Intelligent Machines for Automation in Electrical Casting & Electronic Potting For void free castings in large scale manufacturing

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1 Intelligent Machines for Automation in Electrical Casting & Electronic Potting For void free castings in large scale manufacturing 50 kg/day 2000 kg/day

2 TWIN ENGINEERS l ELECTRICAL CASTING l 02 Proven Machines, Trusted by India's largest manufacturers Instrument Transformers Automation of APG Process with 8 clamping stations for one of India's largest exporters. Epoxy Casting Plant for APG with output of 2400 kg./day Results Fully automated process with 70% reduction in labor 70% reduction in space Over 30% improvement in productivity with simultaneous processes for filling, preparation and consumption Resin Cast Transformers Highly flexible electrical casting solution for one of India's leading exporter. Vacuum Casting Plant with output of 550 kg./day Results Clean process without any manual intervention, whatsoever Significant savings in material, labour Assured quality on all parameters starting from Partial Discharge to Product finish Significant space savings with unified system for filling, preparation, mixing & dispensing CT/PT Manufacturer Automating atmospheric casting process for a fast growing CT/PT Manufacturer Open Cast Machine with output of 250 kg./day Results 99% savings in material wastage as compared to manual process Easy, convenient operations in small space Assured quality with precision mixing and dispensing Reduced labor requirements; low-skill labor Bushings and Insulators Highly flexible electrical casting solution for one of India's leading exporter. Vacuum Casting Plant with output of 550 kg./day Results Clean process without any manual intervention, whatsoever Significant savings in material, labour Assured quality on all parameters starting from Partial Discharge to Product finish Significant space savings with unified system for filling, preparation, mixing & dispensing Current & Voltage Transformer Unified casting solution for a leading, large-scale manufacturer oaf epoxy cast instrument transformers, current transformer and voltage transformer of various ranges in India. Epoxy Casting Plant for APG with output of 300 kg./day Results Savings in time, material and labor Significant improvement in component properties helped boost exports Better profitability with cost-effective solution for entire process Constant Voltage Transformer Open Cast Machine to manufacture Constant Voltage Transformer for a large German conglomerate in electrical and electronics. Open Cast Machine with output of 150 kg./day Results Casting quality & component properties that exceeded the global norms Cost-effective solution with advanced electronic controls Convenient customization to improve operator ease & production environment

3 RESIN HARDNER ACCELERATOR SILICA BATCH BATCH BATCH BATCH TWIN ENGINEERS l ELECTRICAL CASTING l 03 Smart Casting with smart machines Twin serves as your single source in automating casting processes for wide variety of electrical and related components. Twin's systems & machines are based on patented technology & are specifically engineered to offer everything that your process needs - quality, flexibility, safety and seamless operations. Twin's machines come with advanced electronic controls, remote monitoring, support that in turn allows you to analyse the casting process and key production parameters in real-time. Casting for APG Processes Epoxy Casting Plant (Combo System) Portable Casting Plant for APG Processes Casting Plant with Silica Handling Vacuum Casting Atmospheric Casting Vacuum Casting Plant (Combo System) Atmospheric Casting/Potting Machine Industry's highest Precision Coupled with most Advanced Features Gear Metering Systems Ratio accuracy & continual monitoring Homogenous mix Electronically controlled shot size Vacuum Potting for complex profiles Maintenance Pop-ups Smart Data Logging and Reports Built-in E-Manual and Videos Instant Service App MORE >>

4 Introducing advanced, flexible modules for automating casting processes TWIN ENGINEERS l ELECTRICAL CASTING l 04 Whether you want to automate only a specific part in the casting process, upgrade the process stepwise or automate the plant all at once, Twin offers the ultimate freedom to choose from a range of products and options that meet your needs and budgets. All our solutions come as individual modules and are easily integrated with your existing processes to improve quality and efficiency. Resin Tank with Degassing METER MIX DOSING Vacuum pump for degassing Perfectly homogenized material Accurate ratio control with precision metering pumps Motorised stirring prevents sedimentation of material Hardener Tank with Degassing Band Heater Band Heater Metering Pump Static Mixer Prepares fresh mix Casting Techniques Atmospheric Casting Automatic Pressure Gelation (APG) Vacuum Casting

