Beruflich Dokumente
Kultur Dokumente
PUNJAB
Ludhiana
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Original w ork of TERI d one und er the project “IN DIA: TERI-SDC
Partnership: Scaling up Energy Efficient Technologies in Sm all Enterprises
(EESE)”
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Disclaimer
This d ocum ent is an output of a research exercise und ertaken by TERI
supported by the Sw iss Agency for Developm ent and Cooperation (SDC) for
the benefit of MSME sector. While every effort has been m ad e to avoid any
m istakes or omissions, TERI and SDC w ould not be in any w ay liable to any
persons/ organisations by reason of any mistake/ om ission in the publication.
Published by
T E R I Press
The Energy and Resources Institute
Darbari Seth Block
IH C Com plex, Lodhi Road
N ew Delhi-110 003
Ind ia
TERI places on record its sincere thanks to the Sw iss Agency for Developm ent and
Cooperation (SDC) for supporting the long -term partnership project focusing on energy
intensive MSME clusters in Ind ia.
TERI team is ind ebted to Mr Vijay Kum ar (Director, MSME-DI, Lud hiana) Mr R K Parm ar,
(Assistant Director, MSME-DI, Ludhiana) for organising field visits interactions w ith
entrepreneurs of forging units in the cluster d uring the stud y. The support provid ed by Mr S
S Bed i, (Senior Manager, Cham ber of Ind ustrial & Com m ercial Undertakings, Lud hiana)
and Punjab Forging Industries Association (PFIA) w ere extrem ely useful in understanding
forging cluster in Lud hiana. We are extrem ely thankful to Mr Am it Sharm a, Mr Sand eep
Sharm a and Mr Sahil Dhingra of Vast Linkers Pvt Ltd for coord inating ind ustry visit and
accom panying us to industrial site d uring interaction w ith entrepreneur and shop floor visit.
Last but not least, our sincere thanks to MSME entrepreneurs and other key stakeholders in
the cluster for provid ing valuable data and inputs that helped in cluster analysis.
Ludhiana forging industries
Overview of cluster
Lud hiana city w as found ed in 1480 und er the Lod hi d ynasty. The tow n w as originally
know n as Lodhi-ana, w hich m eans the tow n of Lod hi's. The name later changed to the
present nam e Lud hiana. It lies betw een north Latitud e 30°34' and 31°01' and east longitud e
75°18' and 76°20'. It is bound ed on the north by River Sutlej w hich separates it from
Jaland har d istrict. In 1805, d uring the reign of Maharaja Ranjit Singh , Lud hiana becam e an
im portant British cantonm ent.
Lud hiana city is know n as the ind ustrial capital of Punjab and quite-often referred as
Manchester of Ind ia. Post-ind epend ence, num ber of ind ustries started boom ing in the city to
support the agriculturally rich area. Initial d evelopm ent w as of agricultural im plem ents,
tractor ind ustries; slow ly grow th w as seen in allied ind ustries such as forging, found ry,
sheet m etal and auto-parts as w ell. The city is hom e to som e of top national cycle brand s
such as H ero and Avon. In early 1990s Lud hiana started supplying prod ucts not only to
entire Ind ia but also to Mid d le East and Europe. Presently, Lud hiana d istrict has about
39,000 ind ustries in over 20 d ifferent ind ustry estates. A variety of prod ucts such as cycle &
cycle parts, sew ing machine parts, auto parts, forging, machine tools, hosiery, knitw ear and
w oollen garm ents, electronics good s, plastic & rubber good s are being prod uced in the city
in big w ay by sm all and m ed ium ind ustries. Since 2010, though Punjab is seeing a d ecline in
ind ustrial output but the num ber of registered units in Ludhiana has seen a grow th of abov e
15%. A few prom inent ind ustries in Lud hiana cluster are Vard hm an Spinning and Polytex,
Osw al Cotton Spinning Mills (Textile) and H ero, Avon, Rockm an (Cycle).
Presently, there are about 500 forging ind ustries in Lud hiana prod ucing around 1,640 tonnes
of forged prod ucts per day (492,000 tonnes of forged prod ucts per year), of w hich about 25%
is prod uced by about 10 large forging ind ustries. Forging ind usty provid e em ploym ent to
about 13,000 people. Units are m ainly located in Daba road , Saniw al Delo road , Focal point
(Phase I-VIII) and Ind ustrial area A,B and C. Major prod ucts of the cluster are crank shaft,
connecting rod s, brake d rum , spanners, special tools, etc. Total annual turnover of forging
cluster is Rs 3,200 crores. A few m ajor forging ind ustries in the cluster are Mahad ev Forge,
Sud hir forge, Kay Jay Forgings and Sarita Forgings. Major custom ers to forging units are
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Cluster profile – Ludhiana forging industries
USH A, H itachi, Electricity Board , KJ Group, and autom ibile com panies such as TVS, Bajaj &
Sons, Sonalika, Sw araj, Mahind ra etc.
