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GBT COMPOSITES TECHNOLOGY LTD
INTRODUCTION
2/10/2014
GBT COMPOSITES TECHNOLOGY LTD
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GBT COMPOSITES TECHNOLOGY LTD formed in OCT 2013 acquiring the know-how and
infrastructure from General Blade Technology Pvt. Ltd. Formed in 2009 at Baroda..
Our core business and expertise is to manufacture COMPOSITE components and toolings
(plug, mould and Support toolings)
We focus in the fields of Wind Energy, Automobiles, Aerospace, Defence, Mass- Transit
and others fields where we can add values by applying composite expertise and
innovations.
We have strengthened our knowledge, skill & ability in all the composite manufacturing
processes like RIM, HLU, RTM
All the above activities are carried in-house at our Baroda facility, where we can develop
the entire product life cycle from Design to Delivery.
Our core team is constituted by very rich experience in composites and electro
mechanical tooling’s with a collective experience of above 50 years.
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EXPERTISE
FROM DESIGN TO MANUFACTURING TO PROTOTYPING TO SERIES PRODUCTION
•MOULDS AND PLUGS
•PLUGS WITH BASE STEEL STRUCTURE AND TOP SURFACE CNC MILLED
•MOULDS WITH INTEGRATED ELECTRICAL HEATING SYSTEM AND WITH HIGH VACUUM
INTEGRITY
•MOULDS WITH ALL KIND OF MARKINGS TO ENSURE CONSTANT LAY-UP OF MATERIALS
AND FINISHING.
•MOULDS ENSURING CTE TO ENSURE LONG LIFE OF MOULDS.
•COMPONETS MANUFACTURING
•JIGS AND FIXTURE TO PRODUCE COMPONENTS
•ELECTRO MECHANICAL TOOLINGS.
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INFRASTRUCTURE
PLANT SIZE : 52m x 16m
DESIGN : 7 SOLIDWORKS CAD LICENSES
MANUFACTURING SIZE: MOULDS AND PLUGS UPTO 50M.
PROJECT MANAGEMENT TOOL: DFSS (SIX SIGMA)
QUALITY MANAGEMENT: QCP (IN-COMMMING, IN-PROCESS & FINAL)
CERTIFICATION: IN PROCESS TO START TUV
DOCUMENTATION CONTROL: IN PROCESS TO START ERP
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MACHINERIES & EQUIPMENTS
PRODUCTION EQUIPMENTS:
Blower Bosch Make GBL 800E
Bosh Grinder GPO 12 CE for Buffring
Circular Saw Bosch Make GKS 190
Compressor with Motors
Grinder Machine Bosch Make
Hammer Drill Bosch Make GBH 4-32
Miter Saw Bosch Make GCM 10M
Orbital Sander 92x182 Bosch Make
Portable Heaters
Router POF 1400 AC
Skill Cut Off Saw Machine
Straight Grinder 27000 RPM GGS 27
Vacuum Pump RA 63
Welding Machines Esab RS 400
Weighing Scale 100kg Platform Type
Weighing Scale 50kg Platform Type
Puma Hydraulic Hand Pallet Truck
Semi Electric Stacker
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QUALITY EQUIPMENTS:
LVT Viscometer Brookfield Dial Reading
TQC Make Viscosity Din Cup Model with Nozzle VF 202
Wet film thickness gauges
Dry Film thickness tester
Muffle furnace
Hot air oven
Surface roughness tester-Mitutotyo
Gloss Meter
Verniers, micrometers etc
DESIGN
SOLIDWORKS CAD LICENSES(7 NOS)
DRAFT SIGHT
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PROPOSED INFRASTRUCTURE
SPACE: 200M X 160M (Very near to main roads which touches to National Highways for easy road transport)
PLANT BAY SIZE: 160M X 25M ( 4NOS SHARING WALL)
CERTIFICATION: GL
EQUIPMENTS:
-RESIN MIXING MACHINE
-ADHESIVE MIXING MACHING
-DSC
-PAINT SPRAY BOOTH
-AUTO CLAVE
-CNC MILLING MULTI AXIS MACHINE UPTO 10m
SOFTWARES:-COMPOSITE STRUCTURE FEA
-STEEL STRUCTURE FEA
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CUSTOMER LIST
DESIGN DONE IN-HOUSE
GBT-India support to
manufacture at clients plants
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COMPLETE DESIGN TO MANUFACRURING
OF TOOLINGS DONE AT GBT-BARODA
FACILITY
GBT COMPOSITES TECHNOLOGY LTD
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DESIGN DONE IN-HOUSE
CLIENTS MANUFACTURED TOOLINGS BY
THEMSELVES AT THEIR PLANT.
