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1. INTRODUCTION
1.1 COMPANY PROFILE
Precision Compaid Mouldings Private Limited is a Private incorporated on 18 July 1988. It is classified as
Non-govt. Company and is registered at Registrar of Companies, Bangalore. Its authorized share capital is
Rs. 2,000,000 and its paid up capital is Rs. 1,780,000. It is involved in Architectural, engineering and other
technical activities.

Precision Compaid Mouldings Private Limited's Annual General Meeting (AGM) was last held on 30
September 2017 and as per records from Ministry of Corporate Affairs (MCA), its balance sheet was last
filed on 31 March 2017.

Directors of Precision Compaid Mouldings Private Limited are Srinivasa Varadhan Sridhar and
Purushothaman Damodaran.

Precision Compaid Mouldings Private Limited's Corporate Identification Number is (CIN)

U74210KA1988PTC009288 and its registration number is 9288.Its Email address is
[email protected] and its registered address is 27-B, VEERASANDRAINDUSTRIAL AREA,
HOSUR ROAD, BANGALORE BANGALORE KA 560100 IN , - ,.

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1.2 GENERAL INFORMATION

1.3 MANAGEMENT POLICY

The Precision Compaid Mouldings is trusted because

☞ Of our strong and passionate commitment to Quality and innovation in all its approaches, system and
belief.
☞ We maintains complete transparency in all its activities
☞ We strongly believe in the concept of long term relationships.
☞ We provide complete and unstained utmost satisfaction.
☞ We believe that our employees are our greatest assets.

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2. DEPARTMENTS

2.1 QUALITY DEPARTMENT

QUALITY SYSTEM
The company is ISO/TS 16949:2009
SQ Mark certified By Hyundai.
We are familiar with PPAP/FMEA requirements.
In-house and External rejection in PPM Monitored.
Continuous Improvement Process (CIP) followed.
5S is being actively implemented.
In house Millipore testing facility.

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2.2 SHOP FLOOR OVRVIEW

PCM MOULDING MACHINES

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2.3 TOOL ROOM DIVISION

MOULD MAKING

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1. The moulds are manufactured using the following Raw materials.

2. Mould Base - C45

3. Core & Cavity - Stevax ESR, HDS, HCHCR, P 20 & OHNS with vaccum hardening.

4. Customer moulds are maintained periodically & Mould history cards preserved.

PCM ENGINEERING DESIGN SERVICES

1. Equipped with in-house Mould design facility.

2. The Design team is conversant with usage of 3D tools

NX 10 & CAD CAM Licensed software with 4 Axis.

3. The Design team has requisite exposure, qualification and hands on experience to handle simple to
complex Mould designs, product designs and Rapid prototyping.

4. We are supported by associates for conducting Mould Flow analysis.

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3. INJECTION MOULDING MACHINE

3.1 INTRODUCTION

Injection moulding is nowadays the most popular method to produce 3-dimensional parts of different kinds
of polymeric materials. It is a fast process and is used to produce large numbers of identical items from high
precision engineering components to disposable consumer goods. It is a suitable method for thermoplastics,
thermosets, thermoplastic elastomers, elastomers, short fiber and particulate filled polymers. Today, more
than one-third of all thermoplastic materials are injection moulded and more than half of the polymer
processing equipment is for injection moulding. Injection moulding is a production method for large series
and it can be characterized as follows:
• Part shape can be very complex and it has no specific limitations
• Part size is not limited (from very small parts to quite big products)
• High fundamental investigations, injection moulding machines (300 000 FMk and more), injection moulds
(50 000 FMk and more)
• Short cycle time
• Very good dimensional stability
• Very good visual quality
• Integration of different post processing methods (coating, inserts) possible.

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Typical Material Used

Most thermoplastics can be processed by Injection

Moulding. Some of the commonly used materials are:
• Acrylonitrile-Butadiene-Styrene
• Nylon
• Polycarbonate
• Polypropylene
• Polystyrene

Injection moulding can also be used to manufacture parts from aluminium or brass. The melting points of
these metals are much higher than those of plastics; this makes for substantially shorter mould lifetimes
despite the use of specialized steels. Nonetheless, the costs compare quite favourably to sand casting,
particularly for smaller parts.

3.2 PROCESS

1. CLAMPING
An injection moulding machine consists of three basic parts; the mould plus the clamping and
injection units. The clamping unit is what holds the mould under pressure during the injection and
cooling. Basically, it holds the two halves of the injection mould together.

2. INJECTION
During the injection phase, plastic material, usually in the form of pellets, are loaded into a hopper on
top of the injection unit. The pellets feed into the cylinder where they are heated until they reach molten
form (think of how a hot glue gun works here). Within the heating cylinder there is a motorized screw that
mixes the molten pellets and forces them to end of the cylinder. Once enough material has accumulated in
front of the screw, the injection process begins. The molten plastic is inserted into the mould through a
sprue, while the pressure and speed are controlled by the screw.
NOTE: Some injection moulding machines use a ram instead of a screw.

