Table of contents
- Surface Solutions Segment
- Manmade Fibers Segment
- Drive Systems Segment
- Vacuum Segment
- Among Top 5 fully integrated manufacturers of PFY in India
- Number one in the polyester business
- JCB India Limited
- Kingyoup: First large order for MAGiNTEGRA
- Ahno Cutting Tools: customer confidence thanks to Balzers coatings
- High-performance coatings for Tata Motors tools
- Nobody shifts faster
- Vacuum system advances world-class research
Surface Solutions Segment Development partnership for tailored coating solutions
Bosch Automotive Technology is the largest company division in the Bosch Group. Among other things, the division develops and produces fuel injection systems for combustion engines that reduce the consumption and emissions of modern engines by up to 15 %. The components of these systems are exposed to high temperatures and pressures, and are thus subject to extreme stresses during their service life. For more than 20 years, Bosch Automotive Technology and Oerlikon Balzers have been working together to produce shared solutions to effectively protect components that are under huge stresses using hard and friction coatings. Every year, Oerlikon Balzers coats over 100 million components, including piston pins and injection systems, for the automotive industry from various sites around the world. A total of 93 coating centers in 34 countries guarantee accessibility and a throughput time of just a few days.
Manmade Fibers Segment Expanding the value chain
DPTL is an Indian company with an annual revenue of CHF 400 million, manufacturing bottle grade PET resins, which are sold globally to be used for packaging food and beverages, edible oil and pharmaceuticals. Oerlikon Barmag is the technology supplier for DPTL’s second plant, which was commissioned in Haldia in West Bengal, India, in 2012. The plant has a sanctioned capacity of 600 metric tons per day and is the first continuous polymerization project undertaken by Oerlikon Barmag. The entire plant was set up from scratch, including the civil engineering works. DPTL’s CEO Biswanath Chattopadhyay states: “Initially Oerlikon Barmag did not feature in our plans, as we first thought it was only a manmade fiber machine manufacturing company. But they offered to set up the entire plant, including the engineering, procurement, construction and even the commissioning of the project. The commitment and spirit of Oerlikon Barmag were impeccable, and the plant was up and running in only 23 months. You have to be a good sport when implementing a project of such magnitude, and Oerlikon Barmag was just that.”
Drive Systems Segment Intensive cooperation makes all-wheel drive possible
As a car manufacturer, Mercedes-Benz is characterized by performance, safety and comfort. The very first 4MATIC all-wheel drive system for the luxury car manufacturer’s compact vehicles also embodies these characteristics. It is twice as efficient and half the weight of similar systems. Oerlikon Graziano developed the central power take-off unit (PTU) of the new gear system in close cooperation with Mercedes-Benz. In the high performance A-Class AMG model, the PTU transfers up to 360 hp from the transversely mounted front engine to the rear drive shaft. In the space of less than three years, Oerlikon Graziano went from first designs to series production with this innovative project. Oerlikon Graziano’s engineering and high production standards will ensure that around 100 000 compact-vehicle drivers each year have the privilege of experiencing the Mercedes-Benz all-wheel drive.
Vacuum Segment 20 % cost savings with steel degassing from Oerlikon
When it comes to state-of-the-art steel production, Oerlikon Leybold Vacuum is the perfect partner. The Mexican steelmaker Talleres y Aceros S.A. de C.V. (Tyasa) recently ordered a complete steelmaking plant from Siemens VAI, which will reduce costs by 20 % and CO2 emissions by 30 % due to its brand-new electric arc furnace and plant layout. An essential part of this project is the latest steel-degassing solution from Oerlikon Leybold Vacuum, which removes unwanted elements or interfering substances while the steel is melted. This process is crucial to ensuring highest steel quality and requires 100 % reliability and cost efficiency. The innovative and highly flexible design of the Oerlikon vacuum solution needs 30 % less energy and thus benefits the whole plant. Oscar Chahín Trueba, CEO of Tyasa, commented on the relevance of this project as a reference for other companies in the world. The complete solution of Siemens for the compact steelmaking plant convinced Tyasa, and Oerlikon Leybold Vacuum contributed to this success.
Among Top 5 fully integrated manufacturers of PFY in India “A ‘One Stop Shop’ for our customers, having developed over 200 varieties of Specialty Yarns”
— Anil Kumar Gupta
Chairman and Managing Director, Wellknown Polyesters Ltd
Wellknown group started its manufacturing operation in the year 1987. Mr. Anil Gupta was the key promoter to take the group to a respectable size in a decade. He promoted a new entity Wellknown Polyesters Ltd to replicate success in a big way in the year 1998 in Mumbai, India. In around 15 years the company has become the biggest producers of FDY (Fully Drawn Yarn)in India. Wellknown and Oerlikon Barmag have been collaborating closely since the time first BARMAG made Texturing machines was installed in the year 1999.
