Pracsol Chemical & Machinery - Know Your Supplier Aug 2015

Know Your Supplier

Rubber Machinery & Accessories

Pracsol Chemicals & Machinery

M MRUBBER Rubber

MachineryWorld

Special Edition

In Conversation With

Harish Nene, Chief Executive Ofcer

‘Practical Solutions’ on Equipment Simplified

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FROM RUBBER TO YOUR FINAL PRODUCT

MANUFACTURE WITH THE RIGHT MACHINERY

Weekly Digest

From the

Editor’s

Desk

Hi

At , we understand the information Rubber Machinery World

requirements of industry stakeholders, hence our theme “From

Rubber To Your Final Product – Manufacture With The Right

Machinery”.

Our effort on this portal has been to share authentic information

to help you source your machinery wisely. This effort remains

incomplete without notes on equipment suppliers.

Hence, series is an advertorial initiative ‘Know Your Supplier’

to provide you information on the machinery supplier ecosystem

- Manufacturers, OEM Suppliers, Machine Rebuilders, Used and

Pre-Owned Equipment Buyers & Suppliers, and Agents - from

whom you buy your rubber and tire equipment.

In Know Your Supplier editions, we cover a equipment supplier’s

Competency, Capacity, Commitment, Culture, Communication,

Market Presence, Technology & other details that you seek; so

you know these organizations better and reach them quicker.

In this edition, we cover , a ‘Pracsol Chemicals & Machinery’

rising Indian Company that is fast building on its rising confidence

and customer trust to extend practical equipment solutions

to the industry. Also included is a special article ‘Internal Mixer:

7 Quick Tips About Batch Weight Calculation’ from our portal.

I welcome your feedback on [email protected]

Regards

Prasanth Warrier

2011

Sale of a Reconditioned F270 to Tega

Industries amidst tough competition

from established suppliers.

2014

Secured order for supply of 84inch

Reconditioned Four-Roll Calender

(Presently under reconditioning in

USA)

Supply of Machinery to overseas

manufacturing units of a Indian

customer.

2015

Secured order for supply of New Batch Off

to a client in Europe. (Under Execution)

4 Know Your Supplier - AUG 2015| Pracsol Chemicals & Machinery |

Pracsol At A Glance

Started in

2007Trading

Machinery, Chemicals &

Raw Materials

5 Major Revenue

Partnerships

Both

USED & NEWEquipment

40+EquipmentSupplied

7+Global BrandsAs Customers

HQ Thane (Mumbai)

India

24 HoursResponse

Time

70%Repeat

Customers

Value-AddFreight & Clearing

Services

Serving Indian

Tyre & Rubber Industry

Few Milestones

2012

Key role in helping a Indian client procure 96 inch

Calender Line from Czech Republic


Pracsol Chemicals & Machinery is into trading of Machinery,

Raw Materials and Chemicals since 2007 and is growing in

reputation in machinery business.

We understand from , our conversation with Harish Nene

Chief Executive, that in the last 4 years they have secured

landmark orders for Used Machinery from Indian Rubber

and Tyre industry. Pracsol is now fast building on this rising

confidence and customer trust to extend practical equipment

solutions to the industry in new machinery as well.

of International Trade hands-on

sweating it out in JNPT (Nhava Sheva

Port – Mumbai) with the CHA's and

Customs Officials. I handled commercial

aspects for my employers importing

raw materials, chemicals and machinery

for setting up their projects in India. In

this process, I became aware of the

simple negligence on documentation

that companies make while importing

their equipment. This resulted in delays

for clearing shipment and loss from

additional costs (penalties, demurrages,

etc). I knew I had an opportunity to make

a difference.

During this period in 2007, I met Michael

Dyer at an expo. Michael owned JM

Machinery and was selling used

equipment from USA. We discussed the

prospects of promoting his machinery in

India and we clicked together. I did brief

him with my experience. After verifying

my credentials through his friends in

India, we reached an agreement and I

settled in this Industry. Looking back, I

would say that I was fortunate to meet

Michael at right place and at right time.

Since then we have sold many used and

reconditioned machinery in Indian

market.

Harish, you come from a dif-

ferent background. How did

you choose Rubber and Tyre

Machinery as an area of your

business?

Yes. I am a Graduate of Bombay

University with Post Graduation

in Central Excise & Customs. For

over 12 years, I learnt the ropes

Pracsol is a strange name. What

is the story behind this name?

Pracsol is derived from the words

‘Practical Solutions’. Through my

experience of last 20 years in

International Business, I would

state that solution for a problem is

possible if looked at it practically

not by just following procedures.

