visit to bali industries

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MASTER OF BUSINESS ADMINISTRATION

REPORT ON INDUSTRIAL VISIT-2

COMPANY : 1.BALI INDUSTRIES

2.SRI CHENCHANDAI NATKAR KARUNADAKSHI SPINNER

LIMITED

ANNA UNIVERSITY: CHENNAI 600025



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BALI INDUSTRIES

With the changing economic and business scenario, BALI Industries Ltd. identified the

needs of the telecom & IT infrastructure to upgrade from metal cables to optical fibers. With its

rich experience in plastic pipe manufacturing & in-house technical strengths, the company has

developed a product conforming to modern technology named BALLI COM-line. BALLI COM-

Line is a product underlining strategic diversification of PIL with a commitment towards global

telecom & IT infrastructure. BALLI COM-Line conduits are designed and engineered to house

these sensitive nerves of Information technology i.e. optical fibers thus enabling information

transfer across the globe.

The firm is specialized in manufacturing of Permanently Lubricated High Density

Polyethylene Telecom Ducts of sizes 32/26mm,40/33 mm and 50/42mm along with the

accessories Viz., Plastic Couplers, End Plugs and Cable Sealing Plugs as per the BSNL

specification No. GR/ CDS-08/02 NOV 2004 in the name and style.

BALI industries are one of the leading manufacturers of HDPE pipe and Prelubricated

polyethylene pipe (PLB HDPE Pipe). Since many years, the company is engaged in

manufacturing of HDPE pipe and has supplied large quantity of Prelubricated polyethylene pipe

(PLB HDPE Pipe) to various well known government departments such as BSNL.

Prelubricated polyethylene pipe (PLB HDPE Pipe) - Suitable in the field of communication

to cover underground Optical Fiber Cable network system.



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LOCATION:

BALI INDUSTRIES having the registered office and factory situated at Shed No. 87, Bs

20 & 21 Sidco industrial Estate, Kappalur, Madurai-625 008.

INFRASTRUCTURE:

The firm was established in 8th August 2002 with the distinct motto of serving the

customers with the high quality, low profit and large turnover. The unit is provided with

adequate Infrastructure with sophisticated machinery with advance technologies, well equipped

laboratory for ensuring the quality.

Notes on Organization

The firm is a partnership venture consists of two partners who are having the vast

experience in the manufacturing and trading activity since 1987. Since both the partners are

having the enormous experience in the field the various activities of the firm i.e., Production,

Quality control, marketing, Accounts and inventory control are in the direct supervision and

guidance of the partners.

Infrastructure Facilities

Since the machinery is a vital element for a manufacturing company the selection of the

machinery were carried out after the several discussion with the experts of the field and the

sophisticated machinery were purchased so as to obtain the targeted production with the high

quality and in low maintenance and operative cost. The photograph of the Machinery is enclosed.

The errection and installation and trial run were carried out by ourselves up to the stage

of the commercial production without any external assistance with constant efforts are on theright way from beginning to maintain the quality.

Up keep and maintenance of the machinery in its efficiency is our key word so as to

produce the quality goods at the competitive prices. For that the preventive maintenance is

followed. The machineries are maintained and operated by the specially trained operators who



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are having the long experience in the field. All safety precautions are taken to avoid

embracement and down time of productive time by the technicians. Since our Bulk customer is

M/s Bharat Sancher Nigam Limited, whenever an item is developed the Infrastructure

Assessment and the Proto Evaluation test are carried out by Engineers from BSNL so as to

access our production capacity for the particular item, quality of the product by means of our In-

house laboratory and also by the third party test in the Approved Laboratories like CIPET,

CACT etc.

Only after the sample was proved to be acceptable the Technical Specification Evaluation

Certificate was issued by the O/o Chief General Manager, Quality Assurance, BSNL.

