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Post: #1

Industrial training report

.docx  INTIMATE MACHINES PVT LTD.docx (Size: 21.36 KB / Downloads: 87)


Intimate Machines Pvt Ltd is the first branch of Welbound established in 1989 in Monvila Industrial Estate, Thiruvananthapuram. It is small scale manufacturing industry. The firm consists of Research & Development department, Manufacturing department and Assembly department. The products of Intimate Machines are Post-Printing equipments like Perfect Binder, Gathering Machine, Folding Machine, Trimmer etc. Intimate Machines (P) Ltd won the Award for Quality Products (State Level) from the President of India (for the year 1993). The firm got ISO 9002 certification in 1999.
The idea of this product was conceived by two enterprising individuals Sanjeev and Kumar. They started the manufacturing small binding machine in the beginning as a small scale unit. The product was an innovative one during that period and was widely accepted in the market. The unit grew and was registered as a private limited company – “Intimate Machines” In the beginning, the company was mainly the assembling unit in which the main components are manufactured in Coimbatore. Afterwards the company started manufacturing its components by themselves. In 1989, “Impel Machines” was registered at Sasthamangalam, Thiruvananthapuram. In the early stages, Impel Machines got managerial, technical advices from Intimate Machines. Since 1999 the company has been functioning as an independent
unit registered as independent company to meet the following.
• Service centers regional wise to meet service requirement all over India and abroad.
• Procurement centre to procure items from established suppliers and quality
assurance system in place.

Different types of machines are manufactured depending upon the number of books binded. The Company has adequate infrastructure for fabrication, assembling, and surface treatment. This includes mechanical, electronic devices system and assembling unit. The trained and experienced man power is the strength of the company. The factory is set up in approx. 8000 sqft with crucial plant & machinery which includes 25 CNC machines. The R&D section involves 3D modeling and analysis of components using SolidWorks. Using various 14 softwares, the designers prepare part and assembly drawing and also Bill of Materials, alteration proposals etc. Manufacturing department consists of most modern production machines which includes 25 CNCs. The assembly section is divided in the basis of product. The strength of the company lies in the research and development centre, which brings new products and utilities and continuous improvement on existing product profiles based on market feedback.
• Single Clamp Perfect Binder with Automatic Jogging and Clamping of the
• Facility for Binding 2 identical books of size upto 1/8th Demy in a Single Binding Cycle.
• Easy Job Change over - Clamping of different jobs are automatic;
• Sliding Type Milling Front plate, Self Adjusting Cover Nipping Plates.
• Can handle a wide Range of jobs of thickness from 2mm to 70mm.
• Milling Cutter with Notching Tools for exposing maximum fibre possible.
• Grinding Wheel Attachment for Pad Making.
• Separate, Powerful Suction Device for Milling Waste Extraction.
• Excellent Control over Gluing with Roller and Scraper Mechanism.
• Cover Nipping Station with Facility to control the nipping and cover breaking
pressure; Facility to vary the duration of Nipping.
• Safety Control Mechanisms - Book, Cover and Delivery Sensing.