Pracsol is derived from the words

‘Practical Solutions’.

- Harish Nene

Pic: Row of Reconditioned Mixers at JM Machinery Plant in USA


experience specializing in the rubber and

plastics machinery field. They have seen

what works and what doesn't. They are

approved supplier and rebuilder to the

world's major tyre companies.

Machinery is examined by experts before

transactions. At Pracsol, we are available

for almost 14 hours in a day to our

customers and normally respond within

24 working hours or even less when

buyers contact. Our repeat customers

know that we do error free documentation

and give prompt status updates on their

machinery purchases. Apart from

providing excellent used and reconditio-

ned machinery for the rubber and tyre

industry in India; we provide to our

customers all services under one roof

from procurement till the consignment

reach their manufacturing unit.

Purchasing machinery is a major

investment for most buyers and they

would need technical inputs and

customization. What level of pre-sales

support do you offer?

We provide all the important technical

details about the machinery with

photographs. Through JM Machinery, we

can aid in design and engineering from

concept thru completion of the desired

machine.

If the customer insists on Physical Verif-

ication Report then physical verification

is carried out by our principals' engineers

and a report is provided. The client has

the liberty to visit for physical verification

if the machines are available at our

warehouse in USA.

How about service?

JM Machinery can provide field-service for

rebuilt machinery worldwide. In addition,

our availability for 14 hours and Inter-

Continental timings make the difference.

We respond within 24 working hours.

doing business with Private

Companies is easier than doing

business with Public Limited

Companies.

What are the major strengths

of Pracsol? How do you add

value to equipment buyers in

the rubber and tyre industry?

Used equipment can be a bad

investment for buyers if not

handled well. Hence, our

principals or we ourselves do

not buy and sell machines that

do not work.

JM Machinery has over 40 years

Having started in 2007 how has

been your experience so far in

this industry?

Business Ethics, Honesty, Hard

work and Transparency is import-

ant. Customers who do business

with me recognize that they can

expect these from me and have

helped me succeed in the rubber

and tyre industry. I also have

good support from my principal

company. This makes things

simple and gives me time to

focus on delivering value to

customers. From my last 7 years

experience, I would opine that

Pic: A Mixing Mill Under Reconditioning

Pic: A Fully Rebuilt 4-Roll Calender At JM Machinery, USA

We have over 40 years experience

specializing in the rubber and plastics

machinery field. We have seen what

works and what doesn't. We are

approved supplier and rebuilder to

the world's major tyre companies.

- Michael L. Dyer

liter mixers, 100” mills, 21/24 inch

extruders, and 2000 ton presses.

How do you compete technol-

ogically on your products to

offer?

We strive to keep up with the

latest advances in all aspects of

our rebuilding and manufacturi-

ng techniques. We send our

electricians to seminars, classes,

and training on the latest PLC’s

and control functions.. Our

welders are constantly

upgrading our hard surfacing

techniques and materials. Our

employees are urged to take

advantage of our company

policy of paying for any class

pertaining to their field of work.

is the end result JM Machinery

of 40 plus Michael L. Dyer's

years of service in the Rubber

Industry. He brings the experien-

ces of design engineering, shop

assembly foreman, field service

technician, and salesman to his

business. His knowledge of the

industry, it's people, and the

machinery and processes used in

it is unsurpassed. Here’s what

Michael adds:

What are your manufacturing

infrastructure and capabilities?

Can a potential buyer look at a

long-term partnership with you

for their flexible as well as

scalable requirements?

We can handle up to 50 ton piece

with our cranes and lifts. Our

machine tools are constantly

being added to and size range

ever expanding. We currently are

building from lab equipment to

production equipment from 370

Pic: Overview of Mixer Spares (Left) and Three-Roll Calender under Rebuild (Right) at JM Machinery

What challenges are you tackling today

to improve customer service and

enhance their overall satisfaction?

The flood of cheaply made machinery

from low grade materials has given the

industry a false reading of pricing. Our

typical late model rebuilt machine weighs

50% more than most of the new

equipment coming out of China or Taiwan.