In fact Wellknown’s pursuit to manufacture most qualitative yarn was major force to invest in a poly-condensation plant. The company has been manufacturing first-class PES granulate for its own yarn production using state-of-the-art Oerlikon Barmag spinning systems.
Wellknown is the most active company within the high-quality premium segment to manufacture specialty yarn. “The poly-condensation unit emerged from the company’s objective to have total control over the entire process chain. A shortage of good quality products and processes compelled the company to go for reverse integration to serve its global customers.”
Barmag has installed the world’s first as well as the 10 000th WINGS system at Wellknown’s plant. The WINGS system, a plug-in machine unit that is revolutionary as it increases productivity and efficiency, and guarantees consistently good quality.
Mr Gupta expressed that, “Based on our vision of best quality manufacturer and the faith in quality output through Barmag technology, we chose the distinction of the first company to invest in the new WINGS technology. It was a calculated risk, but Wellknown is renowned for always pioneering innovative ways to provide superior output. Your technology supplier must be a committed long-term player. Oerlikon Barmag possesses after sale support is unique and hence it was natural to choose Oerlikon Barmag as a partner.”
Number one in the polyester business “We are constantly striving for peak performance.”
— Bian Ping-Gang
Owner of Jiangsu Sanfangxiang Group
To consolidate its leading market position, the Chinese Jiangsu Sanfangxiang Group is taking the advantage of cutting-edge technologies for manmade fibre production from Oerlikon Neumag, and in future also from Oerlikon Barmag.
“We are constantly striving for peak performance on the basis of scientific progress. To be a winner in the market of tomorrow, we are backing technological innovativeness, quality and integrity today. These are the values that bind us to our long-standing and respected partner Oerlikon Textile.” These are the words of the company owner Bian Ping-Gang talking about the strategic orientation of a global market leader. The Chinese Jiangsu Sanfangxiang Group, based in Jiangyin in the hinterland of the Yangtze Delta, claims to be the world’s most competitive manufacturer of polyester with a production capacity of 2 million tons per year, which includes 1.2 million tons of bottle-grade PET chips and 800 000 tons of polyester staple fibres. The company’s core business now also includes the manufacture of PTA, cotton spinning, printing and dyeing fabrics, generating thermoelectricity, and the international trade. The group now employs 8 280 staff and has an annual turnover of CHF 3,7 billion.
Jiangsu Sanfangxiang has worked hard to achieve this enduring success with the consistent use of cutting-edge technologies. Since 2000 these have included complete staple fibre lines from Oerlikon Neumag, which were the most advanced technology on the market even then with a production capacity of 200 tons per day. “We know what we’re getting from Oerlikon Neumag with this investment: top quality, efficiency and energy savings, low conversion costs and reliable, user-friendly operation,” says the General Manager Qin Peng.
When a decision had to be taken in 2011 on a strategic development entailing the expansion of the product portfolio at Sanfangxiang, the company’s management ordered manmade fibre spinning lines from Oerlikon Barmag with a contract value running into hundreds of millions of euros.The new lines will have a capacity of over 600 000 tons of filament yarns per annumand will commence production in mid-2014. “This is another big step towards growth and even more profitable business for us. Our partner Oerlikon Textile will be by our side in this success as before,” says the chairman of the board Mr. Bian Ping-Gang.
JCB India Limited “The quality of Oerlikon Graziano is a differentiator”
— Bhagwati Appan
Vice President – Procurement of JCB India Ltd
JCB India Limited (India’s largest manufacturer of Earthmoving and Construction equipment ) is a fully owned subsidiary of JC Bamford Excavators Limited (U.K).
Oerlikon Graziano supported JCB in gaining high market share of construction equipment in India. Today, JCB is a synonym for reliability in the market.
JCB India Limited started operations in 1979 as a joint venture company. In 2003 JCB UK acquired 100 % shares in the joint venture and today JCB is the fastest growing company in the Indian earthmoving and construction equipment industry. The company is a pioneer in the industry and has developed and expanded through launching revolutionary products and adherence to world class JCB corporate identity norms. Today in India, JCB has sold over 125 000 machines and out of every two Construction equipment sold in India, one is a JCB.
JCB transmission is today a synonym of Reliability in the market. Oerlikon Graziano a company with a similar mindset to innovate, excel, and carry forward the success had been associated to JCB India since 2002 with gears for backhoe loader machines. Intensifying the relationship, Oerlikon Graziano India now is providing drive solutions in terms of pin-type and strut-type synchronizer assemblies and electron-beam welded powershift clutch housings, which were localized in India for JCB 3DX machine while for 2DX is still under development. Most of JCB India products produced today contain a high-quality Oerlikon Graziano drive solutions, which differentiates JCB from others. JCB honored Oerlikon Graziano India with its coveted Quality Supplier Award in December 2011.