3. DWELLING
The dwelling phase consists of a pause in the injection process. The molten plastic has been injected
into the mould and the pressure is applied to make sure all of the mould cavities are filled.

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4. COOLING
The plastic is allowed to cool to its solid form within the mould.

5. MOULD OPENING
The clamping unit is opened, which separates the two halves of the mould.

6. EJECTION
An ejecting rod and plate eject the finish piece from the mould. The un-used spres and runners can be
recycled for use again in future moulds. The injection moulding process requires some complex calculations.
Every different type of resin has a shrinkage value that must be factored in, and the mould must compensate
for it. If this value is not precisely determined, the final product will be incorrectly sized or may contain
flaws. Typically, this is compensated for by first filling the mould with resin, holding it under pressure, and
then adding more resin to compensate for contraction. Other complications may include burned parts
resulting from the melt temperature being set too high, war page resulting from an uneven surface
temperature, or incomplete filling due to a too slow of an injection stroke.

INJECTION MOULDING

Introduction
There is no need to dwell on the challenges facing today’s injection moulding industry. In the last couple of
years, injection moulders have made sizable capital investments to improve quality and efficiency in an
effort to counter competitive pressures as well as rising material and labour costs. New injection moulding
machines, advanced automation and inspection devices, to automated assembly machinery and sophisticated
materials handling equipment have enabled moulding plants to significantly increase output with a lower
operating cost basis. As a result, they now enjoy the highest historical productivity rates. However, in spite
of all these advances, the injection moulding industry faces its biggest challenge yet. To further optimize
efficiency, there is a need for an integrated approach that guarantees a flawless execution from the
conceptual stage of part design, to its high volume production, to its ultimate delivery to the customer.
Unfortunately, the injection moulding manufacturing process is a patchwork of disparate systems with
which it is difficult to intelligently exchange data, making the planning, setup and ramp-up of new
production lines time-consuming and plagued by inefficient trial-and-error and fine tuning methods.

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From Design to Manufacturing Optimization

Mould flow needs no introduction into the world of part and mould design optimization. It virtually invented
the space, and Mould flow’s design analysis products have become the world’s most widely used CAE
solutions in the injection moulding industry. The CAE space has gradually evolved from basic problem
solving tools in the 1980s to modelling and simulation for problem avoidance in the 1990s. The new frontier
for CAE is a more comprehensive approach that also includes manufacturing optimization, an area where
Mould flow remains on the forefront. Mould flow Plastics Advisers® (MPA®) products are easy-to-use,
3D solids-based plastics flow simulation tools that allow part designers and mould makers to predict the
manufacturability and quality of their designs during preliminary product development stages. MPA users
benefit by avoiding potential downstream problems that can lead to production delays and cost overruns.
Mould flow Plastics Insight® (MPI®) products are a complete suite of advanced plastics process simulation
tools for predicting and eliminating potential manufacturing problems and optimizing part design, mould
design, material choice and processing conditions. MPI products simulate the broadest range of
manufacturing processes and support all design geometry types associated with plastics moulding processes.
Set Up, Optimize, Control and Monitor Once the part and mould designs are optimized and the effects of the
moulding processes have been taken into account, the logical next step is to deliver optimal processing
parameters to the primary equipment and other process controls in the manufacturing cell. Automating the
setup process enables production to start more quickly and shortens the time required to determine and
achieve the ideal process parameters such as shot size, injection speed, and temperature and pressure
settings. Used intelligently, design analysis simulation (DOE) results can provide appropriate initial
conditions from which to begin the manufacturing process setup and downstream optimization and control
tasks. The more complex the part, the material or the mould, the narrower is the processing window and the
higher is the need for continuous monitoring and optimization during production.
In a networked environment, monitoring and optimization can now be handled automatically from a single
operator console in a central location, limiting operator interventions in the production cell to major
equipment failures.

Optimal Temperature and Flow

Production capacity and yield are ultimately determined by the speed, reliability and quality by which the
melt flows from the machine into the mould. This is where advanced hot runner controls come in, as they
assure that materials are kept in an optimal molten state until injected into the part cavity. This “final control
element” guarantees higher yields, reduced cycle times and better part quality. Mould flow now also offers
the world’s most advanced hot runner control technology.

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Process Setup
Successful process setup requires an operator to determine a machine-mould-material combination of
processing conditions to achieve acceptable quality parts. Mould flow’s process setup module eliminates the
guesswork over process parameter permutations and instead provides an intuitive, systematic method for
establishing the best combination of process parameters that produce good moulded parts. This scientifically
created process results in less time spent on setup and less material wasted on trial-and-error iterations.

Process Optimization
After determining the combination of process parameters that will produce an acceptable quality part, it is
important to further determine or verify a robust processing window. Mould flow’s process optimization
module performs an automated Design of Experiments (DOE) that builds on the foundation established
during the process setup phase. The technology allows users to further optimize the combination of
processing parameters to determine a robust, “good parts” processing window. The predefined DOE runs
automatically, so no special expertise in statistical process control (SPC) is required for a machine operator
to determine a robust, “good parts” processing window quickly. Once this robust processing window has
been determined, the process is less likely to go out-of control and produce out-of-specification parts.

