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Index KATT Introduction
Profile
Profile
KATT Technologies, Products for Railway Industry
Interiors
WC Modules
HVAC units
Front End & Cab Interiors
Interior Refurbishment
Case Histories
Case Histories
Case Histories - Advanced Composites
Introduction
Alte and Kineco combine their efforts and strengths under this JV Company to offer innovative, cost competitive train solutions. The JV headquarter is located in Goa (India), with more than 10000 m2 area and its activity is specialized in the manufacture of composite products for railway applications for the Indian market.
Alte’s know how from 30 years experience in the railway industry all over the world with any kind of customer requirements and Kineco’s technical knowledge in composites and industrial environment in India gives KATT a top position in the Indian market.
Goals and StrategyCommercialSupply the Indian Railway Market with high quality products within local producers and international producers to be located in India.
QualityAchieve world class rail standards of quality in all products.
Production and ProcurementHigh level of manufacturing technologies.On time deliveries according to customer requirements.
FinancialFinancial autonomy.
Ethics and EnvironmentSocial responsibility of helping employees to achieve a good balance between work and family. Environment friendly management of residues.
Profile
• State-of-the-art products with latest technology in railway industry on the global scale.
• Three main product lines: Rail car interior, WC modules andHVAC units
• More than 12000 WC modules, 5000 HVAC and 1300 units of interiors delivered.
•Preferred supplier for WC modules for Alstom, Bombardier, CAF and Talgo.
•30 years of experience in design, engineering, manufacture and installation of complete train interiors, toilet modules, sanitary systems and HVAC systems.
• In-house design and engineering set-up, equipped with latest tools like Catia V5, Eplan etc.
• Alte facilities are ISO 9001:2008, ISO 14001 and IRIS certified.
• International presence through subsidiaries which offer our clients closer service and optimize production processes.
• Worldwide experience and performance history. Experience in Western Europe with practically all main Rolling Stock builders.
Profile
• Leader in technology and design of wide range of products for Railways, Automotive, Defense and Aerospace sectors.
• 15 years of performance history in the composite industry with several innovative product developments to its credit.
• Multi-dimensional composite producer supplying to diverse markets such as Railways, Automotive, Chemical industry, Medical Diagnostics and advanced composites for Aerospace and Defense applications.
• Expertise in Glass, Carbon & Aramid reinforcements with Polyesters, Vinylesters, Epoxies & Phenolic resin systems.
• In-house expertise in tool making. Equipped with 5 axis CNC router for pattern machining.
• All facilities are ISO 9001:2008 certified. Advanced Composites Division certified to AS 9100 (aerospace certification).
• ´Supplier of the Year Award´ by US multinational for two consecutive years
• ´JEC innovation award´ for Composite Undercarriage Water Tank developed for Indian Railway air-conditioned passenger coaches.
• Exports to USA, UK, Europe & Middle East.
Technology
State-of-the-art Composite Manufacturing Technologies:
• Resin transfer molding (RTM)
• Vacuum assisted resin transfer molding (VARTM)
• Resin infusion
• Vacuum bagging / Autoclave moulding
• Conventional hand lay-up
• Filament winding (using CNC machines)
Organization Structure
Representative
Board of Directors
General Manager
CommercialQuality &
Engineering R+D
Production & Procurement
Financial Administration
Representative
Interiors
• Tailor-made interiors. Flexible solutions adapted to every project from new coaches to refurbish operations, from metro to long distance trains including commuters.
• Modular systems for maximum integration of components in modular kits.
• Materials used highly resistant to vandalism and aging, easy for maintenance and cleaning.
• Fulfilling any fire, smoke and toxicity requirements.
WC Modules
• Leader in technology and design of toilet modules for the railway sector.
•Tailor-made solutions for any type of train and space envelope.
• Complete solution including toilet system, tanks and under frame piping.
• Own patented vacuum toilet system with references all over the world including countries with low level of maintenance.
• Minimum consumption and maintenance requirements.
HVAC Units
• HVAC equipment specifically build for destination market with in-house technology and know how.
• Compact and Split units that can be mounted on the roof or under frame.
• Experience with projects in countries with low level of maintenance and extreme climatic conditions.
• Compliance with rail safety and environmental standards.
• Maximum passenger comfort.