Micro 20 10 1.0
Sm all 60 25 5.0
Med iu m 200 50 15.0
Large 1000 150 75.0
D istribution of forging units in cluster
Majority units (~300) fall und er small category, in m icro and m ed ium there are 150 and 50
units respectively. The total prod uction of closed or open d ie forging prod ucts in the cluster
is about 1240 tonnes per d ay (about 372 thousand tonnes per annum ). Only m ed ium scale
forging ind ustries run round -the-clock (three shifts), rem aining units are und er-utilizing the
facility and run at average capacity u tilization less than 60%. Major prod ucts in cluster
includ e crank shaft, connecting rod s, brake d rum , auto-parts, spanners, special tools, etc.
Photo view s of som e prod ucts are show n in figure.
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Cluster profile – Ludhiana forging industries
321, 321H , 347, 347H . Most of these raw materials are prod uced locally or obtained from
other d om estic m arkets. Long bars and billets are used as raw m aterials in for ging
ind ustries. The m ain sources of raw m aterials of forging prod ucts are steel rolling m ills
located in Mand i Gobindgarh .
Production process
Forging can be performed by open die, closed d ie or ring forging process. The units in
Lud hiana pred om inantly prod uce forged com ponents using im pression d ie forging process.
The closed d ie forging or im pression die forging is the d eform ation of m etal at forging
tem perature w ithin one or m ore d ie im pressions or cavities . It is perform ed either in presses
or ham m ers. For sim ple shapes im pression d ie forging can be perform ed in a single press
stroke, but m ore often how ever several strokes of d ifferent forces are used w ith m ultiple
d ies of d ifferent im pressions for preform ing sequential shaping and finish forging operation .
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Cluster profile – Ludhiana forging industries
The m ajor steps of process are “make ready operation” for d ie and raw material follow ed by
heating, forging, trim ming, finishing and inspection & d espatch . Som e prod ucts require heat
treatm ent and or electroplating. A sim plified process flow diagram of a typical forging
ind ustry is given in the figure.
Heating
Forging
Trimming
Finishing
Heat treatment
Electroplating
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Cluster profile – Ludhiana forging industries
first stroke is edging this increases the w ork-piece‟s cross section, second stroke is blocking
to refine the shape for finish forging and final stroke to finish-forging to com plete the
shape. In finish-forging bulk of m etal is forced into the im pression w hile a thin layer
called flash flow s out betw een the dies at the parting plane.
5. Trimming. The thin flash cools rapid ly. Once finish -forging is com pleted , the flash
(excess m etal) is rem oved either m anually or w ith trim ming d ies. Majority of units in
Lud hiana use trim m ing d ie for this purpose.
6. Finishing. It includ es sizing and straightening of the forged prod uct. It involves fettling,
shot blasting, cleaning and m achining (CN C or VMC) of the forged prod uct. A few select
prod ucts are heat treatm ent to rem ove stresses and strengthen. Som e special prod ucts
require electroplating. H eat treatm ent and electroplating is m ostly outsourced .
7. Inspection and despatch. The final prod ucts are inspected for d efects, on passing
inspection they are packed for d espatch .
Technologies employed
The technology em ployed in the cluster is out-d ated and is one of the m ajor barriers for
prod uctivity enhancem ent and energy efficiency. Som e of the m ajor forging
processes/ equipm ent are d escribed below .
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Cluster profile – Ludhiana forging industries
Screw press
(iv) Auxiliary system
A ir compressor: Forging units utilizes com pressed air in number of
process applications w hich includ es finishing, pneum atic fettling,
m achining (CN C/ VMC) and general cleaning. Typically forging
units have com pressor of FAD rating 35 – 100 cfm w ith pow er
rating of 7.5–22 kW. Majority of m icro and sm all units use
reciprocating type air com pressors w hereas the m ed ium sized units
use screw type air com pressor. All the com pressors are fixed speed
type and leakage level in com pressed air system is v ery high.