Bangalore . The production capacity of the firm for PLB HDPE Duct of sizes 32/26mm, 40/33

mm & 50/42mm is accessed. The copy of the infrastructure Assessment Certificate is herebyenclosed.

We are having the valid TSEC we are having the valid TSEC for the supply of the ducts

in all the eight colors viz. Green, Orange, Yellow, Red, Brown, Violet, Grey, and Blue. The copy

of the TSEC Certificates and the sample for each color is enclosed.

The firm is having the adequate machinery for the manufacture of the accessories and the

Infrastructure Assessment is carried out for these also and the approval for its manufacturing isaccorded by the BSNL Authorities. The copy of the approval is hereby enclosed.

Since Right from the beginning the object was to produce the product in highest quality

on process checks like Dimension, Ovality, Visual Inspection checks are carried out by the

trained supervisors and the product is offered to the quality control wing of the firm for further

Inspection.

The unit is having a well equipped Laboratory with all the required testing equipments

and the tests are carried out by the well trained Personal in the department. The equipments are

calibrated by the supplier of the equipment itself within the due date of calibration. Apart from

the equipments the laboratory is having all the relevant standard specification references, test

procedure details, Data Books on the plastics etc.,



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The product after production is tested in all aspects in the lab and after the entire

satisfaction of the QA Wing the product is offered to our valid customers for their acceptance.

The unit has successfully executed the purchase orders of PLB HDPE Telecom Ducts

along with accessories from the various circles and projects of M/s Bharat Sancher Nigam

Limited and the performance statement for the supplies are enclosed.

The turnover of the firm for the period 2002-03 is Rs. 1.01 Crores, 2003-04 is Rs.4.40

Crores, 2004-05 is Rs. 12.31 Crores, 2005-06 is Rs. 20.05 Crores, 2006-07 is Rs. 12.45 Crores

and 2007-08 (up to 26th November) is Rs. 19.10 Crores.

Accounts are managed by qualified assistant under the direction and the supervision of

the company's Auditor. For effective finance control and utilization periodical meetings are held

and close follow up is instituted on decisions.

We have field representatives who will follow each consignment sent by us till the same

is inspected at their end and taken into stock. The customer's suggestion is passed on to us for

improvements for immediate implementation and thereby better relationship is maintained.

PRODUCTS

PERMANENTLY LUBRICATED HDPE TELECOM DUCT

Available sizes:

32/26mm

40/33mm

50/42mm

Products (accessories)



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PRODUCT DESCRIPTION:

PLB HDPE DUCT consists of 2 concentric layers , the outer layer being HDPE , co

extruded with an inner layer of solid silicone permanent lubricant to reduce the internal

coefficient of fraction (ICF) .

Alternatively the duct can be of a homogeneous construction without a separate inner

layer the ducts are also manufactured in homogeneous construction with inside containing

smooth lubricants for easy and convenient pulling of cables.

MATERIAL:

UV established HDPE resin used for the outer layer of plb hdpe duct shall conform

to any designation of IS-7328 or any equivalent standard meeting the requirements when

tested as per IS-2530.

DENSITY:

0.940 - 0.958 g/cc @ 27 deg cent

MELT FLOW RATE (MFR) :- 0.2 to 1.1 g/10min @ 190 deg cent and 5 kg load .

INNER LAYER :

The inner lubricant material shall be of friction reducing, polymeric material. The

coextruded inner layer of solid permanent lubricant shall be integral part with HDPE and

white in color, clearly visible in cross section of duct.



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DIMENSIONS OF DUCTS:

Size 40mm/33mm 32mm/26mm

Outside dia 40mm+0.4mm 32mm+0.3mm

wall thickness 3.5mm(+-0.2mm) 3.0mm(+-0.2mm)

standard length 1000(+-100m) 1000+-100m

Duct coils are also available in various lengths from 100-2000m in single coil as per the

customer requirement.

COLOURS:

The ducts are available in various colors as per the customer requirement for

immediate identification and suitability.

