Advanced B&R automation makes Technoshell world-class 

Highest accuracy in tube stamping and capping

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Nashik-based Technoshell Automations Pvt. Ltd. manufactures printing and packaging machines for applications such as hot foil stamping, capping, labeling, packing, and other custom-designed machines for plastic tubes. Over 15 years ago, Technoshell began using B&R’s automation solutions to build world-class accuracy and productivity in its machines.
Referred to B&R in Pune by one of his friends, Nikhil Baste, director of Technoshell, says, “With the help of B&R’s components and software we started making very good machines which were exportable even to developed markets and which were appreciated globally. In the entire process, the B&R control systems and components made a huge difference and made us world-class.”

In tube industry, Technoshell is focused on machines for capping, hot stamping and for packing tubes into the shipping cartons. It also has robotic packers for the tube industry. With a strong design team including software, electrical and mechanical designers, the company manufactures and exports CE compliant machines to almost 37 countries. Baste calls it a niche market saying, “The kind of machines we make compete on quality with European manufacturers.” The company exports to Asia (excluding China) and Europe but still hasn’t cracked the US market.

Technoshell offers a wide range of printing and packaging solutions to beautify products and packaging
Technoshell offers a wide range of printing and packaging solutions to beautify products and packaging

Technoshell has over 130 high speed cap stamping machines. “For the auto industry, we are the approved vendors for Bosch and Samsung for their stamping machine applications. In cosmetics, 90% of the Fair and Lovely caps are being stamped on our machines.” The company’s direct customers include label manufacturers, contract manufacturers and packers for companies such as Garnier, HUL, Godrej, Samsung, and several other cosmetics, pharma, and consumer product players.

The highest accuracy at an unmatched price

According to Baste, Technoshell and B&R came together initially for the hot foil stamping machines for tubes. Speaking of these, he confidently and credibly asserts, “We have higher speeds and better machines whose process accuracy is unmatched anywhere. The kind of accuracy we give for hot foil stamping machines is equal to the best that anybody gives in the world.”

By using B&R’s hardware and software, including its vision systems, Technoshell can meet the requirement of the most advanced customers and remain at the leading edge of automation, including IoT implementations that are the next big thing in any manufacturing or production process. “The features that we are offering with B&R are not there in any other machine. For example, the highest level of camera integration with the B&R programmable logic controller (PLC). The speeds of image processing and the reaction time are the fastest presently available because of B&R’s deep integration with the PLC. With these highly integrated camera systems, we were also able to bring down the equipment’s cost. Therefore the price at which we are giving high accuracy and automated features are unmatched in the whole world.”

Tube Hot Foil Stamping TSMglitter 60 – Very high precision Tube Hot Foil Stamping Machine designed to decorate plastic tubes & sleeves at speeds up to 60 per minute.
Tube Hot Foil Stamping TSMglitter 60 – Very high precision Tube Hot Foil Stamping Machine designed to decorate plastic tubes & sleeves at speeds up to 60 per minute.

Technoshell uses B&R’s servo motors, stepper motors, cameras and vision systems, and its industrial PC in its machine. Furthermore, B&R’s mappView allows uploading manual and training videos on the PLC itself. Baste adds that with his in-house design team and the B&R controller, Technoshell is proud to be among India’s two or three companies that use B&R’s latest technologies, such as its camera and vision systems. “This is the reason we can stand next to the latest European machines. A European company can sell our machines along with their machines as a team.” And this often happens when the European salesperson confronts a unique request that only Baste’s company can supply.

Nikhil Baste, director, Technoshell Automations
Nikhil Baste, director,
Technoshell Automations

Baste further explains that the camera helps register the stamping or graphics precisely where required in automated machines. “For tube hot stamping machines, two accuracies are usually measured – the radial accuracy where the tube rotates and axial accuracy. You need to register printing into both dimensions. Our accuracy for the machine is +/- 0.1mm axially and +/- 0.15 mm radially. It is also the best level of accuracies that such machines can give anywhere.”

Industrial IoT

Today’s factories require machines with Industrial IoT features for both operation and remote maintenance. Technoshell has been offering such advanced solutions to its customers. “Our focus has always been on technology, and we can offer all these next-generation features in our machines if our customers ask for it. Although in India, most of our customers so far do not ask for IoT, they need remote diagnostics for maintenance purposes, and MIS reports.”

Baste is pleased with Technoshell’s relationship with B&R and openly says that he has never faced any issues with its technology or products. “In case something arises, their application engineers, who are well-versed with the technology, can correct it very quickly.” Although he agrees that selling his machines in India with B&R’s PLC is challenging, he is satisfied since, with B&R technology, Technoshell can produce world-class leading-edge products with the latest automation.

Panel PC 2100 runs B&R’s Windows-based real-time operating system, ARWin, and provides the robustness and determinism needed for industrial applications
Panel PC 2100 runs B&R’s Windows-based real-time operating system, ARWin, and provides the robustness and determinism needed for industrial applications

Global recognition of the B&R technology used by Technoshell makes its machines eminently exportable. A world-class supply chain of components with absolute integrity and security makes the machines reliable and maintainable for export customers. Ultimately, it is possible to make a modern machine with leading-edge automation capabilities in India. However, it requires the focus, imagination, and persistence to invest in the design and manufacturing capabilities that Technoshell has.

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