MACHINE SPECIFICATIONS

SR. NO. MACHINE UNIT SPECIFICATION SCREW DIAMETER THEORITICAL INJECTION VOLUME PS 3 INJECTION WEIGHT PE 4 INJECTION PRESSURE gram 2320 3360 177mpa 184mpa 190mpa MM MITSUBISHI 850T- A 110 MITSUBISHI 850T- B 160 FERROMATIK MILLACRON 600T- A FERROMATIK MILLACRON FERROMATIK MILLACRON FERROMATIK MILLACRON 450T- A 450T- B 450T- C

HAITIAN

600T - B

HAITIAN

450T - D

HAITIAN 200T

L&T

150T

90

105

80

85

80

80

70

70

45

45

cm3

3140

4540

1810

2497

1607

1607

1231

1239

320

295

gram

2890

4180

1722

2272

1531

1531

1172

1127

291

225

kgf/cm2

1820

1815

1843

1463

1463

1910

INJECTION RATE

cm3/sec

790[650]

960[795]

477

458

458

350

339 g/sec

158g/sec

PLASTICIZING CAPACITY

kg/hr

445[365]

555[455]

74 gm/sec

74 gm/sec

53 gm/sec

44.9 g/sec

20 g/sec

SCREW SPEED

rpm

152[124]

132

149

140

169

169

169

185

245

INJECTION STROKE

mm

495

525

332

440

320

320

320

322

201

160

MOULD CLAMPING FORCE

ton

650

850

500

530

350

350

350

380

160

125

MOULD OPENING FORCE

ton

62

62

10

MOULD CIOSING SPEED

m/min

31[26]

37[32]

11

MOULD OPENING SPEED

m/min

31[26]

37[31] 1240x1250 1030x1040 705x705 700 X 700

12

PLATEN SIZE [HXV]

mm mm

1530x1530

1800x1700

1245x1250

1010x1010

1010x1010

1010x1010

13 TIE BAR DISTANCE [HXV]

1060x1060

1300x1200

870x870

840x830

710x710

710x710

710x710

730x730

470x470

450x450

7 MOULD HEIGHT (MM) 8

MIN

mm

450

560

400

350

540[300]

540[300]

540[300]

280

180

220

MAX MOULD OPEMING STROKE

mm

1050

1000

950

830

620

550

mm

1350

1600

800

850

960

960

960

700

430

430

10

OPEN DAYLIGHT

mm

1800

2160

1650

1800

1500[1260]

1500[1260]

1500[1260]

1530

1050

980

11 EJECTOR 12

EJECTOR FORCE

ton

20.2

20.2

12

158kn

70

70

70

110 kn

33kn

EJECTOR STROCK

mm

200

200

250

220

125

125

125

180

140

160

13

PUMP CAPACITY

kw

90

110

55

55

55

45

45

37

22

22

14

HEATING CAPACITY

kw

47.5

53.5

43

44.45

29.5

29.5

29.5

24.85

11.25

15

OIL TANK CAPACITY

lit m

1400 9.4x2.6x2.5

1750 10.6x3.0x2.6

620 9.2x2.3x2.9

1040

960 7.8x1.93x2.71

960 7.8x1.93x2.71

960 7.8x1.93x2.71

750

350

300

16 OVERALL DIMENSION (LXWXH ) M/C WEIGHT

9.33x2.2x2.66

7.46x1.96x2.15

5.15x1.35x1.96

4.4x1.25x1.9

17

ton

38

47

25.8

26

16.25

16.25

16.25

15

5.3

6.5

16/1/2003

5./8/2003

16/6/2006

27/7/2006

ELECTRONICA 140T

40

320

300

180

140

700 X 600

450 X 380

180

385

400

785

120

25

9.5

280

4x.9x1.7

CHECKLIST FOR PREVENTIVE MAINTENANCE ( Machines )

Machine : Fully Auto Injection Moulding Machine Machine No. WEEKLY CHECK Sr. No. Check Points 1 Hydralic Oil Temprature Check Oil level & Leakages in line Requirements Temp. with in Range 32 - 50 C Make :

Observations O.K. N.O.K

Remarks

Oil level gauge, No oil leakage

Outside Machine Surface Should be clean & greasing & sliding section done on sliding parts Limt Switch of Safety door Operating properly & rear side door. Temprature controller working properly Set Value must match gain value

M/c moving platern, Working properly , no Abnormal Ejector System & Injection Motion System Suction Filter MONTHLY CHECK No abnormal sound

Sr. No. 1 2 3 4 5 6 7

Check Points Sliding Section Full Checking Checking inside Control Panel -wiring, right signal, continuity Limit Switches Band Heaters Thermocouples Clamp & Scerw position on indicator Solenoid Valve