PLB HDPE DUCT ACCESSORIES:

The following accessories are available for jointing the ducts:

• Plastic coupler

• End plug

• Cable sealing plug

• End cap

Plastic Coupler



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It is used to couple two ducts. The design of this shall be simple, easy to install and shall

provide air tight and water tight joined between the two ducts. The coupler shall ensure that the

two duct are butted smoothly without any step formation in the inner surface.

The jointing shall meet the air pressure test of 15kg/cm2 for a minimum period of two

hours without any leakage.

End plug

This is for sealing the ends of the empty ducts, prior to installation of the OF cable and

shall be fitted immediately after laying of the duct, to prevent the entry of any dirt, water,

moisture, insects/rodents etc.

Accessories Available for all sizes:

32/26mm

40/33mm

50/42mm

Cable sealing plug



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This is used to seal the ends of the ducts perfectly, after the cable is installed in the duct,

to prevent the entry of dirt, Water moisture, insects/ rodents etc., This is required at all places

where cable has come out of the duct either for joining or entry into the building as required. The

sealing plug shall be capable of accommodating standard sizes of optical fiber cable taking into

account the variation in diameter due to tolerance limits, etc.,

End cap

This cap, made of hard rubber/ suitable plastic material, shall be fitter onto both ends of

duct coil after manufacturing the duct, This shall avoid entry of dust, mud and rain water into the

duct during the transit and storage.

Manufacturing process in BALLI INDUSTRIES



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RAWMATERIAL:

Raw materials used are SUPERIOR GRADE OF HIGH DENSITY

POLYTHYLENE MATERIALS.

MELTING THE RAW MATERIAL

To start the process they have some initial set up such as

Starting temperature -2100 C

A machine takes three hours of constancy to enhance the process, after

that the running temperature is about 1100C to proceed the methodology.

VACCUM TUBE/TANK:

They are been used for the size maintenance of the pipes

CHILLER TANK:

Temperature set up =10-150C

Where the raw water is converted in to cool water through chiller machine

for the purpose of reliability of the pipes.

ONLINE PRINTING:



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After the cooling process the pipes are introduced to flame where they are

used to enhance the permanency of the title printing, Where they code for

the brand name according to their suppliers through automated software’s.

LAB TESTING:

There are various kinds of testing available for size, ash and oxidation

I. TENSILE MECHANISM:

Quality of the pipes is tested in case of occurrence of holes, cracks

etc, where 150 mm is the adjustable expansion limit. They are done

with the help of ESIR chemical test.

II. ASH CONTENT TEST:

The samples are burnt out to check the quantity of the ash content

which should not exceed 0.3%

III. OXIDATION INDUCTION TEST:



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This test is to find out the material life span through PYRIS software

where the micro level samples (5mg) are weighted through small

aluminum plates with the help of PERLIN machines.

SRI CHENCHANDAI NATKAR KARUNADAKSHI SPINNER

LIMITED

INTRODUCTION:

The term “spinning” is sometimes used to denote this final process in the production of

the yarn. This involves attenuating (stretching) the yarn to the required count giving the yarn

strength by adding twist and winding it on to a bobbin.

PROCESS IN SRI CHENCHANDAI NATKAR KARUNADAKSHI SPINNER LIMITED.



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OPERATIONS:

RAW MATERIAL:

100% polyether cotton

MIXING:

Raw materials + usable waste

BLOW ROOM:

R aw material

Mixing

Blow room

Drawing

Simplex

Spinning Cone WindingFly

Winding

DoublingDoubling Yarn

Cone Winding

Packing and

Dispatching



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Tuff form to lap form making.

CARDING:

Fiber to fiber separation.

DRAWING:

Parallazation of fiber

SIMPLEX:

Drafting and finishing wind in a bobbin.

SPINNING:

Drafting and produce to yarn.

RING SPINNING:

FUNCTIONS OF RING:

To draft the material to the required linear density (count).