GBT PROVIDED SUPPORT VIA VISIT OR
WEEKLY TEL-CONS
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DFSS PROJECT MANAGEMENT
TG1
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TG2
TG3
TG4
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TG5
TG6
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ACHEIVEMENTS
1ST plug made in India using CNC milling technology.
1st to develop the mould whose tip can be exchanged to produced two different
lengths of blades and thus two different capacity blades.
1st to develop the mould to produce the single shot 9m blade.
We are kind of company to serve the complete solution from tooling design to
manufacturing, blade prototyping support in the countries like India, China, Korea,
Netherlands, USA, Brazil and Germany.
GBT is the only company India who has developed in-house development of
electrical heating system.
GBT is the only company in India who has developed in-house development of
vacuum system.
GBT is the only company in India to develop PLC based scada electrical and vacuum
system.
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DESIGN TO MANUFACTURING
PROJECTS DONE AT GBT-INDIA
Sr. No.
Customer
Project Description
Scope
Main highlights
1
Aeronautica, USA
26M Blade
Design and manufacturing for:Plug, mould and complete support toolings
-Main mould SS & PS
-Main shear web
-Aftweb
-Trailing edge girder-SS & PS
-V-Clip
-Balancing tray &
-Complete set of support toolings
CNC milled plug on tooling
paste
GBT vacuum system
2
Aeronautica, USA
26M Blade
Production manuals for blade manufacturing
-Installation and prototyping of blades at US
plant by GBT-India team
3
WES, Netherlands
7 & 9M tip interchangeable
mould
This mould was designed to
produce SINGLE SHOT blade
Design and manufacturing for:Plug, mould and complete support toolings
-Main mould SS & PS
4
SKYWIND
51m prefab moulds
Design and manufacturing for:Direct mould and complete support toolings
-Main shear web-LE
-Main shear web-TE
-Aftweb &
-Complete set of support toolings
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CNC milled plug on glass
GBT-India vacuum system
GBT-India heating system
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DESIGN TO MANUFACTURING
PROJECTS DONE AT GBT-INDIA
Sr. No.
Customer
Project Description
Scope
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SKYWIND,
Denmark
51m production manuals
Production manuals for blade manufacturing
-Installation and prototyping of blades at US
plant by GBT-India team
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Gamesa, India
G97i_Support tooling’s
Design and manufacturing for:-GBT-India vacuum system
-Blade root Turner
-Blade tip turner
-Blade carts-Root and tip
-Main mould working platform
-Main web gluing platform
-Blade internal heating system
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Gamesa, India
G97i_Production manual
--Complete set of production manual to
manufacture blades
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Gamesa, Spain
G114_52m prefab moulds
Design and manufacturing for:Plugs and Moulds for:-Main shear web-LE
-Main shear web-TE
-Sparcap-SS
-Sparcap-PS
CNC milled plug on glass
GBT-India heating
technology with scada PLC
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L & T, India
Trimming fixtures for
aerospace components
-Design and manufacturing for the trimming
fixture for an aerospace components
On going
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Main highlights
All the electro mechanical
application are GBT-India
innovatives and in-house
design and production
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DESIGN TO MANUFACTURING
PROJECTS DONE AT GBT-INDIA
Sr. No.
Customer
Project Description
Scope
Main highlights
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ENDURANCE, USA
Nacelle cover
Design and manufacturing of plugs, moulds,
support toolings and components
-Nose cone
-Spinner
-Upper-right
-Upper-left
-Bottom
-Hatch door
-Access door
Plugs and moulds
completed
1st set of prototyping
completed
2nd set of prototyping in
progress
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Renewtech, USA
10M blade
Design for plugs, moulds and support tooling
-Main mould SS & PS
-Hat stiffener
-Tip brake mechanism
-Balancing tray &
-Complete set of support toolings
On going
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GE, USA
30M sparcap mould
-Design for plugs, moulds
-In-house desing and manufacturing for
GBT-India heating system
-Installation and support at site
GBT-India heating system
technology
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BASF, Netherlands
Heating system
Design and manufacturing for heating
system
Installation and support at site
GBT-India heating system
technology
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PROJECT FLOW
RFQ
PROTO
PRIMARY
DISCUSSION
QUOTE
ORDER
FINALISATION
SERIES
PRODUCTION
DETAILED
PROJECT PLAN
INSTALLATION
PRODUCTION
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SECONDARY
DISCUSSION
PROJECT
EXECUTION
BUDGET
ALLOTMENT
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KICK-OFF
METTING
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ORGANISATION CHART
H.V.BENNUR
(MANAGING DIRECTOR)
Management Representative
SIVARAJ CHETTIAR
CEO
DESIGN
Sanket
PRODUCTION
QUALITY
Pradip Nayak
STORE
Dharmesh
PURCHASE
MARKETINB
WIND
Dharmesh Tandel
DESIGN ENGINEERS
NON-WIND
Sistu Prabhakar
ENGINEERS & TECHNICIANS
FINANCE
HR
LOGISTICS
QUALITY TECHS
ENGINEERS & TECHNICIANS
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ADMIN
Akshay
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BUSINESS DEVELOPMENT
CUSTOMER SUPPORT
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CORE TEAM
Key skills:-Design and development of plugs, moulds, support toolings and blades.