“Oerlikon Graziano is part of our success”, say Bagavathy Appan, Vice President Procurement.
JCB India designs and develops the products on the basis of needs and requirements of the customers as well as on the growing infrastructure needs of the country. All machines are high quality products, at par with the world’s best and built to withstand extreme climate conditions, while delivering their optimum performance. “We are always looking for likeminded partners as Oerlikon Graziano to join hands, to achieve and sustain market dominance by becoming unanimous choice of our customers”, says Appan.
Kingyoup: First large order for MAGiNTEGRA
Established in 1974, Kingyoup followed the Taiwanese industrial evolvement by introducing hand tools for quality control, improving productivity and efficiency for manufacturing processes. Oerlikon Leybold Vacuum was a partner from the very beginning.
Kingyoup serves a variety of market applications in fields as diverse as aerospace, automotive, biotech, electronics & mechanical, petrochemical, semiconductor and photovoltaic. The large array of products ranges from straightforward tools to sophisticated production lines, including hand tools, precision equipment, optical instrument, semiconductor inspection system, vacuum sputtering system and environmental protection equipment. Facing a dynamic environment, Kingyoup has also diversified the scope to expand into overseas markets. Cooperating with more than thirty well-known, worldwide manufacturers, Kingyoup has set up a remarkable sales and service network in Asia. With their solid experience in trading for nearly four decades, Kingyoup continuously invests in product research & development, and maintains close relationship with sales partners over the world in order to constantly offer quality services to the customers and to exceed their expectations.
As a manufacturer for inline sputter systems, Kingyoup is using the expertise of Oerlikon Leybold Vacuum. The reliability and performance of Leybold products have created a remarkable reputation with customers of coating technologies. Relaying on the brand reputation, reliability and performance of Leybold’s vacuum pumps and system application know how, they purchased a whole array of pumps and measuring instruments. Due to joint efforts of the local sales staff, technical support and service team, Kingyoup decided to place the first large order on the new turbo molecular pump MAGiNTEGRA. With a bearing life time of up to 80 000 h, this flexible and almost maintenance free robust turbo pumps will extend the up-time of Kingyoup’s sputtering system even further, offering the best vacuum performance of its class. As Kingyoup is entering other coating related business fields such as touch panel manufacturing, Oerlikon Leybold Vacuum will continue to support these endeavors with optimized vacuum technology solutions.
Ahno Cutting Tools: customer confidence thanks to Balzers coatings “We gain customer conficende with coatings from Balzers.”
— Dr. Ke
founder of Ahno Cutting Tools
10 regrinding centres in all the important regions in China and one of the most modern machinery – after only one decade, Ahno Cutting Tools have already assumed the position as leading supplier of carbide tools and provider of tool regrinding services – a success story.
Since the beginning the proprietor Dr. Ke has been placing emphasis on cutting edge technology in order to provide high-performance products himself – coated with Oerlikon Balzers BALINIT® coatings. What originated as an idea is now a prospering company with an exclusive product portfolio. Well-known customers in the automobile industry such as Volkswagen, GM, FORD, Schaeffler or Bosch place their bets on the Ahno Cutting Tools expertise in the tools field, as well as the aviation industry with Honeywell, Pratt & Withney or McQuary and LG for air conditioning systems.
Ahno Cutting Tools benefits from a fast growing tool market in China. The main focus has always been on the quality of the products: „The customers attach high importance to the quality, only cutting edge technology can meet this claim. Particularly due to the fact that we use Balzers coatings, it is easier for us to gain the confidence of our customers”, is how Dr. Ke describes the recipe for success of the cooperation between Ahno Cutting Tools and Oerlikon Balzers. Keeping up the speed in opening up all the important metal-working regions in China on time is decisive in this fast developing market. Only Oerlikon Balzers has thus far been able to keep up with the expansion speed of Ahno Cutting Tools and therefore to ensure a fast, straightforward and highest quality production at the same time. By now Oerlikon Balzers operates 9 coating centres in China. The market for precision tools continues to grow in China. Even after 10 years Ahno Cutting Tools still consider themselves at the beginning in view of market outlook and want to invest in efficient high-capacity products for their customers. The high-performance coatings of Oerlikon Balzers shall thereby continue to help gain the confidence of the customers.