There is no substitute for ‘good metallurgy’

at the core of the machine, metal that will

render a machine unaccepting of a rebuild

is quite common in the cheap stuff. The

customer today finds themselves being

offered machinery from different

continents, at a wide range of prices. We

have established a worldwide network of

trustworthy associates, and can offer

customers our stability and experience. .......Contd on Page 11

JM MACHINERY


Competencies

• Procurement, Trading & Supply of Used/Pre-Owned for Tyre/Rubber

and Plastic Industry

• Reconditioning of Used Machinery for Tyre/Rubber and Plastic Industry

in India & USA

• Trading in Raw Material: Reclaimed Rubber, Off Grade SBR, Off Grade BR,

Repro PE Resin, Thermoplastic Elastomer (TPE) Modifier, Alternative to

EVA

• Goodyear Tyres, Aurangabad

• Balkrishna Tyres, Mumbai

• Tega Industries, Kolkatta (& Group Companies Overseas)

• Falcon Tyres, Mysore

• Oriental Rubber, Pune

• N RC Industries, Amritsar

• Northland Rubber Mills, New Delhi

• Bony Polymers, Faridabad

• Parker & Markwel, Hyderabad

• Karam Industries, Punjab

• Mewat Tyres, Rajasthan

• Ryder Transinternational, Indore

• Nalin Rubber, Jamshedpur

• Prime India Polymix, Faridabad

• Hi-Tech Rubber Moulds Pvt. Ltd, New Delhi

• Matangi Rubber, New Delhi

• Super Floorings, Yamuna Nagar

• RPG Poly Vinyls, New Delhi

• Marvel Vinyls, New Delhi

• Canadian Vinyls, New Delhi

• Triveni Rubber, Thane

• Kiran Rubber, Mumbai

Our client list speaks for itself

- Harish Nene

Pic: Reconditioned Press (Left), Lab Mill (Center) and Lab Mixer (Right)

Pic: 24 inch Three-Roll Reconditioned Calender


Pic: A Fully Rebuilt Mixer Body At JM Machinery, USA

What's your approach towards

communication? How easy is it for your

existing customers and future buyers to

reach you and exchange relevant

information?

We are easily approachable and our client

list speaks for itself. We are available for

almost 14 hours in a day to our customers

and normally respond within 24 working

hours or even less when buyers contact.

My contacts including my mobile number,

skype and email id are displayed on our

website. We provide all the important

technical details about the machinery with

photographs. If the customer insists on

Physical Verification Report then physical

verification is carried out by our principals'

engineers and a report is provided.

Prospective genuine buyers can visit our

warehouse in USA for physical verification

of the machines if available. Our repeat

customers know that we do error free

documentation and give prompt status

updates on their machinery purchases.

Are you launching any new

products?

We are targeting the rubber

industry in Europe & USA to

export our range of new

machinery from India. We have

recently bagged an order to

design, manufacture and

supply a NEW BATCH OFF for

Europe. This is expected to be

despatched by end of

September 2015.

How do you ensure that you

deliver high quality product

and services to your customer?

What processes do you have in

place to ensure consistency of

quality/meeting deadlines?

Rightly asked. Dealing in USED

MACHINERY there are advantages

and disadvantages. The risk factor

for the client is limited to the

normal wear and tear while

buying used machinery because

almost all the aspects are checked

by us prior we buy the machine. If

the machine needs to be

reworked to the extent of

changing important parts, the

work is done and only then offer-

ed to the client. After all it is the

question of repute and no one

would like to tarnish their own

image.

Adds Michael, that after a

complete rebuild with original

standards as the blueprint, a

complete testing with video is

supplied. Deliveries are impor-

tant, but quality does happen

quickly, or by itself. Perfection

is the goal.

We have recently bagged an order for a new

Batch-off for Europe.

- Harish Nene

Pic: Batch Off Work In Progress

Practical Solution

www. .comracsol

Please contact us to discuss your machinery

requirements for

Ph: +91-9819602323

+91-22-25420466

RELATIONSHIP IS ABOUT TRUST, WE VALUE IT THE MOST

Tire, Automotive Profiles, Foam Rubber,

Medical, Shoe, Conveyor Belting,

Custom Mixing, Roofing, Vinyl Flooring

General Rubber Goods Industries,

and Plastic Sheeting Industries

Harish Nene

Skype: harish.nene


3,Chaitanya, A.S.Road, Near Ahilyadevi Garden,

Charai, Thane 400601. Maharashtra. India.

www.pracsol.com


How do you differentiate yourself as well as

compete on price of your products?

As I mentioned before, we take great care to

supply only working equipment to our

customers. It involves examining by experts,

replacing worn out parts wherever required

and arrange for physical verification wherever

required. We still go further to do error free

documentation of the consignment and provide

to our customers single-window services from

procurement till the consignment reach their

manufacturing unit. Used machinery supplied by

us represents exceptional value for money. Hence,

we have over 70% repeat buyers in the last 3 years

who are fully satisfied.

Used machinery price is definitely lower than new

one. We negotiate the price and finalize the order.

Equally, we see to it that we do not end up in Loss.