Front End & Cab Interiors
• Advanced composite and manufacturing systems for any kind of trains. Special knowledge of the Indian market requirements.
• Tooling manufacturing included in our design process and quality coverage
• References on the Indian market including the first Indian train with aerodynamic structural all composite front end cab.
Interior Refurbishment
BEFORE
AFTERBEFORE AFTER
• Complete interior refurbishment solutions with in-house modular components as WC module with sanitary system and HVAC units.
• Improvement of passenger comfort.
• Possibility of conversion to different type of coaches.
• Compliance with latest fire, smoke and toxicity requirements and update of coach to the latest railways standards.
Aerodynamic Front End Cab
Front End Cab for MEMU Trains
Front End Cab for DEMU Trains
Product: Front End Cabs with InteriorsProcess: Resin InfusionMaterials used:Glass reinforced polyester (FR grade)Scope:Design, design analysis and validation, prototype development and serial manufacturing including installation.Quantity:46 Nos.
Product: Front End Cabs with Interiors for Sri Lankan RailwaysProcess: Resin InfusionMaterials used:Glass reinforced polyester (FR grade)Scope:Design, design analysis and validation, prototype development and serial manufacturing including installation.Quantity:6 Nos.
Aerodynamic Front End Cab
Product: Front End Cabs with Interiors for LocomotivesProcess: Resin InfusionMaterials used:Glass reinforced polyester (FR grade)Scope:Design, prototype development and serial manufacturing including installation.Quantity:10 Nos.
Aerodynamic Front End Cab
Metro Cab Mask
Client: Delhi Metro Rail Corporation LtdProduct: Front End Cab MaskMaterials used:Glass Phenolic Prepregs Process: Vacuum Bagging using AutoclaveScope:Tooling and ManufacturingQuantity:2 Nos.
EMU Cab Mask
Client: Bharat Earth Movers LimitedProduct: Front End Cab Mask with Interiors for EMU TrainsMaterials used:Glass reinforced polyester (FR grade)Process: Hand Lay-upScope:Tooling, Manufacturing and InstallationQuantity:6 Nos.
Driver’s Consoles
Client: Siemens, India (MRVC & GP-194 Projects)Product: Driver’s & Shunting Desks for EMUMaterials used:Glass reinforced polyester (FR grade)Process: Hand-LayupScope:Engg. detailing on Siemens AG, Germany concept, prototype development and serial manufacturing.Quantity: 132 Train Sets (264 Driver’s Desk and 528 Shunting Desks)
Toilet Modules
Product: Toilet Modules (for Conventional & LHB Coaches)Process: RTM / Hand-LayupMaterials used:Glass reinforced polyester (FR grade)Scope:Prototyping and Serial Manufacturing as per railway specifications. Quantity:2760 Nos. of Western & Indian type toilet modules for Conventional and LHB coaches.
Coach Interiors
Side / End Wall Panels for EMU Coaches (MRVC Project)
Quantity: 444 Coach sets
Side Wall / Roof Panels for LHB Design RCF Coaches
Quantity: 116 Coach sets
Side, End Wall and Ceiling Panels for Sri Lankan Railway DEMU trains
Quantity: 47 Coach sets
Coach Interiors
Hard Seating System
Client: De-Consult, Germany (IGP project of Western Railway)Process: Hand Layup Product: GRP Seats for EMU train coachesScope:Design, engg. detailing, prototype development and mass production.Quantity: 158 Nos.
Client: Integral Coach Factory (MRVC Project)Product: Polycarbonate Seats for Mumbai Suburban Trains Scope:Prototype development and mass production.Quantity:8274 Nos. of 2, 3, 4 and 6 seaters.
Client: Integral Coach Factory (Kolkata Metro Project)Product: Polycarbonate seats with stainless steel structure & glass partitionsScope:Prototype development and mass production.Quantity:162 Nos.
Hard Seating System
Sky-bus Coach
Client: Konkan Railway Corporation Ltd. (Indian Railway Undertaking) Process: Hand Lay-upProduct: Skybus CoachMaterials used: Glass reinforced polyester with foam core and Stainless Steel Skeletal Structure.Scope: Design, Development & PrototypingQuantity: 2 Coaches
Undercarriage Tank
Product: Railcar Undercarriage Water Tank Process: Filament WindingMaterials used:Glass reinforced Polyester Scope:Design, prototype development and serial manufacturing.Quantity: 110 Nos.
