the elgi magazine 2005

Editorial NoteIt gives us great pleasure to inform you about our Corporate Magazine - The ELGI Magazine. The ELGI Magazine is a yearly

publication containing the latest news and happenings in the compressor, automotive services and related industries. It also ca rries

stories on ELGI’s research and innovation, outlook for the future, partnership news, product news, quality and technology.

ELGI Equipments Limited is the market leader and India’s largest manufacturer of air compressors and automobile service station

equipment. Established in 1960, ELGI has today diversified into various industrial products with applications that impact peopl e’s

lives everyday.

If you are an engineering company in the compressor, automotive services or related industry, this magazine will enrich you wit h

knowledge and information that is useful through interesting application-based articles.

We look forward to bringing you the continuing edition of the ELGI Magazine in 2005.

Send your letters, faxes ande-mails to: The Editor, ELGI MAGAZINE,Corporate CommunicationsELGI Equipments Ltd.,Trichy Road, Singanallur,Coimbatore - 641 005,Ph: +91-422-2574691, Extn:114,Fax: +91-422-2573697email: [email protected] you require reprints of any of thearticles, please contact ELGI CorporateCommunications. Minimum order is 500copies. Prices are liable to vary from articleto article.

MANUSCRIPT AND ART

The Authors of the ELGI magazinebelong to the User Media Group.

The publisher assumes noresponsibility for return of unsolicitedmanuscripts, art, photos or negatives.

The opinions expressed and conclusionsdrawn by the authors do not necessarilyreflect those of the editor or publisher

of ELGI Magazine.

The author indemnifies the publisheragainst any violation of privacy,

plagiarism and copyright infringement ofthe written content in the ELGI Magazine.

V O L . 1 N O . 1 A P R I L 2 0 0 4

T H E E L G I M A G A Z I N E 3

42 Dental CompressorsFocus on the new range of products for dental professionals.

46 Engineering SolutionsNew products from ELGI.

C O N T E N T S

Life Today

Research & Innovation

Business Spotlight

Product Focus

4 The Self-Made CityCoimbatore is on the threshold of becoming an economicsuperpower in South India. Find out what drives the city.

10 Going with the GrainWhat role is there for an air compressor in rice sorting? Find out.

14 A New Beginning for Trucking in IndiaThe Suraksha Project - Shifting gears for the transport industry.

20 Story of Sponge IronDiscover why sponge iron is now the preferred raw material formaking steel.

24 Indian Railways: Tracking the JourneyThe Indian Railways holds a key place in Indian history.

30 Innovation, the ELGI WayELGI Equipments exhibits its power in harnessing the seaof air we live in.

33 Big Things in Small PackagesELGI introduces the world’s smallest screw air compressor.

34 Positively EnrichingPartnership with City University’s Centre for PositiveDisplacement.

38 Power Savers for Power BusinessesELGI’s powerful solutions have contributed to phenomenalpower savings for KG Denim. Find out how.

Coimbatore: The Self-Made City

Industry Insights

Big Things in Small Packages: The World’s SmallestScrew Air Compressor

The Indian Railways: Tracking the Journey

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Fast emerging as one of the leading IT& ITES centres in India, Coimbatore’sstrength lies clearly in its people

C o i m b a t o r e

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Globalization throws upfrequent surprises in everysphere. Today, with the

advent of a “global village” governmentsrealize that cities are the economicgrowth engines of a country. In theIndian context, it is a Mumbai, aBangalore or a Chennai that powersthe country to its rightful place on theglobal map.

The fuel of innovation also springsforth to a large extent from secondarycities, the “Silicon Valleys” of any

A Self-Made CityHaving one of the largest innovation clusters of engineeringand textile units in India, Coimbatore city spells a saga ofsuccess. A saga that owes a lot to its industrious people -those who believe in collective growth over individualinterests and prosperity through an exemplary work ethic.

L I F E T O D A Y

country. These are the cities that have,in the words of Sir Peter Hall, authorof Cities in Civilization, “self-reliance,self-pride and self-made people.”

In an effort to identify India’sinnovation clusters, the Confederationof Indian Industry (CII), the country’sapex industry association set out amethodical study across 36 industrialcities to identify innovation clustersand competitive centres. The studyassessed six categories: communica tion,access to private finance, professional

& educational resources, roadtransport infrastructure, hospitality &tourism infrastructure, and economicgrowth. It promptly rated Coimbatorethe fourth most innovative andattractive investment destinationin India, next only to Delhi, Mumbaiand Bangalore.

How did this seemingly nondescriptcity nestled in a nook of the southernstate of Tamil Nadu burst into suchprominence? In 1866, Coimbatore wasa tiny village known as Kovanputhur,



with salubrious weather and apopulation of a mere 24,000. Locatedon the Western Ghats, Coimbatore wasthe summer getaway of pre-independent India’s British rulers. Theindustrious farmers of this land becameaware of the ensuing industrialrevolution in the United Kingdomand in 1888, they set up the firstcotton spinning and weaving millin Coimbatore.

Today, with over three hundredmills, constituting about half the millsin the state of Tamil Nadu andaccounting for about 13 percent ofIndia’s spindlage, this jungle village ofthe Eighties has been transformed intothe “The Manchester of South India.”

Coimbatore, the district headquarters,is surrounded by knitwear centres,like Tirupur, and has the highestconcentration of textile activity in theworld. Tirupur accounts for around15 per cent of India’s garment exportand 40 per cent of knitted fabricmanufacturing. Tirupur employs about1 million people from across the countryto work in its knitting units.

There are more than 400 textileunits in the district employing about60,000 workers engaged in themanufacture of cotton textilesalone (excluding textile products,manufacture of wool, silk and syntheticfiber textiles).

Coimbatore also has one of the

Coimbatore is evolving fast and isin tune with the explosion of informationand communication technologies.

The city has inabundance, skilled

labour, thepresence of a

dynamic socialenvironment,enterprising

people, access tocapital, the ability

to procure essentialresources and the

talent to createnew technologies.

largest concentrations of engineeringunits in India, with a variety of large,medium and small-scale industries,numbering well over 40,000. Theseunits are mainly in the businessof general engineering, machinetools, metallurgy, textile machinery,farm equipment, and automobilecomponents. About 45 per cent ofmotor pumps in India are manufacturedin and around Coimbatore.

The engineering skills Coimbatoreacquired over many decades, to providetechnical support to the textile industry,have more recently been extended toother advanced and precisionengineering fields like auto components,machine tools, electronics and

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consumer durables, industrialautomation equipment and so on.

The annual export from this regionis over US$ 1 billion, with Tirupuralone earning foreign exchange of overUS$ 800 million every year.

How does Coimbatore do it?To explain the proliferation of

industries in Coimbatore, one canborrow from the “platform leadership”concept of the managementconsultants Annabelle Gawer andMichael A Cusumano. In their bookPlatform Leadership , they present howsuccessful firms exert a strong influencein orchestrating innovation, not onlywithin their own industries, but also inthe industries where they produce anduse complementary products. Thecotton mills of Coimbatore obviouslyacted as anchor industries and modelunits to help others in the communitygain the know-how to create their ownventures. Without the support of thesepioneering units, it would have beenimpossible for others to enter thetextile and engineering sector in suchlarge numbers and make Coimbatorewhat it is today.

To consider a few factors: the cityhas in abundance skilled labour, thepresence of a dynamic socialenvironment, enterprising people,access to capital, the ability to procureessential resources, and the talent tocreate new technologies. However,above all, one important factor thatwould distinguish Coimbatore fromother cities is the community spirit ofits people - the willingness andenthusiasm to put the larger interestof the community above individual

Solely Salubrious

The Town Hall built in 1892, a witnessof the community spirit of its peoplethat distinguishes it from other cities.

Coimbatore boasts of the second largest healthcare infrastructure in TamilNadu, next only to Chennai, the healthcare capital of India. Thanks to its salubriousclimate, abundance of greenery, and a conscientious population, Coimbatore enjoyshealthier living when compared to the larger metros.

The vision and missionary zeal of the industrialists promoting Coimbatore’shospitals have ensured that their services are on par with international standards. At

the same time, the cost of health services is about half of what is charged by hospitalsin metro cities.

Coimbatore is estimated to have a total number of 10,000 hospital-beds and ishome to the healthcare centres of excellence like Aravind Eye Hospital, the world’slargest cataract surgery provider, G Kuppuswamy Naidu Memorial Hospital(GKNMH), KG Hospitals, Kovai Medical Centre and Hospital (KMCH) amongothers. The city has five multi-specialty hospitals and specialty hospitals in fields that

range from neurology, cardiology to urology.A number of competent medical professionals are available, thanks to two

reputed medical colleges - one each in government and private sectors and more thantwelve training nursing, paramedical and pharmaceutical colleges.

The government offers free health care services to the public through its teachinghospitals, district headquarters hospitals, dispensaries, TB hospitals, women’s and

children’s hospitals, mobile medical units, primary health centers and urban familywelfare centres.

In its pursuit to “reach the unreached”, city hospitals are extending services torural surroundings by setting up telemedicine centres. These centres take fulladvantage of the developments in IT and communication technologies. An exampleof this is KG Hospital

which has set up a satellitecentre for telemedicine atthe nearby knitwear city,Tirupur. The GKNMH -Centre for Excellence inHeart Care is all set to

connect its communityoutreach medical centresthrough telemedicine.KMCH is setting up anetwork with 25 hospitalsof different specialties in

the state.

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The well-equipped, state-of-the-art Heart Care Centre at GKNMH


L I F E T O D A Y


interests. Its people pioneered theconcept of self-help, took uponthemselves community problems andtried to solve them without the helpof the government. S Gurumurthy,a senior economic writer, pointedout this unique quality of theCoimbatore people, in a BBC reportthat profiled Coimbatore’s community-based entrepreneurship model.

To cite an instance of the city’scommunity spirit: in 1979 a hugetransportation problem in sourcing theraw material (pig iron, coke, etc) fromNorthern states of India wrackedCoimbatore. With no help extendedfrom the government procurementagencies, industrial units weldedtogether to form a Raw MaterialSociety, mobilizing huge resources to

“...water scarcity will probably becomethe most serious threat in the future.Although, Coimbatore’s Siruvani riverwater is known to be the tastiest water inthe country, its ground water table isslowly depleting as is the case with manyIndian cities”.