5 TWIN ENGINEERS l ELECTRICAL CASTING l 05 AUTO-TRANSFER FEED FROM CONTAINERS (OPTIONAL) Easily transfer the unfilled resin/hardener from IBCs/barrels to the pre-mix or dosing tanks using Twin's auto-transfer systems. The auto-transfer modules pumps the material into the pre-mix tanks from all types and sizes of containers. Get clean work place with no spillage Ensure uninterrupted production with auto transfer mechanism Sieving Hopper for Filler Vacuum Transfer / Screw Conveyor SILICA HEATING AND TRANSFER SYSTEM Twin's filler addition module eliminates all the hassles in filler addition process by automatically introducing the accurate quantity of fillers into the resin/hardener tanks of the preparation system. Bag handling unit for large scale operation Magnetic vibratory sieving to remove metallic elements and other foreign particles Vacuum Transfer/Screw conveyor to transfer of fillers to resin and Hardener tanks Silica blending and heating unit Load cells to weigh measure and introduce accurate filler quantity Suitable for abrasive fillers Flexibiliser Thin film Degassing Vacuum Premixer Load Cells Additives or Accelerator PREPARATION (OPTIONAL) Twin's preparation systems have built-in mechanism to accurately control every process parameter so as to create perfectly degassed and homogenous pre-mix. Continuous Thin film degassing for pre-mix tanks Load cells to weigh and measure filler quantity Metered dosing of additives such as coloring agents, accelerators and flexibelisers Temperature control for tanks System intelligently adjusts the filler quantity to always maintain the desired ratio with respect to resin/hardener All systems are completely assembled at Twin's factory and tested for rated performance and output on materials used in your shop-floor.

6 PRODUCT TWIN ENGINEERS l ELECTRICAL CASTING l 06 Epoxy Casting Plant (Combo System) The newly upgraded Combo System for electrical casting based on the Intellomix platform. This innovative machine combines silica preparation, transfer, mixing and dispensing into a single unit and does not require any manual intervention in the process. The system is designed for seamless integration for APG clamping stations. Key Benefits Automated material handling throughout the process reduces material wastage Substantial improvement in Partial Discharge and other performance parameters Optimized productivity with lowest start-up time Single system for Preparation and Meter Mix Dispensing saves space Suitable for up to 4 clamping stations Specification Tank Capacity 100 L 150 L 200 L Production Capacity 550 Kg. of mix/shift System Flow Rate 2 tank system 0.5 kg/min to 1.5 kg/min and 1.5 kg/min to 3 kg/min Flow rate can be customized as per product or process requirement Features Standard Silica Filling Filler Addition System to automatically introduce accurate quantity of fillers into resin / hardener tanks with screw conveyor Load cells to weigh and measure filler quantity Material Preparation Precision gear metering Touch Screen HMI Programmable recipes Static Mixer Electrical heater Continuous thin film degassing Optional Production monitoring on mobile Metered dosing of additives such as coloring agents, accelerators and exibelisers

7 PRODUCT TWIN ENGINEERS l ELECTRICAL CASTING l 07 Vacuum Casting Plant (Combo System) Twin's Table Top MMD is a compact, power packed machine equipped with advanced electronic controls. The table top MMD can be easily accomodated on a workbench and is ideal to move or operate in smaller workplaces. The table top MMD is well proven for a variety of general purpose and specialised potting applications including micro-dosing (dispensing of 0.1 gm). Key Benefits Saves space with highly compact design, exible layout for material preparation and vacuum chamber Simultaneous bubble free vacuum casting for up to 3 HV & LV Cores in DTT Accurate mixing ratio and near zero material wastage Fully automated casting saves labor, handling costs and investments in related equipment Specification Tank Capacity 100 L 150 L 200 L Production Capacity 550 Kg. of mix/shift System Flow Rate 2 tank system 0.5 kg/min to 1.5 kg/min and 1.5 kg/min to 3 kg/min Flow rate can be customized as per product or process requirement Features Standard Silica Filling Filler Addition System to automatically introduce accurate quantity of fillers into resin / hardener tanks with screw conveyor Load cells to weigh and measure filler quantity Material Preparation Precision gear metering Touch Screen HMI Programmable recipes Static Mixer Electrical heater Continuous thin film degassing Vacuum Casting IR heaters for temperature control of each mould X Y mechanism controlled by a joystick to position the static mixer Set and monitor the exact vacuum level in the chamber Custom designed forklift or tackle for loading and unloading moulds Optional Production monitoring on mobile Metered dosing of additives such as coloring agents, accelerators and exibelisers