Process Control
Assuming a robust processing window has been determined by using the process setup and process
optimization modules, users can access Mould flow’s process control module to maintain the optimized
processing conditions. The process control module allows users to consistently maintain the production
process, resulting in reduced reject rates, higher part quality, and more efficient use of machine time.

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Hot Runner Process Control

The right machine parameters and the wrong process control of the mould will result in slower cycles, parts
out of tolerance, high scrap rates and constant headaches for processing technicians. It is imperative for the
best part-price ratio that the core of a mould, the hot runner when used, be properly controlled. Mould flow’s
Altanium® hot runner process controls are the industry’s first and only modular, small footprint solution
that can support from one to 384 zones. Its unique modular control units can be used freestanding, mounted
on the mould or mounted alongside, behind, or even inside the injection moulding machine. With advanced
technology for auto-slaving, boost control, standby management, mould diagnostics and data collection,

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Altanium® controls offer the highest degree of temperature control accuracy for existing and future low-
mass nozzles, featuring user selectable phase angle or zero cross power control per zone, state-of-the-art
“hall effect” current transducers and enhanced diagnostics and control software. The increased use of
temperature-sensitive engineering plastics, hard-to-mould polymers, and co-injected materials demands the
ultimate in temperature control to assure dimensional consistency, which is where Mould flow hot runner
controls come in.

High Speed Process Monitoring and Analysis

Once a robust processing window has been established and is in control, it is important to continuously
monitor key process parameters to identify any trends in the process. Using collected data, Mould flow’s
process monitoring and analysis modules analyse the manufacturing processes to uncover hidden or latent
problems, as well as collect and archive the data for future part quality conformation.

Statistical Process Control

Fundamentally, statistical process control (SPC) is a method of monitoring a process during its operation in
order to control part quality during production, as opposed to relying on inspection to find problems after the
fact. SPC involves gathering and analysing data about the process itself in near real time, so that necessary
action can be taken. This is done in order to identify special causes of variation and other abnormal
processing conditions, thereby bringing the process under statistical control and reducing cycle-to-cycle or
part-to-part variation. Because of the nature of the injection moulding process, it is ideally suited for
implementing SPC methods. Therefore, a complete manufacturing solutions system should include a method
for performing various SPC tasks.
Mould flow’s SPC module can be used to apply SPC methods to the injection moulding process. Some of its
capabilities include:
• Measure and store up to 50 parameters on every machine cycle and then perform typical SPC treatment of
the data.
• Activate alarms and part diverters when process limits are violated.
• Display run charts to review process parameters and part attributes for up to
100,000 machine cycles.
• Display histograms, X-bar and R charts, and scatter diagrams for additional analysis capability.

These are just some of the SPC capabilities available to help injection molders improve their process and
maintain greater control over it.

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3.3 Advantages of injection moulding

be used

3.4 Disadvantages of injection moulding

Related injection moulding processes

During the recent years the injection mounding process has developed a great deal. There are
several special injection mounding techniques e.g.

• Multi-colour
• Multi-component
• Co-injection
• Gas-assisted
• Injection-compression
• In-mould decoration
• External inserts

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4. HOPPER DRYER

4.1 PERFORMANCE CHARACTERISTICS

• The heating barrel is made from the stainless steel to ensure that the material is not polluted and easier to
be cleaned.
• The air dispersion device of the stainless steel net plate enables the heat air to evenly blow the material.
The temperature is even in the barrel and the material sinters on time.
• There is a hinge connection structure between the heating barrel and the hopper, which facilitates opening,
reloading and cleaning.
• An open-door type magnetic base, which is convenient and easy to take out the magnetic shelf for cleaning
the scrap iron.

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• The timing start up device of any time can be matched to reduce pre-heating time on duty and improve
efficiency.
• The hot recycler device can be matched to reduce energy consumption.
• The whirly dust arrester can be matched to prevent the dust into the workshop.

Cabinet Dryer

Suitable for drying of all kinds of plastic raw materials; able to dry materials with different texture and color
simultaneously, particularly for materials with high demand for temperature, in small quantities and wide
colours; also suitable for other preheating or drying purpose e.g. edible, medical, electronic and
electroplating.

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5. MACHINERIES AND EQUIPMENT

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6. RAW MATERIALS

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PCM PRODUCT SHARE

STORE OVERVIEW

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PRODUCTS

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7. CONCLUSION

To maximize capacity utilization and production efficiency, while improving quality, manufacturers need
integrated manufacturing solutions that facilitate continuous process improvements and ultimately make
them more competitive. Mould flow’s “best-in-class” products allow manufacturers to optimize operations,
drive down costs and increase profitability with end-to-end solutions that optimize the entire design through-
manufacturing process.

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REFERENCES

1. www.precisioncompaid.in/

2. https://www.justdial.com/Bangalore/Precision-Compaid-Mouldings

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