Air compressor
Energy consumption
Forging uses tw o m ain form s of energy: electricity and
furnace oil. H eating accounts for a m ajor share of
about 70 – 80% of total energy consum ed in a forging
unit. The other im portant energy consum ing areas
includ e forging ham m er, air com pressor and finishing.
The share of energy usage in a typical forging unit is
given in the figure.
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Cluster profile – Ludhiana forging industries
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Cluster profile – Ludhiana forging industries
Recuperator for w aste heat recovery from hot flue gasses of furnace
Many of the forging units use oil fired oil fired forging and heat treatm ent furnaces. The exit
flue gas tem peratures of FO fired furnaces are in the range of 450 – 700°C. The w aste heat
available w ith high tem perature flue gases can be recovered using a m etallic recuperator
w hich can preheat the com bustion air. The envisaged energy saving w ith WH R system is
10–15%. Investment for recuperator varies from Rs 1.0-4.0 lakh w ith a sim ple payback
period of 8 m onths to 2 years, d epend ing on type of process and tem perature.
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Cluster profile – Ludhiana forging industries
Major stakeholders
The m ajor ind ustry associations related to the forging ind ustry in Ludhiana, Punjab Forging
Ind ustries Association . It is located in the Chamber of Ind ustries & Com m ercial Und ertaking
(CICU) office in Focal Point – Phase V. The „District Ind ustries Centre‟ (DIC), Lud hiana
provid es several incentives to MSMEs like the Back End ed Interest Subsid y Schem e. Und er
this scheme, MSMEs can avail 3% interest subsidy (subject to a m axim um of Rs 10 lakhs) on
term loans loan on technology.
The MSME Developm ent Institute (DI), Lud hiana provid es assistance for the prom otion and
Developm ent of Micro, Sm all and Med ium Scale Ind ustries. They also im plem ent various
central and state governm ent schem es for MSMEs includ ing Cred it Linked Capital Subsid y
Schem e (CLCSS) and Technology Upgrad ation Schem e (TEQUP) for technology and quality
upgrad ation. They also organize aw areness w orkshops for the forging ind ustries on
pollution, environm ent, energy efficiency and lean m anufacturing.
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About TERI
A d ynam ic and flexible not-for-profit organization w ith a global vision and a
local focus, TERI (The Energy and Resources Institute) is d eeply com m itted to
every aspect of sustainable d evelopm ent. From provid ing environm ent -friend ly
solutions to rural energy problem s to tackling issues of global clim ate change
across m any continents and ad vancing solutions to grow ing urban transport and
air pollution problem s, TERI‟s activities range from form ulating local and
national level strategies to suggesting global solutions to critical energy and
environm ental issues. The Ind ustrial Energy Efficiency Division of TERI w orks
closely w ith both large ind ustries and energy intensive Micro Sm all and Med ium
Enterprises (MSMEs) to im prove their energy and environm ental perform ance.
About SD C
SDC (Sw iss Agency for Developm ent and Cooperation) has been w orking in
Ind ia since 1961. In 1991, SDC established a Global Environm ent Program m e to
supp ort d eveloping countries in im plementing m easures aim ed at protecting the
global environm ent. In pursuance of this goal, SDC Ind ia, in collaboration w ith
Ind ian institutions such as TERI, cond ucted a stud y of the sm all-scale ind ustry
sector in Ind ia to id entify areas in w hich to introd uce technologies that w ould
yield greater energy savings and red uce greenhouse gas em issions. SDC strives
to find w ays by w hich the MSME sector can m eet the challenges of the new era
by m eans of im proved technology, increased prod uctivity and com petitiveness,
and m easures aim ed at im proving the socio-economic cond itions of the
w orkforce.
About SAMEEEKSHA
SAMEEEKSH A (Small and Medium Enterprises: Energy Efficiency Know led ge
Sharing) is a collaborative platform set up w ith the aim of pooling know led ge
and synergizing the efforts of various organizations and institutions - Indian and
international, public and private - that are w orking tow ard s the d evelopm ent of
the MSME sector in India through the prom otion and ad option of clean , energy-
efficient technologies and practices. The key partners are of SAMEEEKSH A
platform are (1) SDC (2) Bureau of Energy Efficiency (BEE) (3) Ministry of
MSME, Governm ent of Ind ia and (4) TERI.
As part of its activities, SAMEEEKSH A collates energy consum ption and related
inform ation from various energy intensive MSME sub -sectors in India. For
further d etails about SAMEEEKSH A, visit http:/ / w w w .sam eeeksha.org