The Path AheadCoimbatore is fast evolving in tune

with the explosion of information andcommunication technologies. It will soonemerge as one of the leading IT and IT-enabled services centres in India,housing software companies, medicaltranscription and business processoutsourcing units. Thanks to itsconducive climate and fertile soil, thefood processing industry is also becominga productive revenue generator.

Coimbatore has an abundantsupply of trained technical manpower.It has three universities, including theinternationally renowned Tamil NaduAgricultural University. There areabout 80 liberal studies colleges and30 engineering colleges affiliated tothe universities.

purchase raw materials in bulk.Together with the Indian Railwaysthey discovered means foreconomically transporting goods to theState. This raw material was thenutilized by not only the industrieswithin Coimbatore, but by theindustries of other districts in the Stateas well.

To improve internationalmarketing, the people of Coimbatorebuilt an exhibition centre calledCoimbatore District Small ScaleIndustries Association (CODISSIA)Exhibition and Trade Centre on 16hectares of land at a cost of aroundUS$ 3 million. This is perhaps, the onlyexhibition centre of this magnitude tobe built in India by the people, sansgovernment support.

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Tamil NaduAgricultural

University

Doing a SWOT analysis ofCoimbatore, its District Collector,N Muruganandam, said, “The primarystrength of the city is clearly its people,and its most promising opportunitieslie in engineering and food processing.However, water scarcity will probablybecome the most serious threat in thefuture. Although, Coimbatore islocated on the banks of the NoyyalRiver and its Siruvani river water isknown to be the tastiest water in thecountry, its ground water table is slowlydepleting as is the case with manyIndian cities.”

Nevertheless, the city has its own,simple, well-worn solution to addressthe problem: community basedmeasures. Even as the government haspromulgated orders to protect tanksfrom overuse, the people havelaunched a project called Project‘Siruthuli’ (meaning a ‘small drop’ inthe local language, Tamil), to revivewater resources. Siruthuli involvescleaning up tanks and de-silting canals.The project is being executed with thefull financial backing of thecommunity. The project aims atsensitising the masses through streetplays, documentaries in movie theatresand campaigns by student volunteers.

“It is a ‘Coimbatore Citizens’Initiative’, and the contributions to thisinitiative come from every singlecitizen,” says one of the trustees of theSiruthuli Trust. Siruthuli, the “smalldrop,” is set to make an ocean ofdifference, proving once again thatCoimbatore is a vibrant centre of urbaninnovation, with the abiding capacityto fight against all odds.

Situated at the foothills ofNilgiris, Coimbatore is known for itspeaceful atmosphere, cosmopolitanoutlook and private enterprise. Thecity is studded with severalrecreation clubs like the CoimbatoreGolf Club, The Cosmopolitan Club,The Coimbatore Club and TheCoimbatore Flying Club.

Coimbatore, having a largeautomobile industrial base, also hasa enthusiastic following for autosports. The Coimbatore Auto Sports Club hosts a number of rallies everyyear that attract participants from different parts of the country. Wellknown for its racetracks, the city has a number of Karting centres.

In and around Coimbatore, there are several points of interest such as:

Siruvani WaterfallsIt is located about 37 kms west of the city and is well known in the

country for its captivating surroundings and sweet water.

Botanical Garden of UdhagamandalamPopularly known as Ooty, Udhagamandalam is a fragrant rain forest

situated at an altitude of 2268 metres above sea level. The botanical gardenof Ooty was established by the Marquis of Tweeddale in 1847, andcontinues to be a major tourist attraction in India. Ooty hosts the widelypopular flower show and dog show annually.

Ooty is surrounded by smaller hill resorts like Coonoor and Kotagiri.Trout fishing is a popular sport atAvalanche, 24 kms away from Ooty.

Mudumalai Wild Life SanctuarySituated 67 kms away from

Coimbatore, the sanctuary enjoys afavourable climate, is covered withdense vegetation and is the homeof a variety of wild animals liketigers, leopards, elephants, deer,snakes, and birds. Elephantrides are a major attraction.

Captivating Coimbatore

The Siruthuli project aims at sensitisingthe masses through public awarenessprograms, documentaries andcampaigns by volunteers

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The Coimbatore Golf Club


L I F E T O D A Y

Rice is intrinsically connectedwith the everyday lives of people across the globe. Many

traditions and ceremonies include ricenot to mention signature dishes thatmake this nutritionally rich seed anecessity.

Rice is produced in significantquantities in every continent,Antarctica being the sole exception.Asia, where life without rice isunthinkable, accounts for the majorityof the world’s production andconsumption – a whopping 90 per cent.What’s more, four countries - China,India, Indonesia, and Bangladesh – puttogether account for nearly 70 per centof the world production.

A host of factors determine the

glass, stores, and adobe. Wonderingwhat the connection is between thesewords? They are just some of theextraneous contaminants found in rice.If the contaminants in rice remainunchecked, the consumer would be infor a medley of health related problems.The processing of rice to eliminatethese contaminants involves cleaning,hulling, milling, polishing, grading andsorting. While researching the worldof rice, the last stage, sorting, is nowcommanding increased industrialattention.

Unlike in the Western countries,only recently has sorting become anindispensable part of rice processing incountries like India. It wasn’t too longago when grains had to be carefully

Going With The GrainA look at how optical technology has added a whole newdimension to rice sorting

quality of rice - percentage of brokenkernels, conditioning, heat damage,odour, colour and degree of foreignmaterial are just some of them. The ricewe are familiar with is far removed fromits original state. In its natural form,rice has an outer husk inside which isthe kernel covered with a browncoloured coating. Rice oil can beextracted from this coating. Whileengaging in a spirited discussion on thebenefits of rice, one would be amiss, ifrice beer (popularly known as Saki)was ignored. Made from unmalted rice,Saki holds an esteemed position amongJapanese beverages.

No study of rice would be completewithout a study of yellow, immature(green), chalk, pecks, seeds, red rice,

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I N D U S T R Y I N S I G H T S

The purpose of sorting is to removediscoloured grains (discrimination ofan acceptable nature, perhaps) toensure that the rice retains a sense ofuniformity.

The rice we are familiar with is farremoved from its original state.

Asia, where life without rice is unthinkable,accounts for the majority of the world’s productionand consumption – a whopping 90 per cent.

T H E E L G I M A G A Z I N E 1 1

examined in homes for stones andforeign objects, before it was cooked.But, technology has revolutionised theprocessing of rice, so much so, that evenin the sorting stage, highly advancedmachinery is incorporated. The purposeof sorting is to remove discolouredgrains (discrimination of an acceptablenature, perhaps) to ensure that the riceretains a sense of uniformity. Today, welive in a world which has heraldedColour Sortex machines for this verypurpose. The purpose of the machine -to remove contaminants based on thecolour of the rice - has transformed riceprocessing.

Colour SortersPrior to this, the only type of

filtering adopted was to drop the ricein front of a fan that would blow offlighter rice, and this process partiallyeliminated broken and bad rice. Thisfiltered rice would then pass through avibrator bed to separate the best grain.The primary drawback in the olderprocess was that stones and discolouredrice remained obstinately strewnamong the good grain.

Colour sorters, on the other hand,use camera-based systems to view therice grains at varying wavelengths. Itmay come as a mind-bogglingproposition that the rice we so absent-mindedly wolf down receives suchwatchful attention. The stream of ricepasses through infrared cameras thatdetect any colour variation. Thecameras do not play favourites - theappearance of a defective grainimmediately initialises a reject system.With a short blast of compressed airfrom an ejector, the offending grain iswhooshed out of the stream of rice intoanother receiver. Up-to-date sortersuse Charge Coupled Device (CCD)camera technology, combined withspeedy yet precise ejectors to reject asmany defective rice grains as possible,while simultaneously minimising the

number of good grains blown out of thestream. The quality of air used to ejectthe rejected contaminants is key: ascompressed air comes directly incontact with rice, it can affect the lifeof ejectors, which may prove a costlyproposition.

Sorting Through the FactsThe use of sortex machines has

become indispensable in the processingof rice. Some of the mainstreammanufacturers of rice sortex machinesinclude Satake Corporation (Japan),Daewon, Shinil and Ideal (Korea),Buhler (India) also known as SortexLtd. Worldwide, QED Advance

Colour sorters use camera-based systems toview the rice grains at varying wavelengths. Witha short blast of compressed air from an ejector,the offending grain is whooshed out of thestream of rice into another receiver.

System (Bangalore), and Cape Sorting(Coimbatore). With a 50 per centmarket share, Satake is the currentmarket leader in India, followed byBuhler India (35 per cent).

ELGI’s compressors have a 95 percent market share with Buhler, 40 percent with Satake and 60 per cent withothers. With an indisputablereputation for quality, built up over theyears, ELGI proposes furtherconsolidation in the industry,providing rice-sorting solutionsthrough clean, compressed air.

ELGI’s Rotary and ReciprocatingCompressor Divisions have madesignificant inroads into the sortexmanufacturing industry in India, bothin the cleanable and non-cleanableejector categories. Low maintenanceand efficient after-sales service are thehallmarks of the company’s products.Satnam Overseas, makers of theKohinoor basmati rice brand, currentlythe world leader in its segment, useELGI’s rotary compressors.


A New Beginning for



No longer do truck owners haveto invest time and resourceson petty issues like repairs and

spare parts maintenance, or deal withthe local police in case of accidents onthe highways. Thanks to CumminsAuto Services Ltd.’s (CASL) novelconcept ‘‘Suraksha’’ (introduced forthe first time in India) truck ownerscan instead focus on their core businessof trucking. Meaning “safety” in Hindi,Suraksha was created to meet theevolving needs of the Indian truckingindustry. The main motivation behindSuraksha is to aid truck owners inenhancing their business capability.

CASL, part of the Pune-basedCummins Group, a pioneer in thedevelopment and manufacture ofengines operating in diesel, natural gasand dual fuel, has successfullylaunched Suraksha with the aim ofslamming the brakes on trucking-related problems. Says Alok Singh,CEO, CASL, “Suraksha offerscomprehensive truck managementsolutions - from vehicle repairs tomonthly preventive maintenance andattending to breakdowns andemergencies on highways, all done juston receiving a phone call from theclients.” CASL has already opened achain of ‘Suraksha Stops’ operationalon National Highway No. 8 (Mumbai- Vadodara - Jaipur - Delhi), and astand-alone Suraksha Stop nearChennai. These workshops have beenin operation since April 2002.“CASL is shortly planning to extend

Trucking in India

With theintroduction ofSurakshaworkshops,Cummins AutoServices Ltd. hasrevolutionized theIndian truckingbusiness.


the Suraksha network on the Mumbai- Chennai corridor.” Mr. Singh said.

