between Meiji Flow Systems Co. Ltd. (Japan) and Bony Polymers (P) Ltd. for Licensed Assembly and Testing of Hydraulic

Brake Hoses

Bony Polymers (P) Ltd.Meiji Flow Systems Co., Ltd.

Hydraulic Brake Hoses

In Technical Association with EATON FLUID POWER INDIA.

An Association you can rely on……

An Association of Quality

Bony Fluid Power System

(A Division of Bony Polymers (P) Ltd.)

Technical Association

Agency Agreement between TES and BPL for selling in India

Bony Polymers (P) Ltd. (TES)

　

Our Vision

To achieve world class

standards in Quality of Products, Services and Human resources

Overall Man Power

Category StrengthProduction 817

Quality Engineering (Planning & Assurance)

28

Engineering (Product Dev. & Tool Engg.) 21

Research & Development 22

HR, IR, Govt. Liaising & Security 15

Others 10

Total 913

Total Staff = 220(Junior Mgt. to COO)

Total Operatives = 693

Organization Strength

Extensive R & D and Product Testing Facility In-house R & D recognized by Govt. of India, Ministry of Science & Technology

Technical Expertise to meet Global requirement

A Fast Growing Company which has a growth Rate of 25 to 30 % every Year for the last 10 Years

Certified Quality and Environment Management Systems

• An ISO/TS-16949:2009

•An ISO – 14001:2004 (EMS)

Quality Certification & Approvals

• VDA 6.3 by : MANN & HUMMEL,SIEMENS VDO & KNORR- BREMSE

• Govt. of India Ministry of Science & Technology recognition for In-house R&D units

(Recertification under new version)

Customer Awards for Excellent Performance

Environment

•Registered with IMDS (International Material Data System ) The IMDS is the automotive industry material data system. In the IMDS, all materials used for car manufacture are archived and maintained.

•Certified ISO 14001:2004 Company.

Expertise in the development & processing of the following Elastomers:

NATURAL RUBBER (NR) STYRENE BUTADINE RUBBER (SBR) POLYBUTADINE RUBBER (PBR) ISOPROPYLE ISOBUTYENE RUBBER (IIR) CHLOROPRENE RUBBER (CR) NITRILE BUTADINE RUBBER (NBR) HIGH NITRILE BUTADINE RUBBER (HNBR) POLYACRYLIC RUBBER FLUORO ELASTOMER (FKM) CHROLROPRENE SULPHONATED MONOMER (CSM) EPICHLOROHYDRIN (ECO) SILICONE AFLAS NBR/PVC EPDM OTHER SPECIALIZED ELASTOMERS.

Our Expertise

Versatile with following international standards : • ASTM D 2000 for automotive components

• SAE 100 R, SAE J-1403, SAE-30R6, SAE 30R2, SAE20R4 for hydraulic hoses, radiator hoses, engine coolant hoses vacuum brake hoses and hoses for CNG application.

• JIS 6403 Standards, JASO F404 for O-Ring

• DIN standards

• ISO standards• Customer Specific standards

Our Expertise

Product Range

Segments Catered

Two Wheelers 45% Cars 10%

Construction & Agri. Machinery 15%

Trucks & Buses 10%

Railways 18%

Power Plant 2%

Our Products

Anti vibration mountsAnti vibration mounts

Buffers & Transmission Mountings Buffers & Transmission Mountings

Our Products

O - RingsO - Rings

Seals & GasketsSeals & Gaskets

Our Products

Grommets for wiring harness

Our Products

Dust Covers & Cover Ball JointsDust Covers & Cover Ball Joints

Our Products

Boots & BellowsBoots & Bellows

Insulators for CarburettorsInsulators for Carburettors

Our Products

•Suspension bushesSuspension bushes•Bush swing armBush swing arm•Bush engine hanger & Bush engine hanger & •Silent blocksSilent blocks

Our Products

Isolators & Exhaust Hangers Isolators & Exhaust Hangers

Our Products

For Locomotive & Coaches

Our Products

Our Products

Vacuum Brake Hoses

Radiator & Coolant Hoses Heater & Water Hoses

Inter Cooler & Turbo charger (Silicon) Hoses

Fuel Tubes

Our Products

CNG & LPG Hoses – ARAI Approved

High Pressure Hydraulic Hose Assemblies

Our Products

High Pressure Hydraulic Hose Assemblies

Our Products

Anu IndustriesDenso India LimitedFCC Rico LimitedHero MotorsLifelong India Ltd.Munjal ShowaA.G.Industries Autofit Pvt. Ltd. Magnum Components Munjal Auto Multilink Napino Auto Rico Auto Majestic Auto Ltd. Pricol Ltd. Wings Auto

Hero HondaHMSI.Yamaha MotorsSuzuki Motorcycles

Esteemed Customers : Two Wheelers

OEMs Tier 2

Maruti Suzuki India Ltd.