Our principal says, “Not to sit on the iron and wait

till we get our target price. Rather reach a win-win

situation through discussions and negotiation with

the client.” So we do not lose any order on price.

After all, some meal is better than no meal.

What changes do you see happening in the

machinery industry? How are you positioning

and preparing Pracsol for these changes?

The demand for USED MACHINERY will always

be there and we have the capacity to invest

in buying good machines. At Pracsol, we are

focusing on expanding our market. We are

targeting the rubber industry in Europe and USA

to export our range of new machinery from India.

We have recently bagged an order to design,

manufacture and supply a NEW BATCH OFF for

Europe. This is expected to be despatched by

end of September 2015.

Pic: A Fully Rebuilt Pin Type Cold Feed Extruder

For Used Machinery, our

readiness of loading in containers

is within 20 days of receiving

advance payment.

- Harish Nene

Contd from Page 7.

What is your advice on equipment

selection to buyers of rubber and tyre

machinery?

Quality requires a certain level of pricing.

Do not fool yourself into thinking the

lowest price supplier is going to meet the

higher priced standards. Quality is never an

accident, it requires intelligent planning

and execution. We offer Quality!

We offer Quality!

- Michael L. Dyer

JM MACHINERY

Did You Know? In 80% of B2B transactions today, the customer finds the supplier - not the other way around.


Pic: Mixing Mill

Pic: Three-Roll Calender (Left) and Spare Calender Rolls With Bearings (Right)

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Special

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In Conversation With

Harish Nene, Chief Executive Ofcer

‘Practical Solutions’ on Equipment

Simplified

Know

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Wo

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Internal Mixer: 7 Quick Tips About Batch Weight Calculation

Internal mixer is standard

rubber machinery for volume

mixing in both tire industry

and non-tire rubber industry.

When you use one, your most

elementary requirement is to

calculate the batch weight for

your respective mixer model.

Because when mixing rubber

compounds, you should under-

stand that different compounds

based on the same polymer

might require different batch

weights.

And different polymers will

almost certainly require different

batch weights.

Here's 7 quick tips for you to fix

the batch weight for your rubber

mixing.

1) Theoretical Equation

The thumb rule is the theoretical

equation

W= NV x SG x FF, where

W - Batch Wt [kg];

NV - Net Mixer Volume [dm³];

SG - Specific Gravity (density) of

the mixed batch [kg/dm³];

and

FF= Fill Factor.

Generally, most mixer manufact-

urers share this calculation with

you. But remember, what they

give you is only a theoretical

number. This is only a starting or

reference point and you need to

arrive at your own mixing batch

weight for your compound recipes,

following some of the other tips

stated below.

pressure on the compound, poor

dispersion and longer mixing

times. Annual measurements of

chamber are recommended to

update your batch weight correctly.

Excessively worn out mixers will

have to be rebuilt or reconditioned

(Read our posts on mixer rebuilding

- Top 25 Things You Should Know

to Discuss with Mixer Rebuilder and

17 Essential Questions to Select the

Right Rebuilder for your Internal

Mixer)

3) Guesstimate the Fill Factor (FF)

If you have a Tangential Mixer (aka

Banbury) , then your FF can range

between 0.70 and 0.85. And for a

When the mixer is used regularly (or if you have

procured a used-mixer) the effective volume

Increases due to wear on the rotors and mixing

chamber.

2) Net Mixer Volume (NV)

Since Internal mixer has a

fixed volume mixing chamber,

knowledge of the net volume

(in liters) is required. This can

be obtained from the manuf-

acturer directly or in some

cases from their literature for

their various models.

When the mixer is used

regularly (or if you have proc-

ured a used-mixer) the effective

volume increases due to wear

on the rotors and mixing

chamber. If not compensated

for this inside wear, your batch

volume will be effectively too

small leading to insufficient ram

A Fully Rebuilt Mixer by JM Machinery.


Intermeshing Mixer (aka Intermix),

your FF can range between 0.62

and 0.70.

Knowledge of the fill factor is

necessary because an under-filled

mixing chamber results in the ram

bottoming out too soon. This

reduces the pressure on the rubber

stock and increases the mixing time.

An over-filled chamber leads to

unmixed ingredients staying in the

mixer throat. This creates a mess

under the mixer when the batch is

dumped.

For example, NR-rich compounds

in an intermeshing mixer have a fill

factor of around 0.65 while for the

same compound in a two-wing

tangential mixer, it is about 0.75. This

compound will have an increased FF

of about 0.78 for a tangential mixer

with four-wing rotors. Each polymer

also has its ideal fill factor and that

varies again with Mooney viscosity

and filler system.