A typical Suraksha Stop comprisesSuraksha Mobile Service Vehicles,parking space for trucks when the crewis resting, proper rest rooms, toiletfacilities, entertainment facilitiesand medicine shops - all at affordableprices.

Besides these value-added services,Suraksha has also tied up with ICICIbank offering attractive financialassistance to cover the cost of repairsand spares. There are also plans toopen up an IBP retail outlet in theSuraksha workshop so that the truckscan fill up on unadulterated fuel.

It is estimated that truck ownersnation-wide, are spending Rs. 220billion annually on the maintenance ofvehicles. Offering a one-stop solutionto truck owners would mean corneringa large segment of this market. Despitethis kind of expenditure, the truckowners had access only to spurious, lowquality spare parts, and maintenanceby untrained mechanics - all leadingto lower profit margins, and loss ofbusiness due to low up-time. “There isgood scope for value addition in thechosen business model,” Mr. Singhpointed out.

The Main ConcernsIndian highways have a glaring

lacuna of authorised service stations

that deal with all brands of vehicles.Barring a chain of dealerships of theOEMs, reliable stations are simply notavailable. Drivers are often compelledto buy spurious spare parts on thehighway, but they claim bills forgenuine parts. A strong nexus betweenthe drivers and small-time garageowners adds fuel to the fire. Thoughthe truck owner is aware of suchmalpractices, he often has no recourse.Additionally, truck owners are usuallyat the mercy of the drivers aboutinformation regarding the predicamentof their vehicles.

Another worrying issue whilehandling trucks is the volume ofaccidents on highways. Almost everyday trucks get locked into mishaps, asa result of which owners have to face abarrage of police enquiries. Fromshuttling between the accident spot topolice stations, to complying withformalities and relieving goods intransit, truck owners are drained ofirrecoverable time and expenses. Thecompany says that over 80 per cent ofa truck owner’s time is spent handlingthese issues.

Where Suraksha Steps InMr. Singh commented that

Suraksha is just not a repair centre butan intelligent system that delves intothe nuances of the truck business. Thebasic requirement of the industry is

Suraksha runsa preventivemaintenanceschedule thatensuresSurakshatrucks outliveothers.


A Suraksha Stop


The Suraksha Smart Card


Mobile Utility Vehicles - MUVs used by

CASL comprise several pieces of equipment

used in repairs, and maintenance of

vehicles. ELGI Equipments Limited supplies

the equipment, inside all Suraksha MUVs.

Apart from ELGI Diesel Generators, CASL

is using ELGI’s Auto Service Units and

Reciprocating Compressors in their MUVs,

and Rotary Screw Compressors in their

ground workshop. ELGI and CASL

are consistently working together

to ensure a smoother ride ahead

for the Indian trucking industry.

that trucks reach destinations atscheduled times and that repairs do notaffect the business. Suraksha tries tobuild a completely transparent systemof truck maintenance, therebyrelieving the truck owner of tensionsover petty issues. The objective is toallow him to focus on the corecompetencies of his business – that is,to get more loads at profitable rates.

Members who register withSuraksha are given a “Smart Card” – afacility embedded with a multitude ofservices. Just a phone call to Suraksha’s24-hour call centre is all it takes. A vanwith genuine spares immediatelyrushes to the spot on the highwaywhere intervention is necessary, inorder to provide the required auto firstaid. Thanks to Suraksha’s strong ITinfrastructure, regular reports sent totruck owners keep them informedabout the situation. With this in mind,during times of emergencies, truckowners can stock alternate spares atSuraksha centres.

When it comes to possibleaccidents on the highway, a SurakshaSmart Card goes a long way. A call tothe centre would ensure that aSuraksha executive rushes to theaccident spot on behalf of the ownerand also offers the necessary guaranteeto release the goods in transit.

Suraksha handles the A to Z oftransport problems. Vehicles underSuraksha care are on a preventivemaintenance schedule: majorcomponents are thoroughly checkedand repaired if found faulty. Thecompany maintains a progress sheet,

“ With economic reforms opening up the market in India, service industries like transport are bound

to come under intense competition - mainly because of the imminent entry of multinationals and big

logistic operators. Pressure on profitability will increase further, and due to this competition, smaller

operators and even some big operators are likely to disappear.

One of the main catalysts bringing about consolidation in the industry will be the emergence of

heavy duty, four-lane highways (Golden Quadrilateral).

By 2005, predictions hold that the Indian transport industry will undergo a massive change. It is

expected that every month a truck would cover distances of up to 15,000 kms. Thanks to satellite

communication, almost all trucks will be equipped with tracking facilities similar to Global Positioning

Systems, making it easy for truck operators to check on delivery schedules. Two-way communication

between truck operators and trucks will also become available at a more economically viable rate.

The next generation owner will not be able to invest time in staggered purchases of truck parts.

Stocking of all spares, services like leaf-spring repairs, battery and electrical maintenance, fuel injection

pump maintenance will have to be outsourced. The truck solutions provider should also be equipped

to offer related services such as highway recovery and round-the-clock support over a wide

geographical range, while maintaining consistent quality.

These emerging requirements of the trucking industry calls for a forward-thinking maintenance

and support facility like Suraksha. A smooth road ahead awaits CASL – with current industry trends

and the burgeoning needs of the economy, it is a guarantee that services like Suraksha will become

indispensable. A truck owner networked with Suraksha is an operator with added strength and

expanded business potential,” Mr Singh asserts.

Corporate Evolution of the IndianTransport Industry

Alok Singh, CEO, CASL


recording the health of the vehicle.Like a physician’s check-off list, themaintenance programme subjects thevehicle to regular washing, greasing,tightening of nuts and bolts, wheelalignment etc. In the final analysis,Suraksha trucks outlive others.

The Perks“At Suraksha all the fore-

mentioned services are offered free ofcost, and only the change of spareparts is charged. This attracts truckowners to the Suraksha network”, MrSingh added.

He says, since its inception, morethan 22,000 vehicles have beenrepaired through Suraksha stops.

Suraksha stops have networkedwith major players like Apollo Tyres,Lucas TVS, Exide Batteries, MICOand others to ensure the supply ofgenuine parts.

CASL has exclusive arrangementswith ELGI Equipments for the supplyof top of the line tools and otherinstruments.

Apart from ELGI DieselGenerators, CASL is using ELGI’sAuto Service Units and ReciprocatingCompressors in their MUVs, andRotary Screw Compressors in theirground workshop.

ELGI and CASL are consistentlyworking together to ensure a smoother rideahead for the Indian trucking industry.

The Story of Sponge Iron

It must have been a kind of an ‘ironcatastrophe’ many millions of yearsago, that melted all the iron on the

earth’s surface and made it sink to thecore of the earth. This iron went on tobecome the planet’s dominant elementthat has become indispensable tovarious industries that range from themanufacture of safety pins to thebuilding of ships and space shuttles.

What we are talking about is aproduct that is obtained from this ironore culled out from the bowels of theearth. It is referred to as Sponge Ironor in more technical jargon DirectReduced Iron or DRI. When the ironore is reduced, the oxygen content inthe ore is eliminated, this leaves voidspaces in the ore that gives it a porousor spongy look. Hence the sobriquet‘sponge iron’.

Why is Sponge Iron preferred to PigIron or Scrap?

Sponge iron has overtaken theother alternatives, pig iron and scrap,as the preferred raw material for

making steel because of several verygood reasons. Put very briefly it is userfriendly, cheaper and most importantlyserves end user interests effectively.Scrap, while being cost effective (notany more, as the price of scrap is alsorising) is not readily available (thetechnology of continuous castingadopted by most steel makers across theglobe has resulted in a lesser generationof scrap). When it is available, theuncertainty of its quality has left itlagging in the race. Pig iron increasesthe blow time and also tends to affectthe final composition of steel due toinsufficient de-carbonisation. SpongeIron scores over both these alternativesbecause it is an ideal substitute in termsof chemical composition like, balancedcarbon content, very low sulphur andphosphorous content and above all hasthe assurance of uninterrupted supply.Also, the success of using Sponge Ironas a cold charge has added a newdimension to iron and steel making interms of quality and productivity.

Production of Sponge Iron:There are two alternative technologies that are used to produce

Sponge Iron.a) Coal - based plants: These plants are of smaller size, they re-

quire a lower investment and they use iron ore lumps as raw mate-rial. The material used here to reduce the iron ore is coal. The SpongeIron these plants produce are usually in granular or lump form. InIndia as of now there are 40 coal - based units with a capacity of3.118 mtpa (Million Tons Per Annum) At least another 15 coal - basedunits are coming up in the Eastern region. Tata Sponge is India’s firstcoal - based plant established in 1986, in Keonjhar district of Orissa.

b) Gas - based plants: These are of a relatively big size, they re-quire a high capital investment and they use a blend of iron ore andpellets as raw material. The material used here to reduce the ironore is natural gas. There are four gas-based units with a capacity of 3mtpa in India.

The largest Sponge Iron producer in India is Essar Steel.

The world wide DRI productionof Sponge Iron is on the rise.• From 0.79 mt (million

tonnes) in 1970, it has goneup to 43.2 mt in 2000.

• The projected production in2005 is 70 mtpa (milliontonnes per annum).

• The actual production ofSponge Iron in India in 2000-01 was 5.48 mtpa.

• The demand growth rate ofSponge Iron per annum is20%. Estimated demand inIndia by 2004-05 is 14.19mtpa.

• The demand-supply gap is8.71 mtpa.

How Important is SpongeIron in Modern Industry?