High-performance coatings for Tata Motors tools Oerlikon Balzers’ efficient tool coatings enable Indian automobile manufacturer Tata Motors to increase productivity, while also reducing unit costs.
Tata Motors, India
— R. Bhaskar, Plant Head
Commercial Vehicles Business Unite Pune
Tats Motors is India’s largest automobile company, with consolidated revenues of 20 billion dollars. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. It also distributes Fiat cars in India, and has an industrial joint venture with Fiat in India. With over 5.9 million Tata vehicles plying in India, Tata Motors is the country’s market leader in commercial vehicles and among the top three in passenger vehicles. It is also the world’s fourth-largest truck manufacturer and the second-largest bus manufacturer. Tata cars, buses and trucks are marketed in several countries in Europe, Africa, the Middle East, South and Southeast Asia as well as South America. Tata Motors relies on the coating technologies of Oerlikon Balzers. Its high-performance coatings Balinit Acrona and Balinit Futura Nano refine the automobile manufacturer’s gear-cutting tools. The coatings, which are only a few thousandths of a millimeter thick, drastically reduce friction and signs of wear and tear and considerably increase the life of the products, even under heavy use. In addition, the Balinit coatings have enabled Tata Motors to keep tool costs low since the tools can now be resharpened and recoated without impacting performance, which makes them last much longer. Tata Motors has relied on the technologies of Oerlikon for about 15 years now, and the two companies plan to work together more closely in the future. Soon, Oerlikon Balzers will open a coating center near Ahmadabad in the Indian state of Gujarat, where assembly plants for the new Tata Nano, the world’s least expensive car, were recently built.
Nobody shifts faster A seven-speed transmission for the sports-car maker Lamborghini cuts the time required to shift gears in a road car to a world-record 50 milliseconds.
— Stephan Winkelmann
President and CEO
Automobili Lamborghini, a subsidiary of Audi AG, produces exclusive supersports cars. Founded by tractor manufacturer Ferruccio Lamborghini in 1963 and headquartered in Sant’Agata Bolognese, the company is world-renowned for the exceptionally powerful performance, striking design and high exclusivity of its models. Since 2003, Lamborghini has been counting on Oerlikon Graziano’s manual and automated manual transmissions for its Gallardo series. In 2008, the development of the complete drive line system (an automated manual gearbox, front and rear differential) of their flagship product, the V12, successor to the Murcielago was awarded to Oerlikon Graziano. Oerlikon Graziano has developed a seven-speed transmission featuring a range of improvements: the close cooperation with the Lamborghini team and the constant focus on the challenging targets made it possible to achieve all of them. Weighing only 79 kilograms, it is around 10 percent lighter than its predecessor. Due to its compact size, it can be housed completely in the car tunnel, leaving more space for the driver’s cabin. In addition, torque capacity was increased by 10 percent, with the time it takes to shift gears reduced to a mere 50 milliseconds. No other road car shifts gears faster. The new car made its worldwide debut at the Geneva Auto Show in March 2011. Automobili Lamborghini particularly appreciates the fact that Oerlikon Graziano develops the custom-made transmissions granting at all times a close proximity to their own engineering team, from creating the design to programming the control software.
Vacuum system advances world-class research With a research vacuum coating system from Oerlikon Leybold Vacuum, researchers at the University of Kaiserslautern are developing the next generation of storage media.
University of Kaiserslautern, Germany
— Dr. Sandra Wolff
Department Head of Nanostructure Technology
At OPTIMAS, a research center at the University of Kaiserslautern, optics and material sciences are brought together under the overarching research theme of light, spin and matter. International specialists are involved in various research areas, including spintronics, a new field of nanoelectronics. Unlike traditional semiconductor electronics, spintronics aims at using not only the charge, but also the magnetic moment of an electron to display and process information. This will make producing faster and more energy-efficient storage media possible. One of the areas of focus for OPTIMAS is the use of coating systems to develop magnetic micro- and nanosystems for industrial purposes, new materials with a high spin polarization and innovative spin engineering and spintronics. To conduct the experiments, the researchers require perfect conditions, which is why the research center decided to use UNIVEX 450C, a semi-automated experimentation vacuum coating system from Oerlikon Leybold Vacuum, in the Nano+Bio Center of TU Kaiserslautern. The system works using the magnetron sputter deposition technique. In this technique, the applied material is vaporized through momentum transfer and not thermally, so even the most sensitive materials – especially alloys – can be atomized. The system has two process chambers, each with its own high-vacuum pump systems comprising a forevacuum pump and a turbomolecular pump. Using this device, several ultra-thin layers of even the most fragile materials can be applied to nearly any subsurface. With UNIVEX, the University of Kaiserslautern can conduct world-class research in the area of semiconductor technology and spintronics.