In Search of Permanence : Matching Production Speed

Established in 1986, the Dolphin Group is a leading conglomerate in the country comprising nine associated companies, all engaged in a diverse range of manufacturing. One of its companies, Dolphin Poly Plast Pvt Ltd is based in Rajkot and is a well-recognized name among the
manufacturers of HDPE pipes and micro irrigation systems. It offers a comprehensive range of plastic products in India, and is a market leader in the field of PVC pipes and fittings.

Challenges faced

Pipe making is a rapid process and involves a procedure to follow. Marking is just a part of the process, but a highly important one because the visibility of logos, texts and other marks contributes to the perceived quality of the product. Processes cannot be stopped without expensive downtime and scrap, and these lines move at hundreds of meters per minute.

The process for marking on pipes that Dolphin was using had following limitations:

Traceability: The marking lacked contrast and resolution, hence was difficult to view from a distance.

Labor cost: Manpower was required for preparing custom solution for different batches.

Downtime: Changing the solution for every batch required considerable amount of time.

Wastage: Because of the quality of marking, a lot of scrap was produced.

Power: Inability to utilize the full line speed resulted in high power consumption.

Speed: The marking solution used did not support the high production speed.

Impermanence : The marking done was not permanent and often was at a risk of being removed by solvents and abrasive cleaners.

Stencil: The custom stencil that contained the image to be marked posed problems in running sequential data such as serial numbers etc.

Finding the way out

Dolphin being a stickler for quality, had to find some solution for the challenges it was facing in the pipe production. The company approached Sahajanand Laser Technology Ltd (SLTL) that complemented the former’s business with its OTF (On-The-Fly) Laser Marking Solution. SLTL customized a solution to match Dolphin’s production requirements, which:

Helped achieve a line speed of 200 m/min with 92 characters marked;
Reduced manpower by two units;
Proved to be cost-effective;
Reduced one hour of production downtime daily;
Saved 10 percent scrap in the final product;
Resulted in best-in-class precision and quality marking.

SLTL

A pioneer in the field of lasers in India, SLTL offers solutions with its wide range of laser systems for diverse industrial applications. The company houses state-of-the-art facility and holds a reputation of being the largest manufacturer of laser systems in India and the world’s first manufacturer of fiber laser cutting machines. Its product portfolio includes laser cutting, marking, welding systems; solar cell cutting systems; customized automation solutions; material handling solutions; press brakes; ultra-precision equipment for diamond and jewelry processing, RF and microwave solutions; and medical machinery.

The company started off by setting up its base factory in Gandhinagar, Gujarat in 1991 and introduced for the first time in India a laser system for the diamond industry. Since 1995, the company ventured into other industrial applications and has been a frontrunner for the CNC laser systems in India. It is now heading for global ventures.

Laser Marking Benefits

Cost savings from no consumables: High-volume manufacturers can greatly reduce costs with laser marking compared to other methods. The consumable cost for ink or labels far exceeds the initial cost of a laser.

Permanence: Laser etching leads to a permanent mark that can withstand the test of time. It is chemically resistant to solvents, acids and bases. It also has the ability to resist temperatures.

Precision: The sharp finish of laser marking makes it the most precise solution. A laser marking is easy to read, making it far superior to any other method.

Compatibility: Lasers are flexible enough to fit themselves into any production/packaging line. There is no constraint of space and orientation.

Flexibility: Laser marking works on a variety of materials. It can mark any type of image or font and can be programmed in real-time.

Minimal maintenance: Downtime associated with cleaning a printer or changing a stencil can be avoided with a laser marking solution.

High speed: A very high speed can be achieved with laser engraving. It can also be customized to match the existing process speed.

Non-contact process: Laser marking does not have direct contact with the marking surface. Hence, it affects the physical property of the component.

Challenge & Solution

Challenge

Dolphin Poly Plast Pvt Ltd needed a permanent marking solution matching their production line speed for the visibility of logos and other text on its pipes.

Solution:

SLTL’s OTF (On-The-Fly) customized Laser Marking Solution that proved to be best-in-class in precision and quality marking. It was fast and cost-effective, and also helped in saving downtime, expensive labor cost and scrap.