The Preferred Raw Material



Lall Iron & Steels (P) Limited 50Hooghly Metals (P) Limited 100Keonjhar Metallics (P) Limited 50Vasudev Ispat (P) Limited 100Indian Thermo Preserve (P) Limited 100Balaji Melters (P) Limited 50Sen Ferro Alloys (P) Limited 50Durgapur Steels Limited 100Durgapur Iron & Steels Co. Limited 100Gangotri Sponge Limited 100Bindal Sponge Iron Limited 100Bhagwanji Ispat (P) Limited 100Venkateshwara Steel & Power Limited 100Bhawani Cement (P) Limited 50

Upcoming Sponge Iron Plants and their Capacities

The Role of Air Compressors in the making ofSponge Iron

In the long and arduous process of making Sponge

Iron, air compressors play an important role. They are

extensively used in the kiln and in the pollution control

process.

Air compressors are used for operating the pneumatic

cylinders and solenoid valves in the kiln. They are also

used in bag filters used to control pollution. For a 50-

Tonnes-per-day (TPD) plant, the capacity of the air

compressor required is around 100 cfm at a pressure of

7 kg/cm. The recommended ELGI model is E22-7.5 with a

1 m3 air receiver. For a 100 TPD plant the capacity required

is 160 cfm at 7 kg/cm2. The recommended ELGI model is

E30-7.5 with 2m3 air receiver. A single Sponge Iron plant

can come in multiples of 50 TPD and 100 TPD capacities.

Compressors are also used for pollution control where fine

jets of air are used to form tiny water droplets/globules,

which are used for dust suppression.

It was in 1998 that ELGI first supplied its air compres-

sors to this industry. There has been no looking back since,

as with a 59% market share in the industry, they have been

acknowledged as the best in the compressor industry.

In the coal-based method ofproducing Sponge Iron, theiron ore is reduced with thehelp of non-coking coal or lig-nite. Two types of iron ore areused i.e. Hematite and Magne-tite. The reduction process iscarried out in a rotary kiln at atemperature of 850o C-1050o C.The rotary kiln is inclined whichensures that the raw materialmoves from the feed end to thedischarge end and during thismovement the reduction ofiron ore to iron takes place. Thematerial discharged from thekiln is taken to a rotary coolerfor cooling and the cooledproduct after being dischargedmoves towards the productseparation and handlingsystems.

The Chemistry ofSponge Iron

Capacityin Tons Per Day (TPD)



SPS Sponge Iron Limited (Durgapur) 100SPS Sponge Iron Limited (Durgapur) 100Adhunik Corporation (P) Limited (Durgapur) 100Adhunik Corporation (P) Limited (Durgapur) 100Maa Chandi Durga Ispat (P) Limited (Durgapur) 100Haldia Steels Limited (Durgapur) 100Satyam Iron & Steel Co. (P) Ltd. (Raniganj) 100Sh. Gopal Govind Sponge Iron (P) Ltd., (Raniganj) 50Rexon Strips Ltd., (Rourkela) 100Mangalam Ispat Ltd., (Rourkela) 100Scan Sponge A/C.Seleno Steels (Rourkela) 100Neepaz Metaliks (P) Limited (Rourkela) 100Shristi Ispat (P) Limited (Rourkela) 100Utkal Metaliks Limited (Rourkela) 50Sree Metaliks Limited (Barbil) 100Sree Metaliks Limited (Barbil) 100Sree Metaliks Limited (Barbil) 100BISCO Sponge Iron Limited (Jamshedpur) 100Suryaa Sponge Iron (P) Limited (Bhubaneswar) 50Sponge Udyog (P) Limited (Rourkela) 100Shree Ganesh Sponge Iron (P) Limited (Rourkela) 100Vedvyas Ispat Limited (Rourkela) 100Pawanjay Sponge Iron Limited, Rourkela 100

A list of ELGI’s customers in the Sponge Iron sector


Pawanjay Sponge Iron Limited, Rourkela 100Orissa Sponge Iron Limited, Rourkela 100Orissa Sponge Iron Limited, Rourkela 100Bajrang Ispat (P) Limited, Sundergarh 100Orion Ispat Limited, Barbil 100Jagannath Sponge (P) Limited, Rourkela 50Maa Chinnamastika Sponge Iron Ltd, Hazaribagh 200Maa Chinnamastika Sponge Iron Ltd. Hazaribagh 200Maa Chinnamastika Sponge & Power Ltd. Purulia 200Aditya Sponge Iron Limited 100Shyam Sel Limited 100N. K. Bhojani (P) Limited 50Vinayak Steels Limited 100Biswanath Ferro Alloys (P) Limited 50Ashirwad Steel & Power Limited 100Vision Sponge Iron (P) Limited 100Rohit Ferro tech (P) Ltd. 50T R Chemicals (P) Limited 100T R Chemicals (P) Limited 100Khedaria Ispat Limited 100Shree Mahabir Ferro Alloys (P) Limited 100Agrasen Sponge Iron (P) Limited, 100Jharkhand Ispat (P) Limited 50



Darjeeling’s Toy Train

As the largest railway network inthe world , the Indian Railwayshas crossed several milestones.

Here’s a look at the path it hastraversed in capturing an indisputableplace in Indian history.

Fourteen carriages with about 400people made a momentous journey on16 April 1853, exactly at twenty-fiveminutes to four o’ clock. The maidenjourney of the first Indian train.Covering 33.18 km from Boribunder(Mumbai) to Thane, in 57 minutes, thefirst railway line opened up an age ofhope to millions.

Today, after 150 years, the IndianRailways has emerged as the largestmonopolized railway network in theworld. Also, it has the distinction ofbeing the world’s largest organizationunder a single management, employing1,545,300 people. The Indian Railwaysis organised into 11 zones, eachcovering a geographical area of 4,000to 11,000 route kilometers. With over63,000 route kilometers in total andmore than 7,000 stations, the IndianRailways carries 15 million peopleand 1 million tonnes of freighttraffic every day.


Tracking the Journey

TheIndian Railways:

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Rapid strides, marked bytechnological innovations, havepunctuated the development of railtransportation since the Fifties. Usinginformation technology to modernisethe signalling system, updating safetyrelated equipment, and adopting thelatest design technology for passengercoaches, have propelled the IndianRailways into fulfilling thetransportation needs of the nation.

Locomotives TalkThe Indian Railways is focussed on

delivering the best locomotives - thecore of the railways. To foster highlevels of competency, the IndianRailways joined hands with ABB

Transportation Systems Ltd,Switzerland, in July1993, for the supplyof freight locomotives and eleven high-speed passenger locomotives. Theselocomotives service the high trafficdensity routes of Eastern, Northern andSouth Eastern Railways, contributingto considerable savings due to lowermaintenance costs and increasedenergy efficiency. The contract alsoincluded the transfer of technology topermit the Indian Railways toindigenously manufacture theselocomotives. After successfullyabsorbing this technology,Chittaranjan Locomotive Works(CLW), the premier locomotivebuilder for the Indian Railways,

launched the first freight locomotiveon 14 November, 1998.

In the spirit of constant innovation,the Indian Railways plans to enhancethe present maximum speed oflocomotives from 140 km per hour to160 km per hour, in select high-speedcorridors. The first WAP (WideAlternate-Current Passenger)-5 classlocomotive, christened ‘Navodit’, waslaunched in May 2000 and is now inregular production, serving as a modelfor inter-city trains. While previously,diesel locomotives were used forshunting services, today the mostimportant super-express goods andmail trains are being hauled by dieselengines. To upgrade the technology ofdiesel locomotives, the Indian Railwayshas entered into a transfer-of-technology contract with GeneralMotors, U.S., the world’s leadingmanufacturer of diesel locomotives.Thanks to the contract, state-of-the-art, fuel-efficient diesel locomotives arebeing manufactured at the Varanasi-based Diesel Locomotive Works.Already General Motorshas supplied 31 locomotives to theIndian Railways, of which 21 are forthe freight service and 10 for haulingpassenger trains.

Significant LeapsIn the Nineties, keeping in tune

with India’s economic policy, theRailways initiated Build Operate and

TheenchantingOoty Train


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Transfer (BOT) projects. The firstrailway project executed on the BOTmodel was the Konkan RailwayProject. The 760 km, eight-year projectwas started in 1990 with theparticipation of governments ofMaharashtra, Goa, and Karnataka,along with the Ministry of Railways.

In its endeavour to promotepartnership between the private andpublic sectors, the Indian RailwaysCatering and Tourism CorporationLtd. (IRCTC) was started, withonboard catering services in the NewDelhi-Lucknow Swaran ShatabdiExpress in 2001. The IRCTC has beenin the process of successfully setting upfood plazas in different railway stations.

With the objective of utilising theIndian Railways’ experience inconstruction activities, IRCONInternational Ltd., (formerly known asthe Indian Railways ConstructionCompany Ltd.), was set up as a publicsector company in 1976. IRCONhas successfully completed projectsin Algeria, Angola, Bangladesh, UK,Saudi Arabia, Iran Iraq, Malaysia andother countries.

The Indian Railways has also beenproactive in using its infrastructure inthe telecom sector. With the massivenetwork of railway lines, spread over62,800 kms, RailTel Corporation ofIndia was set up in 2001 to provide asuper information highway. Thecorporation is expected to emerge as a

national player in the telecom sector.Initially the plan is to lay a 33,000 kmnetwork across the rails, with aninvestment of over Rs 25 billion. Thecompany has also laid Optical FibreCable over 1,600 kms so as to fill thegaps in linking the four metros.

The 150th year of Indian Railwayswas celebrated as “PassengerAmenities Year” in 2002-2003. Avigorous campaign for expanding therail network through innovativemeasures, including joint ventures withthe state governments and otherparties, renewal of old assets, tracks,bridges and signal equipment wasundertaken. The Railways alsolaunched the service of Jan Shatabditrains from Mumbai to Madgaon, Goa,in keeping with the year of celebration.

Lately, the Indian Railways hasintroduced an indigenously designedand developed technology for electriclocomotives: the dynamic andregenerative braking system. It is saidthat this new technology could savelocomotives from wear and tear as itreduces friction. An interesting featureof the regenerative braking system isthat it uses the energy generated by themotor of the locomotives. With thisregenerative braking system, the IndianRailways can save up to 10 percent onelectricity expenses. An annualsavings of around Rs. 6,000 million isexpected through the use of the newtechnology.

Keeping Track of the Facts

Rail Museum, Mysore. SteamLocomotive ( Metre Gauge), Year1932 by W.G.Bagnll Ltd, UK.

• Indian Railways moves about 15 million people every day.

• India has the largest monopolized railway network in the world.