8 PRODUCT TWIN ENGINEERS l ELECTRICAL CASTING l 08 Portable Casting Plant for APG Processes With Twin's innovative approach preparation and mixing processes are performed simultaneously, and independent of each other, adding huge savings in terms of space, labor, time and utilities. The plug-to-use system can be practically operated by a single, skilled operator. Key Benefits Simultaneous processes in preparation and mixing units saves time and doubles output Compact design enables high volume production in very less space Flexible layout and portable system eliminates fixed infrastructure such as pipes, bringing huge savings in initial investments & maintenance costs Significantly lower installation, commissioning and operations costs Suitable for up to 8 clamping station Specification Tank Capacity 100 L 150 L 200 L Production Capacity 950 Kg. of mix/shift System Flow Rate 4 tank system 0.5 kg/min to 1.5 kg/min and 1.5 kg/min 3 kg/min Flow rate can be customized as per product or process requirement Features Standard Silica Filling Filler Addition System to automatically introduce accurate quantity of fillers into resin / hardener tanks with screw conveyor Load cells to weigh and measure filler quantity Shrinkage Compensation Cylinder Optional Material Preparation Production monitoring Precision gear metering on mobile Touch Screen HMI Metered dosing of additives Programmable recipes such as coloring agents, Static Mixer accelerators and exibelisers Electrical heater Continuous thin film degassing

9 PRODUCT TWIN ENGINEERS l ELECTRICAL CASTING l 09 Casting Plant with Silica Handling Suitable for Casting in atmospheric and APG processes Twin Engineers has designed a completely new machine, developed specifically to meet the needs of manufacturers with consumption of up to 2000 Kg per day. The Intellomix Casting Plant comes with all the modern features that you would expect in future, today & is suitable for Vacuum Casting and APG processes. The plant is also equipped with integrated silica processing and includes bag unloading (1,000 Kg), heating and blending. At the same time, Twin Engineers has not lost sight of the need for flexibility. The new machine comes with significantly lower installation and commissioning costs and offers complete flexibility in process layout to suit your needs. Key Benefits Integrated handling and dispensing system reduces labor, operations & maintenance costs Advanced controls ensure accurate process, for large scale production, without manual intervention Flexible layout and portable system eliminates fixed infrastructure such as pipes, bringing huge savings in initial investments & maintenance costs Significantly lower installation, commissioning and operations costs Specification Tank Capacity 100 L 150 L 200 L Production Capacity 2000 Kg. of mix/shift System Flow Rate 2 tank system 0.5 kg/min to 1.5 kg/min and 1.5 kg/min 3 kg/min Flow rate can be customized as per product or process requirement Features Standard Silica Bag Handling Bag dispensing (up to 1T) Accurate Vacuum Transfer In-line blending and heating Weighing & proportionate mixing Vacuum transfer of silica into resin/hardner tanks Optional Material Preparation Precision gear metering Production monitoring on mobile Touch Screen HMI Metered dosing of additives Programmable recipes Static Mixer such as coloring agents, accelerators and exibelisers Electrical heater Continuous thin film degassing

10 PRODUCT TWIN ENGINEERS l ELECTRICAL CASTING l 10 Atmospheric Casting/Potting Machine Void free potting becomes easy with Twin's Optimix Meter Mix Dispensing machines. The self-optimising Machines help control and optimise every key parameter of the mixing and dispensing process to ensure consistent quality in your production. You are assured of hassle free and productive operations along with several other benefits. Key Benefits Accurate mixing with advanced precision gear metering Homogeneous mix and completely bubble free potting Self-monitoring ensures accurate mixing ratio, and potting quality Labor savings, and lesser costs with easy to clean and maintain Specification Tank Capacity Material System Flow Rate 10 L 35 L 60 L 100 L PU, Epoxy 2 tank system 0.5 kg/min to 1kg/min customized flow rates can be offered as per requirement Features Standard Optional Automation Precision gear mixing Touch Screen HMI Vacuum degassing Electric Heating Motorised Stirrer Programmable recipes Static Mixer Stainless steel Tanks Pressure Transmitters Level Sensors Extension arm with tackle Trolley/Wheels for movement X-Y Table Roller Table Rotary Index Tables

11 TWIN ENGINEERS l ELECTRICAL CASTING l 11 Leading the way Mixing & Dispensing With over two decades of expertise in Mixing and Dispensing technology, Twin Engineers has automated processes for 100+ applications in electronic and electrical potting. The range of Machines includes a bench-top mixer to fully-automated potting and encapsulation plants for large-scale German Designs Twin's Machines are designed with close consultations from German Engineers, through its long standing strategic tie-ups, and adhere to industry-leading process technology and manufacturing standards. Dedicated R&D A dedicated team of application engineering experts with combined experience of over 200 years in automating some of the complex mixing and dispensing processes that use PU, Epoxy or Silicone materials. Instant Support, world over Innovative QR Code based support App for Operators, remote diagnostic facility, dedicated team of 20 Field and back-office Service Engineers to guarantee a quick response and efficient service at every stage of the project. Quality & Output Guarantee Partnering with Twin means an end-to-end solution that meet the specific needs of your process. Going beyond just delivering Machines, Twin's expert team ensures you get the full benefits from your investments. Industry 4.0 Ready All of Twin's Machines come with modern features in that you would expect in future, including IoT connectivity, Mobility, Smart Manufacturing & more.

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