Fill factor of a mixer depends on the

age of the machine, wear and tear of

the rotors and chamber, the rotor type,

rotor speed, rotor friction ratio, nature

of elastomer, ratio of elastomers/fillers,

mixing sequence, kind of polymers,

fillers and individual SG of the

ingredients in your recipe, viscosity of

ingredients, etc. Generally, the lower

the compound viscosity, the fill factor

is higher.

Hence, we initially guesstimate the FF

before stabilizing on the figure later

on through actual trials.

4) Estimate the Specific Gravity (SG)

of your Compound

You can estimate the density of your

compound by multiplying the quantity

of each ingredient with its

individual density (you can

get this figure in any

compounding handbook

or ingredient supplier lite-

rature). Sum up your

individual results and then

divide this number by the

total sum (usually phr). The

result will give you the

estimated density of the

compound. (Mathematically,

this is the weighted average

calculation).

For example, lets consider a

sample recipe as shown

above (I got this recipe from

a web search).

Calculating, the SG of this

Compound mix is arrived at

1.16 (=179.3/155).

5) Know your Internal Mixer

Knowing your internal mixer -

its capabilities, design features

like rotor (tangential or

intermeshing), ram (pneumatic with

dedicated air supply at the plant or

hydraulic), variable speed capabilities

of the motor, SCADA, PLC, automati-

on and control features, etc.

Rotor speeds are critical because you

can use higher speeds at the initial

mix and then reduce the rotor speed

to allow the batch to "knead" well.

This will allow you to get both your

dispersion and distribution tasks of

mixing right. Hence, when selecting

a mixer explore variable speed drives

since it give you advantage in your

mixing process.

(If you are planning a new purchase,

read and download our

Questionnaire for Internal Mixer

Selection).

Similarly, think of ram pressure. If

your ram pressure is too high you

will cause excessive heat build up

and poor flow of ingredients across

the rotor tips. In intermeshing mixers,

this will also cause internal pressure


within the mixing chamber and might

cause mixer failure. If ram pressure is

too low, then you will not get the

ingredients down into the rotors and

this will result in poor mixing.

6) Watch the Ram Action

After the above reference calculations

are done and mixing initiated; watch

the ram action during the mix. The ram

should start high, move up and down

about an inch or two and bottom out

when mixing is complete. Good mixing

practice dictates that when the ram

bottoms out about 30 - 45 seconds

before the batch is dumped, you can

be assured that the chamber is properly

filled and mixed compounds will be of

high quality.

You need to observe the position of the

-ram by watching the tell-tail rod attach

ed to the top of the ram. Hence, this

requires more of practice and

experience than theoretical knowledge.

If you have a good mixing system with

controls and feedback features, you can

correlate the position of the ram with

the current and rise in temperature -

these are important to get an optimized

batch size and high quality of mix.

7) Optimize Your Mix Batch Size

(...Do Not Maximize)

The key to successful mixing is optimizing

your mix batch size, and not

maximizing. And good mixing

is a form of art.

Most mixer users want to get

the most out of their internal

mixer (quite natural!) and they

test its capabilities to the full.

Finally, when they get poor

mixing, they wonder if they

have done the right

investment!

If you try to take your batch

size to the upper limits of the

mixer's "capacity" as specified

in the manufacturer's manual

(that is usually a peak magical

figure) and you have raw

material variations such as

particle size or bulk density

changes in your fillers, this can

lead to poor mixing (dispersion

and distribution of ingredients).

The right batch size will be

smaller, but your internal mixer

throughput is increased by

shorter mixing time and thus

Each mixer is different and it would be very

difficult to determine the optimized fill factor

without actually conducting several mixing

trials. Experience is a key to good mixing.

more batches in the same period.

Thus, optimizing your batch

weight will allow you to get

consistent batch quality and

repeatability that are of

paramount importance to your

(or your customers') downstream

processes.

The key factors that will influence

your mixing optimization are

compound formulation, ram

pressure, mix procedure, mixing

speed and rotor design.

Each mixer is different and it would

be very difficult to determine the

optimized fill factor without actually

conducting several mixing trials.

Experience is a key to good mixing.

Summarizing, when mixing rubber

compounds, different compounds

require different batch weights.

These 7 tips will help you calculate

the optimized batch weight for

your compounding recipes on an

internal mixer quicker.

This article was first published on Rubber Machinery World Portal. You can access the link here: http://rubbermachineryworld.com/2015/03/17/7-quick-tips-about-batch-weight-calculation-for-an-internal-mixer/

Email: [email protected]

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