• More than 80 million people depend on the Indian Railways for their livelihood.

• The Indian Railways manages to run 14,444 trains every day, including about 8,702passenger trains.

• There are more than 100,000 railway bridges and about 38,000 level crossings.

• The Railways traverse through the length and breadth of the country covering63,140 route kms as on 31.3.2002.

• They carry more than a million tonnes of freight traffic and about 14 millionpassengers covering 6,856 stations every day.

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The Journey AheadToday there is a high level of

optimism for global railway equipmentmanufacturers as investment in railinfrastructure is on the rise around theworld. According to the assessment bySiemens Transport System, the globalmarket for automation, power andintegrated services in rail transport isexpected to grow at an average rate of3.7 percent until 2006. The studypinpointed Europe and Australasia asthe regions where growth would bemaximum.

China and India, the two mostprominent developing economies,have planned for huge investments inrailway infrastructure. China hasproposed to spend US$ 8.5 billionbetween 2001 and 2005, while Indiaestimated an average investment ofUS$ 2 billion , for the same period. Theproposals to form new railway zones inIndia is yet another piece of good newsfor equipment manufacturers.

Complete Pneumatic Solutions forthe Indian Railways

Companies like ELGI EquipmentsLtd that supply a complete range ofpneumatic equipment to the IndianRailways can now look for expandedbusiness opportunities in the sector.The Railways has been ELGI’s singlelargest customer for over threedecades. ELGI is, in fact, the firstIndian Company to provide completepneumatic solutions for the IndianRailways. ELGI turns about Rs. 300million per annum, with its supplyof Air Compressors, Air Dryers,Expressors, Exhausters, Water RaisingApparatus, Windscreen Wipers andRailway Horns to the Indian Railways.Almost 90 percent of the electriclocomotives, 65 percent of diesellocomotives and 60 percent of EMUsuse ELGI compressors for theirbraking applications.This indigenous sourcing from a reliablemanufacturer like ELGI has giventhe Indian Railways tremendousadvantages such as-

• Reduction in purchase cost• Shorter deliveries resulting in better inventory control• Easy availability of spare parts

One Of Its KindWith modernization, the steam

engine has gradually been phased out,substituted by the diesel and electriclocomotives. Yet, there remains adiminutive but powerful testimony tothe railways of old. The tiny little “toytrain” that plies between NewJalpaiguri and Darjeeling in WestBengal, has survived the test of time.Interestingly, it has maintained thesame appearance and speed, since1896, commanding a reverence for itsold-world charm. At an elevation of


7,407 feet, Darjeeling has the highestrailway station in the whole of Asia.

In curious contrast to the “toytrain,” the “Palace on Wheels” in thewestern state of Rajasthan has theworld’s most luxurious amenities, andcan accommodate only 75 people.

Engineered To Be The BestThe passenger comes first. With

this mantra in mind, the IndianRailways has streamlined procedures,introducing several path-breakingtechnologies into the railway s ystem.

Indian Railways is undoubtedlymodern. In 1976, the World Bank sentan expert named Will Thomson tostudy the Mumbai suburban system. Hewas f labbergasted that 1.1 millionpeople travelled up and down everyday. He commended the IndianRailways’ massive infrastructure, andwas amazed at its wide network.Thomson believed that themodernization efforts of such acomplex railway system is definitely intune with the rest in the world.

These technical innovations haveincluded the computerisation of reservedpassenger tickets, among several otherfacilities for passengers.

The Indian Railways is nowintroducing a self-service system forunreserved tickets. Stations at NewDelhi are provided with bookingterminals, enabling the passengers topurchase an unreserved ticket 30 daysin advance from any point of departureto any destination. Passengers now havethe freedom to purchase tickets at their


convenience, reducing congestion atticket booking counters. In addition,unreserved tickets will be availablethrough the Self Printing TicketingMachines, wherever such facilities areavailable. With the introduction ofthis system, the Railways will have anonline account of tickets sales andencourage passengers to purchase theirtickets in advance.

Thumbs Up From The World BankIn terms of railway infrastructure,

It’s not its world-class infrastructure.It’s not even its heavy-dutyinvestment. ELGI Equipments does

not bank on these virtues. It is, instead,the power to question convention, toprioritise innovation over acceptednorms. The company’s 1,100-strongteam relentlessly pursues scientificsolutions to address challenges -whether in research, manufacturing orhousekeeping.

A distinct market leader in India’sair compressor industry, andunparalleled for its engineeringexcellence, ELGI rolled out its firstcompressor brand, ELGI URACA, incollaboration with PumpenfabrikUraca, Germany, in 1960. Since thatmodest launch, the company hasconsistently wowed the market byintroducing never-before solutions.One irrefutable piece of evidence ofthe company’s innovative spirit isthe ELGI Micro Rotary - the world’ssmallest compressor that ELGIdesigned in 2003.

Undoubtedly, this engineeringcompany from Coimbatore has come along way. From solely manufacturing

automotive service station equipmentwhen the company first started, todayits product line boasts approximately400 types of engineering products thatrange from air compressors toautomotive equipment and dieselengines. ELGI’s products areomnipresent in the industry, findingapplications in everything fromrailways to rice sorting units. AnnuallyELGI launches a minimum of 15 newproducts in the market, and today thecompany commands an impressive

presence as a Rs. 3 billion company.Just how does ELGI do it? The

company has engendered technologicalleapfrogging by following a two prongedstrategy: One, forming strategicalliances with world leaders forresearch, and two, constant in-houseinnovation.

Listed below are just some of theprime international agreements thatthe company has entered into:

• It is the only Indian company that is

the ELGI wayDriven bytechnology andpowered byinnovation, ELGIEquipments is fastemerging apowerful player inthe industrial airsolutions segment.

nnovation,


licensed to package and marketHitachi compressor products.• With a similar tie-up, ELGI packagescentrifugal compressors for SamsungTechwin.• Pursuing a commercial partnership,ELGI works with SP Air Technologyfor a range of pneumatic tools forautomobile repair, industrialmaintenance, ship-building,fabrication, foundry, etc.• An ongoing research associationwith the UK-based City Universityhelps ELGI push the technologyfrontiers of screw air compressors.

Despite the impressive line up ofalliances, ELGI is unwilling to scrimpon building its own resources. Thecompany has invested substantially inits own research and development – aninevitable step for an organisation thatdesires to be fiercely independent.ELGI’s commitment to innovation isso strong that it plans on scaling up itsresearch investment from its current2.5 per cent of revenue to double thatfigure over the next three years.

Dr Jay Varadaraj, ManagingDirector, explains that in-houseinnovation is a matter of survival,especially for a company that refuses tobe content with its leadership positionin the domestic market. ELGI decisivelytakes on multinational brands ininternational markets.

The company realises that sourcing

research capabilities externally canprove a limiting factor in the long haul– when it comes to cutting edgetechnology, the company pursues the“know why” rather than merely the“know how”.

In the backdrop of a paradigm shiftin economic and trade policies acrossthe globe, the Indian market has flungits doors open to international brands.Yet, even as foreign products choke theIndian market, ELGI is keen on goingglobal. The challenge now for ELGI isdealing with the general perception ofproducts “Made in India”. In thiscontext, the formidable weapon thatELGI wields is technical superiority.ELGI’s aim is clear-cut: to achieveglobal competitiveness by 2005. Simplyput, when an international customerconsiders buying a product (which isone of their core products), ELGIshould figure prominently in thecustomer’s list of options.

New FocusTo add

renewed vigour tothe business, thecompany was recently restructured intofour divisions that represent its majorproduct lines: Rotary Compressors,Reciprocating Compressors, AutomotiveEquipment and Diesel Engines.

The next step was the separationof research from development - theR&D function in each business

Innovation is a matter of survival

ELGI’s aim is clear-cut: toachieve global competitive-ness by 2005. Simply put,when an international cus-tomer considers buying aproduct (which is one of theircore products), ELGI shouldfigure prominently in thecustomer’s list of options.


The Holroyd Rotor Cutting Machine

The Mazak Machine

R E S E A R C H & I N N O V A T I O N

division was split into Core Researchand Product Development. Theresults: clarity in function, increasedteam productivity and a robustspeediness to project implementation.While the focus of productdevelopment is aimed at catching upwith the existing competitivetechnology, core research aims to raceahead of competition.

Theory, practicallyELGI’s research team, at present,

has 25 qualified professionals all ofwhom work on specialised areas.

Today, the company approachestechnical predicaments with a renewedmindset: a few years ago, if there was aquandary like, say, frequent breakageof castings, the team may havesuggested building castings with biggerframes. They now approach theproblem scientifically and find out why

castings are breaking, what forces areacting on it and so forth. ELGI’snumerous formal and informalassociations with academia allow theresearch team to understand,brainstorm and validate projects intheir initial phases.

To give another example, if theobject of research is a piston ring, oneof the smallest parts of a compressor,the research team first comes up witha set of new ways to produce reliablepiston rings. With scientific theoriessupporting the proposals, the birth ofa formal project commences.

Measuring the ResearchELGI is introducing modern means

of capturing organisational knowledgeby digitising Product LifecycleManagement (PLM). The companyhas embraced PLM and six-sigmabased product development/design,

While the focus of product development isaimed at catching up with the existingcompetitive technology, core research aims torace ahead of competition.


which have proved reliable methods ofmeasuring R&D. Currently about 15projects have been developedfollowing the six-sigma method,offering enhanced transparency inprojects.

The company invests in manpoweras well. For engineers with aninclination for research, ELGI isundoubtedly one of the best places towork. Funds have never been aconstraint, whether it is for buying thelatest analytical software or testingequipment. ELGI has fully-equippedCAD stations and rapid prototypingtechnology.

Monetary incentives apart, ELGIprovides incredible opportunities toresearchers who are keen on exploringunchartered territory. ELGI providesthe freedom to go beyond convention,fostering an environment conducive torisk takers.

Building the world’s smallestcompressor is not just aboutminiaturizing an existing larger

model. It is about creative use oftechnology to miniaturize withoutminimizing performance parameters.This is what ELGI has achieved indesigning and manufacturing theworld’s smallest screw compressor.