Honda Siel Cars India

Mahindra & Mahindra

Arvin Meritor Nissan (Delphi Packard) Delphi steering Tata (Minda) Hyundai (Motonics) Land Rover (Mann &

Hummel) Mag Filters& Eq. P.Ltd.Toyota (Tata Yazaki)Toyota (Toyoda Gosei) Ford (Yazaki Wiring) Ford (Cooper Standard) SKH Metals Ltd. MGI Coutier Exotech Sun Vacuum Formers Ltd.

Esteemed Customers : Car

OEMs Tier 2

Toyo SpringQH TalbrosJamuna AutoAlkraftBancoTata Toyo

Ashok LeylandSwaraj MazdaTata MotorsMahindra NavistarJCB India LimitedEscorts Agri machinaries Claas India LimitedEicher International Ltd. L & T KomatsuTelcon

Esteemed Customers: Commercial & Construction Equipments

OEMs Tier 2

Esteemed Customers

Bony Group Plant Locations

Mixing (Plant 1)

Molding & Extrusion(Plant 3)

Friction Material(Plant 2)Molding

(Plant 4) Manesar Sheet Metal Plant

(Saket Fabs.)(Plant 7)

Haridwar(Plant 5)Haridwar(Plant 5)

Lucknow(Plant 6)

Existing

Under Construction

Prithla(Plant 8)

　BONY POLYMERS (P) LTD. (PLANT-1) PLOT NO. 9E/6 (FBD)

• R&D

• COMPOUND

PREPARATIONS

Existing Units

Friction Materials for Railways and Automotives

BONY POLYMERS (P) LTD. (PLANT-2) PLOT NO. 77/6 (FBD)

Existing Units

•Corporate Office

•Moulding Shop

•Extrusion Shop

A state of art facility which has a shop floor area of about 70,000 Sq. Ft., Which will accommodate Moulding and Extrusion operations.

BONY POLYMERS (P) LTD. (PLANT-3) PLOT NO. 37 P/6 (FBD)

Injection Moulding Unit Hose Section Moulding shop Extrusion shop

Existing Units

15000 Sq. Feet

BONY POLYMERS (P) LTD. (PLANT-4) 34/3, IMT MANESAR, GURGAON

Existing Units

BONY POLYMERS (P) LTD. (PLANT-5)

PLOT NO. 6, INDUSTRIAL PARK IV, BEGUMPUR VILLAGE, HARIDWAR

Existing Units

Manufacturing Facilities

Mixing

Computerized Ingredients Weighing System

Mixing & Pre Blanks Preparation

Moulding

Injection Moulding Machine

BARREL VOLUME UPTO 10000 CC

CLAMPING FORCE UPTO 400 TONS

No. of Injection Moulding Machine: 50

(38+12)

Capacity :300 tons Capacity :200 tons

Vacuum Compression Moulding Machine

14 Tanks Metal Pre-Treatment Line

Surface Preparation

AN AUTOMATED ADHESIVE APPLICATION SYSTEM

Adhesive Application

Extrusion

High- Precision Fuel Tubes Pressure Hoses and

Long Length Air Pipes.

Co-Extrusion

Hose Braiding & Knitting Machine

Hose Extraction & Proof testing Machine

Hose Assembly

Crimping Machines

Crimping Machines

Fully Functional Laboratory

Testing Facilities

Parameters We Meet

High Tensile and Elongation

High Compression Resistance

Oil Resistance/Fuel Resistance

Electrical Resistance

Ozone Resistance / Weather Resistance in open atmosphere

High Temp. Resistance /Low Temp. Resistance

Static and Dynamic Stiffness

Axial, Radial and Torsion Test

Shear & Fatigue test

High Air Pressure Resistance &Vacuum Resistance

Other critical Metallurgies of Engine & Transmission parts

For testing of compound

curing behaviour

Rheometer and Rubber Process Analyzer

For testing of viscous and elastic components & dynamic

characteristics of rubber compounds

Vibration Simulator

Testing Equipment

For measuring Dynamic Stiffness or tan-delta ( loss factor )of mounts at high vibration frequency

Universal Testing Machine (15 tonne Instron)

Testing Equipment

For measuring deflection at load of Metalastic ant vibrationmounting

Life cycle testing :

•Engine mounts

•Mount rubbers

•Shock absorber components.