Requirements Proper greasing , No rust or dent marks No loose connection, proper connectivity, signal positive Positive signal during working In proper working condition Giving required voltage Set Value must match gain value Positive signal, No overheating

Observations O.K. N.O.K

Remarks

Fitting od bolts, Nuts & air 8 No looose fitting breather HALF YEARLY CHECK Sr. No. Check Points 1 2 Oil Temp. Controller Hydralic Fluid Viscosity YEARLY CHECK Sr. No. Check Points 1 2 3 4 5 Oil Tank Cleaning, Hydralic Oil Viscosity Hydralic Pump Motor Requirements No contamination, Viscosity as per oil standard. Correct Line pressure, no abnormal sound Observations O.K. N.O.K Remarks Requirements Proper oil temp. shown With in Range Observations O.K. N.O.K Remarks

Panel Controller Battery & Proper voltage other batteries Should be clean & vaccum Suction Filter gauge below 0.013 Should be clean & no extra Line Filter noise Checked By: Mr. Stish Memane
Formate No : DOC. MNT.-02 Issue No : 02

Approved By: Mr. Vikas Shelar

Rev No: Rev Date: 2 20.06.08

MACHINE PREVENTIVE MAINTENANCE PLAN 2009 - 2010

PREPARED BY SR.NO. 6 MACHINE INJECTION MOULDING MACHINE, MG 450-C APR--09 MAY--09 JUN--09 * * * * * *

CHECKED BY JULY--09 AUG--09 * * SEP--09 * OCT--09 * NOV--09 * *

APPROVED BY DEC--09 * JAN--10 * FEB--10 * MAR--10 *

INJECTION MOULDING MACHINE, LTM-150

INJECTION MOULDING MACHINE, EPM 140

INJECTION MOULDING MACHINE, 600-B

10

INJECTION MOULDING MACHINE, MG 450-D

11

INJECTION MOULDING MACHINE, HTF-200

* * *

* * *

* * *

* - WEEKLY

- MONTHLY

- HALF YEAYLY

- YEARLY

MACHINE MAINTENANCE DOWN TIME REPORT

BREAK DOWN START TIME BREAK DOWN STOP DATE BREAK DOWN STOP

MONTH MACHINE

DATE

SHIFT

TOTAL DOWN TIME 2.15 1.10 0.30 4:05 0.3 1.00 0.45

PROBLEM OBSERVED Hot runner temprature problem Barrel returen problem Barrel temprature high Gas pressure low Gas pressure low Refilling problem NCM change

MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09 MAR--09

600 A 450-B LT 150 450-B 850 B 850 A 450 A 600 A

1/3/2009 2/3/2009 2/3/2009 3/3/2009 3/3/2009 3/3/2009 4/3/2009 6/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009 1/3/2009

11:00 17:40 17:30 20:00 21:15 13:30 19:30 3:45

A B B B B A B C

1/3/2009 2/3/2009 1/3/2009 3/3/2009 4/3/2009 3/3/2009 4/3/2009 6/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009 1/3/2009 2/3/2009

1:15 18:50 20:30 1:20 14:00 20:30 4:30

WORK COMPLETE

ROOT CAUSE

SPARES PROBLEM SPARES USED AVAILAB REPETE LE

Hot runner card change Hot runner card faulty

MONTHLY PREVENTIVE MAINTENANCE PLAN FOR UTILITY -- 2009 - 2

SR. UTILITY NO. 1 2 ELGI AIR COMPRESSOR-1 ELGI AIR COMPRESSOR-2

APR

MAY

JUN

AUGUST

AUG

SEP

OCT

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

KAESER AIR D.G. SET 250 KVA D.G. SET 320 KVA BAUER GAS COMPRESSOR SNG-III GAS UNIT DEHUMIDIFIRE - 1 MTC - L&T MAKE EOT CRANE 12T-1 EOT CRANE 12T-2 EOT CRANE - 5T WATER PUMP ( 1- 6) COOLING TOWER - 1 COOLING TOWER - 2

R UTILITY -- 2009 - 2010

NOV

DEC

JAN

FEB

MAR

PREVENTIVE MAINTENANCE PLAN FOR UTILITY 2011 - 2012

SR. NO. 1

UTILITY

APR--11 MAY--11 JUN--11 AUG--11 AUG--11 SEP--11 OCT--11 O O * O * * * * * * O * O O O O O O O O O O O O O O O * O * * * * * * O * O * O * * * * * * O * O * O * * * * * * O * O * O * * * * * * O * O * O * * * * * * O * * O * * * * * * O *

ELGI AIR COMPRESSOR-1

ELGI AIR COMPRESSOR-2

6 7 8 9 10

DEHUMIDIFIRE - 1 MTC - L&T MAKE EOT CRANE 12T-1 EOT CRANE 12T-2 EOT CRANE - 5T

11

WATER PUMP-- ( 1 to 6)