The challenge was put forward by aGerman company that wanted a screwcompressor for a specific application.Traditionally such applications arecatered for by diaphragm or pistoncompressors since the requirement is forsmall air volume. In looking at screwcompressor technology, it wasimmediately obvious that the size of therotors would need to be very small sincethe size of the rotors is one of the criticalfactors that determine the flow volumeof the compressor. It was also obviousthat at these sizes the losses due toleakage would be significant.

The solution demanded acompressor running at high speed inorder to compensate for the losses.However, higher speeds produce higherflow and hence the rotor sizes had tobe further reduced to meet thecustomer’s specifications. Suchdynamic iterative between speed and

size of the rotors resulted in anoptimized design. The results wererotor sizes of 35 mm and 28 mm for themale and female respectively.Additionally, speed capability of up to20,000 RPM. The smallest rotors upuntil this achievement have been in therange between 55-60 mm. Thus,ELGI’s innovative design resulted in a30-40 % reduction in the size of acompressor.

The next challenge wasmanufacturing. All the manufacturingmachines available have been designedwith a certain minimum size in mind,which was higher than the designdeveloped by ELGI. Hence, ELGI hadto work on appropriate manufacturingprocess changes to enable the existingmachines to produce such a smallcompressor. In addition, ELGIsearched the globe to identify standardcomponents such as bearings and sealsthat could be used withoutcompromising the design goals. Boththese were critical in meeting thebudget objectives of the project.

Within a short time of 3 months,the first prototype was put on the testbed and the results were excellent. Theflow, pressure, power and temperaturewere all within the limits defined by the

ELGI introduces the World’s smallest Screw Air Compressor

Big Thingsin Small Packages

design. This was followed by rigorousendurance testing and once again theproduct withstood all the abuse thatwas hurled at it during the endurance.

With this confidence the firstdisplayable working package was madeand exhibited at the Compressed Airand Vacuum Technology Exhibition inHannover, Germany during the monthof April 2003. The reception to thisproduct was a mixture of disbelief andrelief. Disbelief from competitors whocould not accept that such a small screwcompressor was possible. Customers,who had been hankering for such aproduct, reacted with a sense of reliefthat their needs where finally beingaddressed by ELGI.

The reception at the exhibition andat ELGI’s web site has resulted in manynew applications for which the productin being adapted. In addition, thetechnology has opened upopportunities for oil-free compressorsof this size as well as applications forfuturistic technologies such as fuel cells.

The next big challenge would be tocater to the demand for this product.From a few thousands a year, thedemand is expected to be a fewthousands a month.

The company dispelledindustrial misconceptions about

screw compressors, clearlydemonstrating the industrial

efficacy of the product.


ELGI funds and sponsors projects in City University,UK, to broaden its know-how on emergingtechnologies in the air compressor industry.Partnering with the university’s Centre for PositiveDisplacement Compressor Technology has not onlyraised the bar on product design at ELGI, but hasalso expanded the university’s own productdevelopment knowledge base.

PositivelyEnriching

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Forty-three years’ experience inthe field has proved that ELGI isa name to be reckoned with, in

the Asian air compressor industry. Yet,the company is far from complacentabout its standing in the industry,constantly prodding the boundaries oflearning. The association with theCentre for Positive DisplacementCompressor Technology, City

U n i v e r s i t y ,UK proved morethan satisfactory,allowing ELGI andthe University toresearch promising

trends, experiment with variedtechnology and innovate products tomeet industry requirements.

Located in Central London, CityUniversity is a thriving hub of learning.

The 100-year-old universitycontributes significantly to the capital’sacademic, cultural and corporate life.“City”, as it is popularly referred to, hasmade its mark globally: of its 10,000-odd students, 40 percent are

international. It has also won adistinctive place for itself, its graduateemployment record being one of thebest in England. But, of strategicimportance to the university is theemphasis on research.

Among the research centres in theuniversity is the Centre for PositiveDisplacement Compressor Technology,a robust locus of technical e xpertise. Ina nutshell, the main research areas ofthe Centre are performance estimationof compressors whereby the machinecan be tested prior to manufacture,product development of revolutionarydesigns, as well as experimenting withthe nuances of compressor design.Aided by a dedicated team of scientists,professors, Ian Smith and NikolaStosic, explore the intricacies ofcompressor technology. The Centreoffers a spectrum of services - includingtotal design assistance to compressormanufacturers. From evaluatingproposed projects to ensuring thatnoise levels of new products areminimal, the Centre has a tenacious

City University,a thriving hub of learning

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R E S E A R C H & I N N O V A T I O N


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grasp on every facet of compressortechnology. ELGI made certain it wascollaborating with the best.

Backed by fifty chartered engineersfrom City University, the Centre hasextensive support laboratories andworkshop facilities. With Londonoffering a host of compressorexpositions and access to cutting-edgeinformation, ELGI was able toincorporate that knowledge into the

overall design process. As a result, ELGIindependently develops products - thelatest being the world’s smallest screwcompressor. ELGI qualitativelyvalidates and tests these products at theUniversity. Thanks to the host ofindustries represented in the capitalcity, researchers can gain a hands-on,real-world understanding of theirvarious fields of interest.

Some of the other organisationsparticipating and funding the Centre’sprogram include Carrier (USA),Trane (USA), MANGHH (Germany),Drum International (UK), RotaryCompressor Systems (Switzerland).

With this exclusive jointtechnology development agreementwith City University, ELGI hasdemonstrated its commitmentto producing energy-efficientcompressors, which incorporatethe world’s foremost technology.

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The Centre offers a spectrum of services - includingtotal design assistance to compressormanufacturers. From evaluating proposed projectsto ensuring that noise levels of new products areminimal, the Centre has a tenacious grasp on everyfacet of compressor technology. ELGI made certainit was collaborating with the best.

The Centre for Positive Displacement Compressor Technology at the ‘City’

In a nutshell, the main research areas of the Centreare performance estimation of compressors wherebythe machine can be tested prior to manufacture,product development of revolutionary designs, aswell as experimenting with the nuances ofcompressor design.

ApplicationsThe applications of compressed air

systems are very extensive in weavingunits, especially Air Jet weaving looms.What is also important for suchapplications is the appropriateconfiguration of these compressed airsystems and oil free compressorsolutions to ensure efficient operations,quality and cost savings.

SummaryIn December 2002, ELGI

Equipments installed an oil-free screwair compressor system at the weavingdivision of KG Denim Limited,Coimbatore. The project wasundertaken in response to the client’ssudden requirement to increase the airvolume on account of scaling upproduction capacity. Once the new airsystem was installed, KG Denim wasable to increase its production capacitysignificantly, a nd save over Rs. 3 million

on compressed air energy. Sincethe total cost of the project wasRs.3 million, savings of aroundRs. 12,500 per day meant a simple payback of the project cost in eightmonths. The new air system has alsohelped the company avoid freshinvestments in the lower capacityreciprocating compressed air systems.

Company OverviewThe Coimbatore based KG Denim

Limited (KGDL) is the second largestmanufacturer of denim fabric in India.The company, which is part of theRs. 6 billion KG group of companies,owns the well-known denim brands inIndia: Trigger and Trevi. KG Denimmanufactures fabrics using the finestcotton in different weaves catering toclothing for men, women and children.KG is the only supplier of stretch,viscose and yarn dyed colours in thecountry under a single roof.

Benefits:• Saves Rs. 12,500 every day• Ensures product quality• Lowers maintenance cost


A Case Study

for Power SavingsPowerful Solutions

Operating in a highly competitivemarket environment and taking onmultinational brands, KG Denim paysa great deal of attention to quality.Denim at KG is manufactured usingsmooth and unbroken fabric, a resultof superior yarn and good weaving.The products, similarly, are treatedwith high quality dyes that are skinand eco-friendly.

The company manufactures twomillion meters of denim per month.The manufacturing process of thefabric is through air jet looms, whichare pneumatically operated. In theprocess, compressed air takes the yarnfrom one end of the longitudinal warpto the other end so as to interlude andform the weft. Here warp denotes thelongitudinal threads and weft thehorizontal ones. Air jet technologyoffers one of the fastest ways to weaveand a loom of normal capacity requiresa maximum supply of around 40 cfmof compressed air.

Earlier the base load of the plantwas served by a centrifugal compressor,and the peak load by a number ofreciprocating type BOP compressors ofthe capacity of 120 HP each. The BOPcompressors were manually controlledand operated at full load.

Project OverviewELGI studied KG Denim’s

compressed air requirement inNovember 2002 when the companywas expanding its manufacturingcapacity by adding new looms andstriving to lower its production coststo remain competitive. “We had asudden opportunity to scale up ourproduction capacity, when one of theweaving units located in South Indiaoffered to sell their air jet looms,” saysMr. S. Rajagopalan, Vice President -Operations, KG Denim. “Our

“We had a sudden

opportunity to scale

up our production

capacity, when one of

the weaving units

located in South India

offered to sell their air

jet looms.”

Mr. S.Rajagopalan


B U S I N E S S S P O T L I G H T

technical team inspected the loomsand found that they were in goodworking condition. The cost of owningthe looms was irresistibly low and thecompany would have no reason to letgo of the opportunity.”

However, KG Denim faced aproblem of a different nature - thechallenge then lay in increasing the airequity by 1700 cfm in fifteen days sothat the production could start withthe new looms it was purchasing.

Mr. R. Selvakumar, PurchaseManager, K.G. Denim, inquired firstwith a compressor company that hadsupplied its centrifugal compressorsometime ago and also with one moremanufacturer – both conveyed to himthat they would need a minimum of 10to 15 weeks to deliver the compressorof the required size. Keeping the newlooms idle for fifteen weeks wasunthinkable for KG Denim.

Hence the company planned to usetheir reciprocating BOP compressors,despite the fact that these compressorswere incurring huge power andmaintenance costs. The company’sbase load requirement of around 3500cfm was being taken care of by acentrifugal compressor, which wassupplied by one of ELGI’s competitors.The company was willing to makeadditional investments on BOPreciprocating compressors, if required.

However, the inherent problem ofthe reciprocating technology for thisparticular application is that theylose capacity. For instance, thecompressor with an initial outputcapacity of around 1000 cubic feetper minute (cfm) air is likely toproduce only 900 cfm after a periodof usage, resulting in lower efficiency.

ELGI’s ProposalELGI proposed screw compressors

instead of reciprocating compressors asan ideal solution. While reciprocatingcompressors have specialisedapplications of their own, screwcompressors would combat capacity loss.