Endurance Testing Machines

Capacity:30 tons

Testing Equipment

Fatigue Testing Machine

Testing Equipment

Measures resistance of metalastic antivibration mount to repeated compressive load cycling at defined frequencies

Cordinates Measuring Machine (CMM)

Measuring Equipment

Profile Projector

Testing Equipment

Ozone Chamber

For simulating weatherresistance upon exposure of a stressed rubber component to high ozone concentration

Testing Equipment

Torsional Fatigue Testing Machine

Testing Equipment

Dust Cover Mud Endurance Test

Rig

Testing Equipment

Humidity Chamber

High Voltage Tester

Low TemperatureTesting up to –70°c

Measuring cold flexibility of Hoses & Rubber Components

Testing Equipment

IRHD Hardness Tester

Resilience Tester

Dispersion Analyser

Abrasion Tester

MooneyViscometer

MICRO HARDNESS TESTER

ELECTRONICDENSIMETER

Testing Equipment

Hose Leakage Testing

Under water with air pressure

Testing Equipment

Hose Durability Testing Machine

Testing Equipment

Measure resistance of Vibrating / radiator / heater hoses to air circulatinghot coolant under simulatedengine condition

Hose Bending Test Machine

Testing Equipment

Hose Flexure Testing machine

Measure resistance of AirBrake Hose to high stressflex cycling

Testing Equipment

Tool Design

Software used: -

•CAD 2005

• Pro-e (wildfire)

• Uni-Graphics NX3

• Iron CAD

• Delcam

• Solid Edge

• Catia

• Tools made on CNC Machines

Tool designing -In house

Tool Manufacturing Facilities

EDM-1Vertical Milling MachineCenter LathePolishing MachineSurface GrinderDrilling Machine

Vertical Milling Center (VMC)

Training & Education

• Advance Product Quality Planning (APQP)

• Production Part Approval Process (PPAP)

• Measurement System Analysis (Gage R&R)

• Process FMEA

• Statistical Process Control (SPC)

• Total Productive Maintenance (TPM)

• Kaizen

• Small Group Activities

• Jishu Hozen

Quality Practices

Continual Improvement Activities being followed:

Future Plan

A RUBBER MIXING LINE FOR CAPACITY OF 5000 METRIC TON PER ANNUM, WHICH IS “ A FOURTH GENERATION MIXING TECHNOLOGY”

Future Plan

New Plant coming up in 12000 sq Ft. for supply to TATA Motors (CMV) Lucknow

Plant In Lucknow)

Plant Available for Future Expansion

18/3, AJRONDA , MATHURA ROAD, FARIDABAD

15000 Sq. Feet

Saket Fabs (P) Ltd.

• Presses ranging from 20 tonnes to 600 tonnes

• Self supporting tool room

• Spread over an area of 8000 sq. Yards

A Press Metal Company

Introduction

• An ISO 9001:2000

• An ISO/TS-16949:2002

• An ISO – 14001:2004 (EMS)

• Approved by RDSO (Ministry of Railway)

Quality Certification & Approvals

• Direct On Line to HHML

Esteemed Customers

Major OEMs Tier-2

Overall Man Power

Category Strength

Production 72

Quality 4

Engineering and R&D 3

Administration 4

Others 2

Total 85

Products We MakeProducts We Make(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)

•Four Wheeler Products•Railway Products•Two Wheeler Products

Cabin Parts

Back Panel

Seat Pans

Plates Set IN LH-RH Plates Set OUT LH-RH Cross Member LH-RH

Chassis Parts

Panel Front Lower

Piller B-Out LH-RH Hing Assembly

Body Parts

Mounting PadsCorner Bracket LH-RH

End Plate

Other Parts



For Locomotive and coaches

Our Product Range



Engine Parts

Fuel Filters

Body Parts

Manufacturing Manufacturing (Sheet Metal & Fabrication)(Sheet Metal & Fabrication)

•Manufacturing Facilities•Testing Facilities•Tool Design & Tool Room


Press Shop

Press Shop


Weld Shop



•Manufacturing Facilities•Tool Design & Tool Room•Testing Facilities

Tool Design

Software used: -

•CAD 2005

• Pro-e (wildfire)

• Uni-Graphics NX3

• Iron CAD

• Delcam

• Solid Edge

• Catia

• Tools made on CNC Machines

Tool designing -In house

Tool Manufacturing Facilities

Center LatheSurface GrinderDrilling MachineProfile millingTurret milling


•Manufacturing Facilities•Tool Design & Tool Room•Testing Facilities

Testing Facilities

Salt Spray Testing Chamber

Cupping Test Machine

Testing Facilities

Hardness Tester Microscope

Group Mid Term Plan

Group Sales Trend & Forecast

17 26 32 42 5880

100 115140

190

300

500

050

100150200250300350400450500550600650

Val

ue

(in

Rs.

Cro

re)

2000

-01

2001

-02

2002

-03

2003

-04

2004

-05

2005

-06

2006

-07

2007

-08

2008

-09

2009

-10

2010

-11

2011

-12

Tentative Plan

1 US$ = Rs. 47

40

Million $

63

Million $

106

Million $

30

Million $

20

170

220

30

50300

50

150

Bony Polymers + Prime India

BSTL

Saket Fabs