SYNOPSIS ON
Machine Design and Assembly
to be submitted by
Mahika Jayaswal, (BTBTR21035)
Under the supervision of
GUIDE- MR PURANLAL SHARMA
COMPANY-SHUBHAM FLEXIBLE PACKAGING
For the award of the degree of
[Link], Mechatronics Engineering
SCHOOL OF AUTOMATION, BANASTHALI VIDYAPITH
BANASTHALI – 304022 July-Dec
1. INTRODUCTION
Founded in 1998 as Ganga Packaging and rebranded in 2002, Shubham Flexible Packaging
Machines Pvt. Ltd. has emerged as a leader in manufacturing advanced packaging solutions
under the leadership of Mr. Virendra Sharma, CMD. Headquartered in Faridabad,
Haryana, the company operates two facilities: Sector 6 for precision parts and Sector 59 for
machinery assembly. Shubham Flexible produces over 300 machines annually, including
Tetra Pack and multi-track systems, serving industries like FMCG (Fast moving consumer
goods) pharmaceuticals, and food processing. Known for innovation and sustainability,
Shubham pioneers eco-friendly packaging, catering to global clients such as Unilever, P&G,
and Tata with the motto "Pack with Confidence."
1.1 OBJECTIVE
The project focuses on improving the efficiency and performance of modern packaging
machines to meet the dynamic needs of the industry. Existing systems often struggle with
limitations such as downtime, inefficiencies in precision, and the inability to handle diverse
materials or packaging types. What is required is an advanced solution integrating
automation, sustainability, and enhanced operational features to minimize waste, improve
speed, and ensure compliance with global standards.
The project involves the use of technologies such as servo-driven mechanisms, pneumatic
systems, and PLC-based automation for precise control and efficiency. SolidWorks and
FESTO tools are utilized for designing, modelling, and simulating machine components.
Processes include 3D modelling, circuit design, and extensive shop floor testing to validate
performance. Testing ensures accurate calibration of components like HMI systems, web
aligners, and coders, focusing on reducing errors and maximizing throughput.
The expected performance includes faster production cycles, improved material handling,
and user-friendly operations. However, limitations like high initial costs and maintenance
requirements may need to be addressed. The end product is a versatile, eco-friendly
packaging machine suitable for industries like FMCG, pharmaceuticals, and food processing.
Its usage improves productivity, reduces material waste, and supports sustainable packaging,
offering significant operational and environmental benefits.
2. Feasibility Study
The proposed project aims to design and optimize packaging machinery by integrating
advanced technologies such as servo-driven mechanisms, pneumatic systems, and PLC-based
automation. A critical aspect of technical feasibility is the use of tools like SolidWorks for
precise 3D modelling and FESTO equipment for pneumatic system simulation, both of which
are accessible and efficient. The project involves creating components like HMI systems,
web aligners, and coders, which are integral to modern packaging machines.
During the training period, shop floor observations and R&D activities confirmed that the
company possesses the required technical infrastructure, such as 3D design software, EPDM
systems for data management, and an experienced workforce. However, potential challenges
include coordinating multiple design iterations and ensuring compatibility of sub-assemblies.
With proper planning and adherence to timelines, these challenges can be addressed, making
the project technically feasible.
2.1 Profitability and Impact of the Project
The profitability of the proposed project is promising due to the increasing demand for
advanced, sustainable, and efficient packaging solutions in industries such as FMCG,
pharmaceuticals, and food processing. By designing machines that reduce downtime,
increase speed, and enhance material efficiency, the project can result in significant cost
savings and improved production output for the company. Furthermore, the use of recyclable
materials aligns with global environmental regulations, adding value to the product.
This study will also benefit the company by creating innovative packaging solutions,
enabling it to maintain its competitive edge in the global market. The adoption of advanced
automation reduces operational costs, improves precision, and meets industry demands for
faster production cycles.
The feasibility of completing the project within the internship period was confirmed by
dividing the tasks into achievable milestones. Key components, such as SolidWorks
modelling, BOM creation, and sub-assembly design, were completed systematically during
the training. Contributions to R&D activities and the assembly process accelerated progress.
3. Design Phase
The methodology for this project begins with a comprehensive conceptualization phase,
which involves identifying the objectives and functional requirements of the proposed
packaging machine. This stage includes studying existing designs, analyzing customer needs,
and determining areas for improvement, such as efficiency, precision, or sustainability.
Utilizing SolidWorks, the initial step is to create 3D models of machine components,
ensuring that all parts meet the required specifications for dimensions and functionality.
Detailed technical drawings and simulations are performed during this phase to evaluate the
feasibility of the design. SolidWorks' simulation tools allow for stress testing, motion
analysis, and identifying design inconsistencies. This phase also involves creating a Bill of
Materials (BOM), which includes a list of required components, raw materials, and sub-
assemblies.
3.1 Development, Testing and Design
The development phase involves assembling the designed components, beginning with the
production of precision parts and their integration into sub-assemblies. Hands-on
involvement on the shopfloor enables real-time observation of wiring, programming, and
assembly processes. HMI systems and web aligners are tested to ensure they align with the
design specifications and perform reliably.
Regular testing is conducted to validate the machine's performance under simulated working
conditions. This includes motion and functionality tests for moving parts and checking for
seamless operation of the pneumatic systems designed during the FESTO training.
Components are evaluated for their durability, alignment, and compatibility. Any
discrepancies are addressed through iterative improvements in the design or assembly
process.
The final step is implementing the machine in a controlled environment to assess its end-to-
end functionality, followed by the preparation of operational and maintenance manuals.
Documentation is created to record the project’s progress, challenges, and solutions,
providing a reference for future designs.
This structured methodology ensures that the project remains aligned with its objectives and
adheres to timelines, ultimately delivering an optimized and functional machine within the
stipulated training period.
4. Facilities, Components, and Software Required
The successful development of the proposed project requires access to specialized facilities,
components, and software tools that enable precise design, manufacturing, and testing of
packaging machinery.
The facilities required include a well-equipped design department with high-performance
workstations, access to SolidWorks software for 3D modelling and simulation, and EPDM
(Enterprise Product Data Management) for efficient design file storage and retrieval. The
manufacturing facility must have advanced machinery for producing precision components,
such as CNC machines, and an assembly floor equipped with pneumatic systems, electrical
wiring setups, and testing stations. A controlled shop floor is essential for assembling and
testing prototypes, ensuring real-world conditions for validation.
The project also demands specific hardware components, including servo motors, sensors,
web aligners, coding units, and HMI systems, all of which are critical for achieving
automation and functionality in packaging machines. Pneumatic components like actuators,
valves, and compressors, supported by FESTO tools, are required for system integration and
testing.
On the software side, apart from SolidWorks, tools like AutoCAD for technical drawings,
ERP systems like SAP for resource planning, and HMI programming software for
configuring control systems are essential. These tools collectively streamline the design,
manufacturing, and testing phases, ensuring the project’s success within the stipulated
timeframe.