“We explained to the customerthat an oil free screw compressor isbest suited for the requirements,particularly of textile units. Wemade presentations and organiseddemonstrations for the customer toshow that BOP Reciprocatingmachines would have a capacity dropof around 10 to 15 per cent over aperiod of time. We also explained thatthe power consumption of BOPcompressors is higher than that of anoil free screw compressor after certainperiod of running hours,” says Mr.Prakash, DGM- Manufacturing, ELGIEquipments Ltd.

KG Denim’s engineers were invitedto examine ELGI’s oil-free screwcompressor model NH 265-7 of1695 cfm capacity at the company’splant. After a few rounds of testing,KG engineers were satisfied with theperformance of the compressor. Butbefore releasing the purchase order forthe machine, there were two concerns:delivery time and the payment terms.To KG’s relief, ELGI promised them thatthe compressor would be up and runningin just fifteen days! Added to thatwas an attractive flexibility on payment.

Project ExecutionA thirty-member team comprising

installation engineers and consultantsexecuted the project in a record timeof one and a half weeks.

ResultsELGI guaranteed KG Denim four

things:• Superior machining technology

and quality• Instant delivery and installation• Power savings• Remarkably low maintenance

costELGI compressors at KG Denim

generated energy savings, whileimproving product quality andincreasing system reliability. Althoughthe company has the centrifugal

compressor for their base load, theELGI screw compressor as a trimcompressor has proven its technicalcapability by continuous running andzero maintenance. The greaterquantity of stored air combined withthe optimum control allowed the unitto stabilize the system pressure at 7 bar.This improved the productivity of theair jet looms, leading to consistentproduct quality.

“Buying the ELGI compressor was

an instant decision but we arehappy we took that decision.” saysMr. Selvakumar, Purchase Manager,KG Denim and adds, “I deal with threemajor clients (including ELGI) in theair compressor industry. I can tell youwithout hesitation that ELGI hasvery good technology, excellentinfrastructure, human resourcesand financial power to keep itscustomers, not just satisfied,but delighted.”


A typical weaving process is about interlacing horizontal yarns (weft) into warp sheets, which is madeof hundreds of yarn threads. The weaving factories produce the warp sheet using machines and passthem through a starch-based solution to make the sheet strong enough to withstand tension and chafingin the weaving stage.

Different techniques are used to carry the weft yarn across the warp sheet. In the handloom, it is thrownfrom one end of the sheet to another by hand. The same is done using power in power looms some ofwhich function based on the following insertion and weaving techniques:

• Rapier • Projectile • Water jet • Air jetAir jet weaving looms use air for the weft inserting motion. A

high-pressure blast of air moves the yarn from its package (1) whichis drawn from the yarn package by the “measuring” wheel (2) asshown in the picture. Air current flows through a tube in the oppositedirection to the yarn at a certain pressure to ensure a straight evenfeed of yarn (3) The main jet (4) is the major projecting force for theyarn, although supplementary jets (5) are activated to ensure theyarn’s complete run across the other side of the warp. Air jet loomscan achieve the rate of weft insertion of over 1000-1500 meter/minute and is by far the most productive weaving technique.

Fabrics out of thin air


Project Name: KG DenimProject Date: December 2002Product Type: Oil free Screw AirCompressors for Air Jet WeavingProduct Capacity: 1695 cfmProject Cost: Rs. 3 Million

B U S I N E S S S P O T L I G H T

In today’s world of gloss and glamour,even middle-class families indeveloping countries stretch their

resources to ensure that their kids havea set of perfect teeth. Visits to thedentist have become weekly affairs.Hand in hand, the dental profession hasbeen embedded with technology andresources that would have beenunimaginable a decade ago. No longerare dentists operating out of clinics thatcomprise a chair for patients to squirmin and a set of crude lookinginstruments. Today, dentists are moreaware of the need to give superiorservice to patients, since patientsthemselves are conscious of emergingtechnologies in dental care.

Thanks to the range of aircompressors now available, dental careis safer, more hygienic and can tonedown the dread factor during yournext visit to the dentist…


Dental Compressors

An area that has seen tremendousdevelopment is air compressortechnology in dental clinics. Bettercompressors translate into superiordental care. Newer designs ofair compressors with multiplefeatures, performance, and operatingparameters have recently becomepriority in the industry. Severalcompanies have engineered compactcompressor units where maximumperformance has been generated evenwhile minimizing the motor power.

What’s The Connection?Use of compressed air in a dental

clinic is intrinsic to the profession.Compressed air is used in syringes, airturbines are used to run high-speeddental tools, air abrasion units, andthe dental unit itself depends on theperformance of air compressors. Interms of composition of compressors,high technology, oil -free aircompressors use Teflon-coated, dryrunning pistons, which give thecompressor increased performancecapacity. This technology also keepsnoise levels minimal.

Oil-free air improves treatmentefficacy in dental practice because afilm of oil does not impair the adhesionof composites. For instance, whenfilling a cavity, the area must be blowncompletely clean and dry to reconstructthe tooth with composite. Even thefinest film of oil or a minimal level ofmoisture can impair proper adhesionof the filling material to the tooth. It isimperative to use finely filtered andhygienic compressed air that has aneutral taste.

Additionally, dental care requiresthe highest quality of hygiene,especially when treating open dentalwounds. The scary truth is thatcompressed air that contains moisture,oil, or germs, is liable to ruin patients’health. Since germs can spread fromthe oral tract eventually into the bloodstream, there is a high likelihood that

ELGI’s Dr. Vayu oil-free (1.0 to 4.0 HP) compressors are ruggedin construction, and come with the added benefit ofrequiring no installation. Essentially, they are designed to bea “plug-and-use” machine. Thanks to the friction free designof the compressor, lubrication becomes unnecessary. Thedesign therefore ensures that the air delivered is oil-free.Other add-ons include low maintenance costs - again aconsequence of no internal contact components. Low onnoise emission, they are ideally suited for use in enclosedsurroundings such as dental clinics.ELGI’s Dr. Vayu oil-free compressors find applications,particularly in the health-care services such as dentistry,medical services, hospitals, pharmaceutical research,nitrogen and gas generators, food, beverages, bakeries,instrumentation, jewellery work, etc. It alsofinds relevance in chemical plants,food plants, water and sewagetreatment plants, andhospitals/laboratories forsurgical purposes.The 2.0 HP and 4.0 HPcompressor modelscome with a drierattachment to ensurethat the compressedair delivered is notonly oil-free, but isalso dry. These aresuitable in a sterileworkingenvironment, suchas surgery rooms,decontaminationchambers, deep-sea(scuba) diving, etc.They are also suitablefor metal workingwhere corrosion wouldotherwise retard thequality of theproduct.


P R O D U C T F O C U S

spare parts to the service site matchedby technical assistance at the nearestservice branch office. These trendshave differentiated the pro-activecompressor companies from the merelyreactive ones.

What Dentists WantThe discerning dentist should look

at the following features in choosing anair compressor unit - compactness indesign, high performance, durability,and reliability with low maintenancerequirements. Some of the latestcompressors cover air demands from 40to 300 litres per minute, and are suitablefor dental clinics with up to eighttreatment units, as well as for medicaland technical laboratories,pharmaceutical and food industries.

Enclosing the compressors in dentalacoustic enclosures significantly reducesthe already low noise levels of oil-freecompressors. The enclosures should havea solid base, which prevent anycontaminants from being drawn in fromthe bottom, while a thermostaticallycontrolled fan provides the efficientventilation and maintains optimumtemperatures. To allow easy operation,control panels should be located at thetop of the acoustic chamber.

Many manufacturers have alsointroduced duplex compressors.Duplex compressors ensure anextremely reliable and economicalsupply of compressed dry air. Easy toinstall, these compressors are

Dental care requiresthe highest quality ofhygiene, especially whentreating open dentalwounds. The truth is thatcompressed air thatcontains moisture, oil, orgerms, is liable to ruinpatients’ health.


Dr. Vayu Oil Free Compressors

the patient will contract diseases.Contaminated air is also extremelyharmful to the several high-precisionand particle-sensitive instrumentsused in clinics. Poor quality air canlead to expensive repairs andreplacement costs.

Talking TechnologyAs already discussed, moisture

tends to hamper dental practices.However, many manufacturers havesuccessfully combated the problem - aprecision dry air system is now used toremove residual moisture fromcompressed air. The hygrostat, as theinstrument is called, constantlymonitors the air humidity in the tank.As germs cannot grow in suchconditions, risk of infection is alsoprevented. Further, dry air means nocondensation. Hence, additionalseparators and filters in the compressedair network become obsolete. Suchcompressors are technologicallyadvanced and operate virtuallywithout maintenance. Corrosion-protected air receivers, such as thosewith epoxy internal coating, havefurther enhanced the quality of storedcompressed air. Desiccators withintermediate coolers and fine filtersalso ensure that the air is free from anyimpurity whatsoever.

To complement the list ofinnovations is the sterile filter. Thesefilters act as a sieve straining outcontaminants like bacteria, fungusspores, viruses, and any otherimpurities carried by air.Decontaminated air is no longerrelegated to wishful thinking.Decontaminated air is no longer thehope of a good dentist – rather it is adentist’s reality today. Users simplyhave to remember to change the filterat regular intervals. This simple yetregular maintenance provides dentistswith consistently high levels ofperformance and dependability intheir compressed air system.

After-Sales ServiceThe latest in compressed air

technology are hotlines that dole outsuggestions for user problems, as wellas provide in-depth information oncompressed air technology. Anotherrecent development: quick dispatch of

particularly suitable for large clinics.Duplex compressors are equipped withtwo compression units, giving twice theair supply and twice the reliability. Onecompressor supplies the air required,while the stand-by automaticallyswitches on when demand increases.The result is uninterrupted workschedules. Visiting the dentist may bea daunting proposition for a lot ofpeople. Nevertheless, with the latestdevelopments in the related aircompressor units, you can settle intothat ominous leather chair at thedentist’s knowing that things areundoubtedly a whole lot safer andassuredly hassle-free.