• Single clamp Perfect Binder with easily adjustable book clamp
• Milling station with cutter, notching teeth and a powerful dust extractor
• Optional grinding wheel attachment for pad making
• Gluing station with Single Roller and Scraper mechanism. Doctor blades provided for increasing or decreasing adhesive layers
• Cover nipping station with facility to control the nipping pressure
• Timers for adjusting feed-in-time, cover nipping duration and delivery.
• Automatic jogging & clamping of signatures
• Facility for binding 2 books of size up to 1/8th Demy, in a single cycle
• Easy job change over. Wide range of jobs can be done and changed over fast
• Milling cutter with notching teeth and powerful dust extractor. Optional strip type milling cutter which removes paper from book spine in strip form
• Optional grinding wheel attachment for pad making.
• Trident Three roller gluing system (with reverse spinner). The first roller penetrates adhesive into the notches, the second roller builds up adhesive layer and the reverse spinner removes the excess adhesive as well as levels the coating.
• Cover nipping station with facility to control the nipping and cover breaking pressure.
• Facility to vary the duration of nipping.
• Safety control mechanisms- book, cover & delivery sensors
• Automatic clamping of signatures
• Easy job change over. Wide range of jobs can be done and changed over fast
• Milling cutter with notching teeth and powerful dust extractor. Optional strip type milling cutter which removes paper from book, spine in strips form
• Three roller gluing system (with reverse spinner.) The first roller penetrates adhesive into the notches, the second roller builds up adhesive layer and the reverse spinner removes the excess adhesive as well as levels the coating. Separate Side Gluing, station with Disc Type Applicators
• Cover nipping station with facility to control the nipping and cover breaking pressure
• Facility to vary the duration of nipping.
• Automatic Cover feeding with Online Creasing Attachment.
• (Optional) Stack Delivery System.
• Safety control mechanisms - book, cover & delivery sensors.
5. WELBOUND 2000
• 6 book clamps traveling in an oval shaped path, where th book back is in line th crucial binding stations.
• Calibrated book clamps, with single knob adjustments - Easy job change over
Variable speed of operation
• Continuous flow of clamps to the feed-in station with "No book - No cover" system
• Special type milling cutter which removes paper in "strips" from (which has
commercial value) and avoids generation of paper dust
• Three roller gluing system with reverse spinner; Head & Tail end cut-off to avoid adhesive squeeze out
• Separate side gluing station with tank and gluing discs. A thin & even layer of glue is spread along the side adding value to the book finish
• Automatic, pile type cover feeder with on-line creasing attachment. (Optional feeer Tray for manual feeding of gatefold covers)
• Pre-setting station and moving type cover nipping station which can handle high speed with accurate cover registration
• Chute delivery system
• Safety covers; built in safety systems with emergency stops; indicators for
temperature, speeds
Pickwel is a modular (offline) signature gatherer. It can be expanded from 8 to 24 stations.
• Sturdy design incorporating safety features
• PLC controlled system; operations through Touch Screen Panel
• Offline gathering - Base model of 8 Stations with delivery unit, expandable up to 24 stations.
• Manual feed station
• Suction - gripper Type of separation and pulling of forms from the feed stations.
• Error Detection protocols :
o Missing signature detection (optical sensing)
o Multiple signature detection
o Low Level detection (Optical Sensing)
• If and error is detected the corresponding signatures are rejected into a Rejection Tray, without stopping the machine
• Optional crisscross stacker delivery unit.
A Three Knife Trimmer that is Versatile , User friendly and provides superior Trim
Quality. The machine is designed keeping in view, the stringent safety mechanisms for Guillotines and Three Knife Trimmers. High Grade Cast Iron structures, engineered for maximum Rigidity and Durability are used for the main frames.
Controls of the various Modes of Operation of the Machines and Safety systems are
through a PLC based System.
• Document Binder using hot melt adhesives
• Economic, user friendly, versatile and compact
• An ideal offline perfect binder for Digital Printing Units
• Automatic Clamping of loose sheets / signatures
• Milling cutter with notching teeth; Suction device for extraction of dust
• Optional pad making attachment
• Roller type adhesive applicator
• Cover nipping can be controlled to match the cover & book thickness
• Automatic control mechanisms Book, Cover Sensing
• Machine has the latest safety systems and is PLC Controlled
• Capable of folding in 4 parallel and 3 cross folds.
• Sheet to sheet gap variable
• Built in double sheet detectors provided.
• Creasing attachments after buckles folds and after the first knife
• Perforating Or Slitting attachments after buckles and after first knife.
• Knife Setting automatic based on Sensors. (no mechanical setting need be done for Knife timing when the paper size changes).
• 3rd knife (or final fold) Mobile Type Unit and have the choice of either left hand or right hand folding.
• Speed Indicators provided
• Totalizers (up to max 6 digits) provided
Post: #2
I want a Industrial visit report

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