‘JEC Innovation Award Winner’
Major Projects
Project Type Costumer Project Country Number of units
Complete Interiors
ALSTOM
AR-41 BELGIUM 80+16UTE’S SILICIO PORTUGAL 58
S/447 SPAIN 33UTE’S BW SPAIN 1
RENFECATENARY RENFE SPAIN 1
S/447 SPAIN 27
METRO MADRIDS/5000 SPAIN 5
CATENARY MM SPAIN 1METRO
BARCELONA CAF SPAIN 75
EMEF ALLAN 300 PORTUGAL 21
Driver’s Cab
ALSTOM PEARL LINE SHANGHAI CHINA 32+24
BOMBARDIER CP 2000 PORTUGAL 34
ANSALDO BREDA METRO MADRID L10 SPAIN 30
Major Projects
Project Type Costumer Project Country Number of units
Front Masks
ALSTOM
AR-41 BELGIUM 80+16UTE’S SILICIO PORTUGAL 57
CIVIA SPAIN 80PEARL LINE SHANGHAI CHINA 32+24
BOMBARDIER CP 2000 PORTUGAL 34
ANSALDO BREDA METRO MADRID L10 SPAIN 30
EMEF ALLAN 300 PORTUGAL 21
MER MEC CARONTE (TRENITALIA) ITALY 28
Main Characteristics
AR 41
– Client ALSTOM
– User SNCB
– Country Belgium
– Date 2003
– Number of Units 80+16
– Unit Type Complete Interiors
– Train Type DMU
Main Characteristics
METRO MADRID: SERIES 5000
– Client METRO MADRID
– User METRO MADRID
– Country Spain
– Date 2004
– Number of Units 5 Composition
– Unit Type Complete Interiors
– Train Type METRO
Main Characteristics
METRO BARCELONA : L5
– Client CAF
– User METRO BARCELONA
– Country Spain
– Date 2004
– Number of Units 75
– Unit Type Drivers Cab & Interiors
– Train Type METRO
CP 2000
– Client BOMBARDIER
– User CP
– Country Portugal
– Date 2004
– Number of Units 68
– Unit Type Front, Driver Cab & Interiors
– Train Type EMU
Main Characteristics
CERCANÍAS 447
Main Characteristics
– Client RENFE
– User RENFE
– Country Spain
– Date 2008
– Number of Units 60 Compositions
– Unit Type Complete Interiors
– Train Type EMU
CETENARY METRO MADRID LABORATORY VEHICLE
Main Characteristics
– Client METRO MADRID
– User METRO MADRID
– Country Spain
– Date 2006
– Number of Units 1 Composition
– Unit Type Complete Interiors
– Train Type METRO
Main Characteristics
UTE’s BW for FGV
– Client ALSTOM
– User FGV
– Country Spain
– Date 2003
– Number of Units 1 Composition
– Unit Type Complete Interiors
– Train Type EMU
BEFORE AFTER
Main Characteristics
PEARLINE: SHANGHAI
– Client ALSTOM
– User Shanghai , Admin
– Country China
– Date 2004
– Number of Units 56
– Unit Type Front Mask
– Train Type METRO
Main Characteristics
AR 41
– Client ALSTOM
– User SNCB
– Country Belgium
– Date 2003
– Number of Units 96
– Unit Type Front Mask
– Train Type DMU
Main Characteristics
METRO MADRID: L10
– Client ANSALDO BREDA
– User METRO MADRID
– Country Spain
– Date 2003
– Number of Units 30
– Unit Type Front Mask
– Train Type METRO
Main Characteristics
CP 2000
– Client BOMBARDIER
– User CP
– Country Portugal
– Date 2004
– Number of Units 34
– Unit Type Front Mask
– Train Type EMU
Main Characteristics
ALLAN
– Client EMEF
– User CP
– Country Portugal
– Date 2003
– Number of Units 42
– Unit Type Front Mask
– Train Type Autorail
Main Characteristics
RENFE: S/596
– Client RENFE
– User RENFE
– Country Spain
– Date 2003
– Number of Units 15
– Unit Type Front Mask
– Train Type DMU
Main Characteristics
CIVIA : RENFE
– Client ALSTOM
– User RENFE
– Country Spain
– Date 2009
– Number of Units 80
– Unit Type Front Mask
– Train Type Suburban Train
Main Characteristics
HIGH SPEED AVE REFURBISHMENT:
– Client Alstom
– User Renfe
– Country / City Spain
– Date 2006-2008
– Wall material Phenolica
– Total number of Toilet Modules 180