Engineering

Embedded with cutting-edge technology, the E 75 is touted as the nichesolution provider for any compressed air application like textile, spinningmills, cement plants, as well as other engineering instrument requirements.Created as a tailor-made product, with improved features, the E 75provides a perfect fit for applications requiring 500 c.f.m of air. The E 75is, in essence, a product, bearing ELGI’s unmistakable stamp of quality.To embellish its tech-suave, the product incorporates the OSBID (OilSeparation by Impact and Deceleration) process. This allows oil and airto be separated, with minimum pressure drop, once again testifying toELGI’s clean and green branding. In the face of competition, ELGI believesthat technical prowess will propel the E 75 far ahead.

When industrial needs evolve, ELGI thinks on its feet. The new HorizonTandem compressor stands as proof of ELGI’s spirit of innovation.Designed as per the international safety standards, the new HorizonTandem, is a two-stage screw air compressor, redesigned with energyefficiency being a key feature. So, how does this “two-stage” rotarycompressor distinguish itself? Simply put, compression is done in twostages to improve the volumetric efficiency and thereby contributing todecrease in power consumption thus saving costs. ELGI has the distinctionof being the only company to manufacture rotary compressors thatincorporate such advanced technology. Also known as the EE series, thisnew version is available in 75 kW to 132 kW motor power range. Allmodels of Horizon Tandem are enclosed in a canopy. Aesthetics andoverall efficiencies including significant reduction in operating noise levelshave been incorporated in this new model along with improved featureslike reduced oil consumption, PLC etc. The icing on the cake? The newHorizon Tandem symbolises revolutionary power saving technology toensure lower operating costs.

Optimum Operations

In Tandem With Industry Needs


Horizon Tandem

E 75

SOLUTIONS


The Rotary Compressor Division at ELGI recently launched a newset of drain valves called the ELGI Airmate Drains. Theseelectronically operated, high efficiency drains completely remove thecondensate from compressed air. Ordinary drains like ball valves ortimer drains are inefficient and almost always cause the leaking ofprecious compressed air. ELGI Airmate Drains work on the zero-airloss principal. An in-built sensor detects the condensed water leveland vents out the condensate when it reaches the upper limit. Inaddition, these valves are IP 64 protected as well. Overall, this systemefficiently prevents the seeping of expensive compressed air, offeringthe customer huge cost benefits.

Zero Air Loss Advantage

Airmate Drains

With the RR20100, ELGI is on the hi-tech track yet again. Thecompressor is ideally designed for the new-generation, 3-phase electriclocomotives, indigenously manufactured by CLW (ChitranjanLocomotive Works) for the Indian Railways. ELGI is the only IndianManufacturer to develop this Compressor meeting world classquality standards. Thanks to the RR20100 compressor, engines thatchug away at speeds of 160 km/hr can come to an instant stop.Indigenization of this compressor has provided tremendous savings incost, delivery and service support to the Indian Railways. What’s more,its new design is sophisticatedly discreet – the compressor is actuallyslung underneath the engine. So even though the RR20100 is out ofsight, it is certainly in top form.

The New Generation RailwayCompressor

Never say die. That’s the lifeline of the TRC1000 MN compressor. For over four decades,ELGI’s most successful railway compressor hasbeen used for air brake application in ElectricalLocomotives. Aptly nicknamed theWORKHORSE, it has been labouring tirelesslyfor the Indian Railways in grit, grime andextreme conditions. Its unquenchable energy,allows the TRC 1000 MN to race ahead of therest. In fact, no competitor has been able tomatch ELGI’s technology. Competitors likeKirloskar and IR have attempted to make inroadsinto this category but have failed miserably. Itcomes as no surprise that the compressor hasproved to be the Railway division’s star product.

Time Tested Technology

TRC 1000 MN


ELGI’s Automotive Equipment Division has devised the idealworkstation for cars and other automotives. The compact Low HeightLift can fit snugly in smaller workshops and tyre repair shops,automatically enhancing the utility of smaller bays. The unit is designedto facilitate wheel and brake service, minor under-bonnet repair andaccessory fitment. But if you thought repair work is all about dirt andgrub, think again. The stylishly designed, trendy unit looks more like apiece of equipment at an upscale gym, than a booth at a workshop.Deceptively sleek, this device can withstand heavy-duty wear and tearand can carry a whopping 2,500 kgs. Investment in the piece translatesinto a cost-effective addition to the work environment. The mechanicsinvolved are precise - the lifting and lowering time is a mere 20 seconds.The unit works on hydro-electric power and bears the branding of anenvironment-friendly, repair-adaptive, indispensable tool in anyautomotive workshop. The clincher? The affordable rate. The LowHeight Lift is big on utility and easy on the wallet.


Top brass engines deserve the best in compressor technology. Varanasi-based Diesel Locomotive Works (DLW), in confluence with GeneralMotors (GM), Illinois, has created new-generation Diesel locomotivesfor the Indian Railways. For the first time in its history, GM exporteddiesel engine technology, to enable the production of the locomotives.These diesel locomotives can go up to speeds of 110 km per hour. Withthe engines embedded with top-end technology, it was expectedthat the compressor used for the braking application be on par.ELGI’s 66101W was the Perfect Partner. ELGI is the only Indianmanufacturer to develop these compressors meeting world classquality standards. The 66101 W is definitely riding the wave of success.

Riding High

Fumes, toxins, pollutants, dust. Just part of theroutine at a body-repair shop. To foster a cleanerwork environment for its employees, Hondacommissioned the development of a PaintPreparation Station that would reduce thehazardous effect of primer painting and sanding.The Automotive Equipment Division’s R&Dteam thought on its feet and quickly created arevolutionary preparation booth. The productsucks up impurities in the air through its airblower unit, equipped with numerous ducts.Depending on customer specs, both single anddouble bay stations can be manufactured. Thefirst such environment-friendly booth wasinstalled at a Honda dealership in Delhi. Withthe success of the project, similar booths are tobe set up across all Honda dealerships inthe country.

Paint Booth

Breathe Easy

Utility At Its Trendiest

Low Height LIft

Any bustling metropolis in India is bound to have an army of dazzlingyellow autos, and a host of other three wheelers. Consequently, ELGIdecided to complement this distinctive mode of transportation with asuitably designed service station. The unit is created to lift autos andother three-wheelers to a height of 1800 mm – in a zippy 45 seconds.Although, at first glance, the unit may not seem big on brawn, it cancarry loads of up to 650 Kgs. With its expertise in designing servicestations for two and four wheelers, ELGI has now developed a one-of-a-kind lift for three-wheelers as well. The lift does away with the needfor sprawling garages and repair shops: fitting perfectly in the mostcramped areas, it uses space optimally. Once the vehicle is hoisted up,any part of it can be quickly accessed. With 42 years in liftingequipment technology, ELGI, the leader in automotive serviceequipment, has proved its mettle once again with the three-wheelerservice lift.

The Quick & Compact Weightlifter


Make a statement. That’s what Hondawanted to do. What better way to do that thancomplementing a perfect interior witha lustrous exterior that glinted in the sun, makingevery other automobile turn green with envy.ELGI’s Automotive Equipment Divisiondelivered right on target. With materials sourcedfrom the US, the company created the TwinHead Polisher that simply outshonecompetition. An electric motor drives the twoheads of the light-weight, aluminum product. Atthe click of an easy-to-operate trigger, the TwinHead Polisher is turned on. Honda has giventheir thumbs-up to the product, and soon everydealer in the country is going to be giving theircars the perfect finish.

No Glossing Over Gloss

Twin Head Polisher

ELGI has many firsts to its credit. Here’s one more - for the first timein India, ELGI has indigeneously manufactured an Electronic TyreInflator with a built-in compressor. The retractable air hoses of theinflator make the whole process of inflation and deflation, convenientand compact. ELGI has done away with lengthy hoses in this new modelthat are cumbersome and difficult to manage. Moreover, the in-builtcompressor has the capacity to start tyre inflation instantly andautomatically. This new tyre inflator is user friendly with an LCD,seven segment display and is best suited for residential complexes. ThisElectronic Tyre inflator is best suited for residential complexes, parkinglots, shopping malls and of course, petrol bunks, garages and tyre shops.This product is also available with a stainless steel cabinet that isdesigned to perform under rugged conditions with low maintenance.The ELGI Electronic tyre inflator can be used for inflating tyres ofcars, LCVs and HCV and bicycles.

Indigenous Technology

A Three - wheeler Lift


Electronic Tyre Inflator

After careful study of the air requirements of fuel stations and small-scale industries, ELGI’s Reciprocating Compressor Division hasintroduced the Petro Series models of air compressors with new featuresand price benefits. These two models are specifically designed for fuelstations, garages and small-scale industries. The two models can delivercompressed air volumes of 192 lpm (liters per minute) at 3HP and 292lpm at 5HP respectively. Both models have totally enclosed belt guards,which ensure complete protection against mishaps. The inter-stagesafety valves in both models provide extra safety to the user. The airreceiver has been designed as per ASME/Euro norms.

The Versatile Workhorse

The ELGI Petro Series Compressor

The ELGI Vidyuth 4000, is India’s onlyportable generator with 3.5 kVA capacity. Inaddition, there are more features that make it aleader in the Indian market. Vidyuth is the onlydiesel Genset with a Recoil-starter in the Indianmarket and the only Genset in the Indianmarket with an Auto Decompression Lever(ADL). What’s more, it has the highest powerto Weight Ratio (3500Watts / 78kgs) amongall Gensets in the Indian market in this category.The Engines Division is planning to soonlaunch more products under the Vidyuth brand– Vidyuth 5000, Vidyuth - Whispering Gensets,Vidyuth – Welders and Vidyuth - With ColdStarting Equipment.

Packing A Punch

The ELGI Vidyuth 4000


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FactoriesSinganallur Trichy Road, Singanallur, Coimbatore - 641 005, India

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Foreign OfficesBangladesh ELGI Equipments Limited, C/o. IFAD Enterprise Limited, Sonartori Tower (15 th & 16th floor) No. 12,

Biponon C/A, Sonargaon Road, Dhaka - 1000, BangladeshTel: +880-9671453-57 Fax: +880-2-8616148 Email: [email protected]

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Branch OfficesELGI Ahmedabad “ELGI HOUSE” 2, Mill Officer’s Colony, Behind La-Gajjar Chambers (Old Reserve Bank),

Opp Times of India, Ashram Road, Ahmedabad - 380 009, IndiaTel: +91-79-26583736/26581274 Fax: +91-79-26587683 Email: [email protected]

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the elgi magazine 2005

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