Twisting (high twist, to make strong yarn by traveler).

Package winding (bobbin easy for transport).

How its work?

A ring frame was constructed from cast iron, and later pressed steel. On each side of the

frame are the spindles, above them are the draughting (drafting) rollers and on top is the creel

loaded with bobbins of roving. The roving (unspun thread) passed downwards from the bobbins

to the draughting rollers. Here the back roller steadied the incoming thread, while the front roller



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which was moving much faster pulled thread out (attenuated) forcing the fibers to mesh together.

The rollers are individually adjustable, originally by mean of levers and weights. The attenuated

roving now passes through a thread guide that is adjusted to be exactly above the spindle.

Thread guides are on a thread rail which allows them to be hinged out of the way for doffing or

piecing a broken thread. The attenuated roving passes down to the spindle assembly, where it is

threaded though a small ring called the traveler. The traveler rotates on the ring. It is this that

gives the ring frame its name. From here it is attached to the existing thread on the spindle

Like the hour and minute hands on a mechanical clock, the traveler, and the

spindle share the same axis but travel at different speeds. The spindle travels faster. The bobbin

is fixed on the spindle. In a ring frames, the different speed were achieved by drag caused by air

resistance and friction. The spindles rotate at 7000 to 8000 rpm, this spins the yarn. The traveler,

winds the yarn on the bobbin. The traveler on the ring is fixed on a lifting ring rail which guides

the thread onto the bobbin in the shape required: i.e. a cop. The lifting must be adjusted for

different cotton counts.

Doffing is a separate process. The attendant winds down the ring rails to the bottom. The

machine stops. The thread guides are hinged up. Removing the bobbin coils thread around the

spindle, and placing the new bobbin on the spindle firmly traps the thread between it and the cup

in the wharf of the spindle. This done, the thread guides are lowered and the machine restarted.

MATERIAL FLOWCHART:

Input=roving on package.

Output=required count yarn on bobbin.



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1. CREEL ZONE(ROVING PACKAGE PLACED ON IT):

The creel of the ring frame is a simple device that holds the roving. It is very important to

properly unwind the roving without breaking roving. To facilitate proper unwinding the roving

bobbin is held vertically on the bobbin holder placed at the upper portion of the frame which

moves slowly for easy winding of roving without breaking the roving.

2. DRAFTING ZONE(ROLLERS DRAFTING TO REDUCE THE LINEAR DENSITY):

In ring frame roller drafting system are used. Ring frame roller drafting system consistsof three lines of rollers with apron mounted on the middle rollers; the drafting zone is very

important part of ring machine that directly influences the eveness and strength of yarn. At ring

frame high draft is given to get a required count and for that high draft slippage of fibers occurs

that’s why apron are used in the roller drafting. Aprons give support to fibers throughout the

roller spacing between middle to front rollers not letting even the shortest fiber to float.



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3. TWISTING

The mechanism used for twist insertion in the ring spinning is the ring or traveler. The

ring is spring ‘C’ metal shaped trip called traveler positioned horizontally over a spindle edge.

one turn of twist is being inserted in the length of the yarn between package and the front rollers

and the twist level would increase for each revolution of the traveler. Optimum twist is inserted

in the yarn because high twist can damage the yarn strength while low twist can also decrease the

strength of yarn. Hence optimum level of twist inserted in yarn, which can with stand the

production on the loom without too much breaking of yarn, is very necessary.

4. WINDING

The yarn after being twisted by the traveler has to be properly wound on the package

called bobbin. In order for the yarn to be wound on the entire length of the cylindrical ring

bobbin, the ring is raised and lowered which is mounted on a longitudinal ring rail. The ring rail

on which the ring is mounted is moved up and down by the builder or reflector motion in a

special manner. The separator is used in the ring frame to separate the balloon from the other

spindle balloon during winding because the entanglement of balloon caused breakages of yarn

and effect on the quality of yarn.

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