– PMR Toilet Modules 18
– STANDARD Toilet Modules 162
– Toilet System Chemical system
– PMR Module Door Electric
– Train Type High Speed Train
– Special Features Refurbishment
Main Characteristics
HITACHI CTRL DS
– Client Hitachi
– User HSBC
– Country / City United Kingdom
– Date 2006-2008
– Total number of Toilet Modules 58
– PMR Toilet Modules 29
– STANDARD Toilet Modules 29
– Toilet system Pressure - Vacuum
– PMR Module Door Electric
– Train Type High Speed Train
– Special Features -
Main Characteristics
VIRGIN CROSS COUNTRY, UK
– Client
– User
– Country / City UK
– Date 1999-2003
– Total number of Toilet Modules 274
– PMR Toilet Modules 274
– STANDARD Toilet Modules 0
– Toilet System Permanent Vacuum
– PMR Module Door Electric
– Train Type Long Distance train
– Special Features Waste water system
Main Characteristics
ATPRD
– Client
– User
– Country / City Spain
– Date 2003-2004
– Total number of Toilet Modules 84
– PMR Toilet Modules 12
– STANDARD Toilet Modules 72
– Toilet system Pressure - Vacuum
– PMR Module Door Pneumatic
– Train Type High Speed Train
– Special Features -
Main Characteristics
Desiro UK
– Client
– User
– Country / City UK
– Date 2000-2004
– Total number of Toilet Modules 137
– PMR Toilet Modules 137
– STANDARD Toilet Modules 0
– Toilet system Pressure - Vacuum
– PMR Module Door Electric
– Train Type Suburban Train
– Special Features -
Fire Performance & Compliance
Fire Standard Country Project
NF F-16, 101 & 102 France TTNG, Regina
UNI–CEI 11170-3 Italy AGV
DIN 5510-2 Germany NedTrain, Regina
UNE 23-727 Spain AVGL
BS 6853 UK NIR1, NIR2, Wabtec, Hitachi
UIC 564-2, NCD 1409 India Indian Railways
Case Histories: Kineco’s Advanced Composite Products
High end composites using vacuum bagging / autoclave moulding. This technology can be adopted to produce light weight glass-phenolic sandwich interior parts (with Nomex
honeycomb).
Motor Sports
Product: Racing car componentsProcess: Auotclave MouldingMaterials used:Carbon fibre sandwiched construction with nomex, aluminium and rohacell core materialsScope:Tooling, prototyping and serial manufacturing
RACE CAR COMPONENTS: Carbon Epoxy with Aluminium Honeycomb Core
MONOCOQUE: FRONT UPPER
MONOCOQUE: REAR UPPER
NOSE BOX
RACE CAR COMPONENTS: Glass Epoxy with Aramid (Nomex) Honeycomb Core
REMOVABLE SEAT
RAD DUCT ASSEMBLY
Patient Positioning Table
Client: GE MedicalProcess: Autoclave MouldingProduct: Patient positioning TableMaterials used:Carbon fibre sandwiched construction with rohacell core materialScope:Tooling, prototyping and serial manufacturing
Airborne Radar Structure
Product: Airborne radar structureProcess: Autoclave MouldingMaterials used:Monolithic carbon fibre laminates and sandwich construction of carbon fibre and aluminium honeycomb materialsScope:Design, analysis, prototyping and serial manufacturing
Radar Support Cabin for Naval Ships
Products: Composite Cabin with Radar FrameProcess: Autoclave MouldingMaterial used: Carbon Fiber Epoxy PrepregsScope: Design, prototyping and serial manufacturing
Carbon Fibre Bicycle Frame
Products: Carbon Fibre Sports Bicycle FrameProcess: Autoclave MouldingMaterial used: Carbon Fiber Epoxy PrepregsScope: Prototyping and Serial Manufacturing
Kineco Alte Train Technologies Pvt Ltd,60, Pilerne Industrial Estate, Bardez,
Goa 403 511, IndiaPh : +91-832-6648888
Fax : +91-832-6648889Email : [email protected]