12 13 14 15 16

COOLING TOWER - 1 COOLING TOWER - 2 D.G. SET 250 KVA D.G. SET 320 KVA TRANSFORMER O - DAILY

- WEEKLY

* - MONTHLY

- QUARTERLY

- HALF YEARL

OR UTILITY

NOV--11 DEC--11 O * O * * * * * * O * O O O * O * * * * * * O *

JAN--12 O * O * * * * * * O *

FEB--12 MAR--12 O * O * * * * * * O * O * O * * * * * * O *

O O

O O

O O

O O

- HALF YEARLY

- YEARLY

MACHINE PREVENTIVE MAINTENANCE PLAN 2011 - 2012

PREPARED BY SR.NO. MACHINE INJECTION MOULDING MACHINE, MMG 850-A APR--11 MAY--11 JUN--11 O * O * O * O * O *

CHECKED BY JULY--11 AUG--11 O * O * SEP--11 O * OCT--11 O * NOV--11 O * O * O *

APPROVED BY DEC--11 O * JAN--12 O * FEB--12 O * MAR--12 O *

INJECTION MOULDING MACHINE, MMG 850-B

O *

O *

O *

O *

O *

O *

O *

O *

O *

O *

INJECTION MOULDING MACHINE, FMI 850-C

O *

O * O * O *

O *

O *

O *

O *

INJECTION MOULDING MACHINE, FMI 600 T

O *

O *

O *

O *

O *

O *

O *

INJECTION MOULDING MACHINE, FMI 450 T

O *

O *

O * O *

O *

O *

O *

O *

O * O * O *

O *

O *

O *

O *

O *

O *

INJECTION MOULDING MACHINE, FMI 300 T

O *

O *

O *

O *

O *

O *

O *

O *

O * O *

O *

O *

O *

O *

INJECTION MOULDING MACHINE, HTF-200

O *

O *

O *

O *

O *

O *

O *

O *

O *

O *

O *

O *

O - DAILY

* - WEEKLY

- MONTHLY

- HALF YEAYLY

- YEARLY

KOSI PLAST PVT. LTD.

INJECTION MOLDING MACHINE DATA SCREW DIA. (mm)
90

SR.N MACHINE O.
1

INJ. CAPACITY (gm)

2890

CLAMPING STROKE (mm)

1350

DAYLIGHT (mm)
1800

MOULD HEIGHT ( mm)

450 x 1040

PLATERN SIZE (mm)

1530 x 1530

850 T - A

850 T - B

4180

110

560 min

1800 x 1700

850 T - C

3283

100

1850

2250

400-1200

1790x1470

600 T

1722

80

1250

1650

400 x 1000

12450 x 1250

450 T

1531

80

960

1260

300 min

1010 x1010

300 T

821

65

830

1080

250 min

880 x880

200 T

291

45

870

1050

180-620

705 x 705

ATA EJECTOR STROKE (mm)

200

TIE BAR DISTANCE

1060 x 1060

LOCATING KW EJECTOR RING HOLES (mm) MOTOR HEATER

150
90 57

CONNECTE LOAD

1300 x1200

200

150

110

65

1390x1070

250

150

75

62

870x870

250

150

55

37

710 x710

125

100 x400

150

55

30

620 x620

100

100 x400

37

24

470 x 470

140

120

22

12

TOTAL CONNECTED LOAD SR. NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

MACHINE
INJECTION MOULDING MACHINE - MHI 650 T INJECTION MOULDING MACHINE - FMI 500T INJECTION MOULDING MACHINE - FMI 350T INJECTION MOULDING MACHINE - MHI 850 T INJECTION MOULDING MACHINE - FMI 850 T INJECTION MOULDING MACHINE - FMI 250 T INJECTION MOULDING MACHINE - HTI 160 T COOLING TOWER GRINDER OVERHEAD CRANE HOPPER DRYER ( 7 NOS) HOPPER DRYER 300T OVERALL LIGHTING GAS COMPRESSOR OFFICE OTHER MIXER AIR COMPRESSOR

CONNECTED LOAD ( KW ) 147 92 85 175 137 61 34 60 38 40 75 15 30 40 75 50 7

77

TOTAL LOAD

1238

KOSI PLAST PVT. LTD. INDEX

SR. NO. MACHINE

INJECTION MOULDING MACHINE - MHI 850 T - A

INJECTION MOULDING MACHINE - MHI 850 T - B

INJECTION MOULDING MACHINE - FMI 850T - C

INJECTION MOULDING MACHINE - FMI 600T

INJECTION MOULDING MACHINE - FMI 450 T

INJECTION MOULDING MACHINE - FMI 300 T

INJECTION MOULDING MACHINE - HTF- 200 T