-Material selection for the tooling's.
-Project management from design , manufacturing to installation.
-Project execution within budget.
-Vendor Development and follow-up.
Sivaraj Chettiar
Achievements:-First time CNC milling of plugs in India.
-Single shot 9M blade with tip interchangeable concept.
-Perfect thermal expansion system in the prefab moulds.
Total experience of 12 years in the field of CAD/CAM/CAE, Plastic Injection moulds and
Wind energy.
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CORE TEAM
Dharmesh Tandel
Manf Leader
Sistu Prabhakar
Manf Leader
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Key skills:- Manufacturing of Composites Plugs, Moulds & Rotor Blades.
-Installation and prototyping and on Site Support,
-Manufacturing planning and material control and cost saving ,
-Manufacturing teambuilding skill Development,
Achievements:-Manf of plug made of wooden and steel structure, which was CNC milled on tooling paste and Glass
in two different project.
-Manf of single shot moulds
Total experience of 12 years in the field of Manufacturing of Wind energy.
Key skills:- Manufacturing of Composites Plugs, Moulds & Rotor Blades.
-Installation and prototyping and on Site Support,
-Manufacturing planning and material control and cost saving ,
-Manufacturing teambuilding skill Development
Achievements:Develop Hi gloss molds for high gloss product
Manf of plug made of wooden and steel structure, which was CNC milled on tooling paste and Glass in
two different project.
Manf of single shot moulds
Total experience of 11 years in the field of Manufacturing of Wind energy.
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COMPOSITE MATERIAL SUPPLIERS
GLASS/CARBON -FABRIC/PREPEG
SAERTEX
OCV
KUSH
ZOLTEK
AXON
ADHESIVES:
HUNSTSMAN
HENKEL
ELECTRONICS AND CONTROLS:
SIEMENS
RESIN:
MOMENTIVE
HUNTSMAN
ADITYA BIRLA
ATUL
ASHLAND
DOW
CORE:
DIAB
ARMACELL
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AEROSPACE WORKS
TRIMMING FIXTURES
-BY VACUUM HOLDING,
-TRIMMING WITH
ROUTUERS
-GUIDANCE HOLE FOR
DRILLING HOLES
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CORE STRENGTH HIGHLIGHTS
Plug milling on 5 axis CNC
Laser scanning for waviness & contour measurements
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CORE STRENGTH HIGHLIGHTS
Quality and Accuracy of Plug with CNC milling
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CORE STRENGTH HIGHLIGHTS
Complete frame and
working platform design &
manufacturing in-house
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CORE STRENGTH HIGHLIGHTS
Validation of frame design
Buckling analysis
Stress analysis
Displacement
analysis
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CORE STRENGTH HIGHLIGHTS
Electrical heating system-in house development for moulds
Tracing wire
layout design
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CORE STRENGTH HIGHLIGHTS
•Frame adjustment
•Heating system design
•Vacuum line with centre
tube for profile adjustment
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CORE STRENGTH HIGHLIGHTS
52m WEB AND SPARCAP MOULDS PRODUCTION
52M blade
Web in 2 parts
Web TIP
Cap mould being infused
Web ROOT
Cap in 2 parts
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CORE STRENGTH HIGHLIGHTS
NACELLE COVER PRODUCTION
USING UPR SYSTEM
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CORE STRENGTH HIGHLIGHTS
BLADE MANUFACTURING
52m PREFAB
26m BLADE
26m BLADE
56m BLADE
26m BLADE
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56m PREFAB
56m BLADE
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26m PREFABS
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CORE STRENGTH HIGHLIGHTS
ELECTRO MECHANICAL TOOLING’S
Root Air heating system
Vacuum control system
Root Cart
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Tip Cart
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CORE STRENGTH HIGHLIGHTS
Mould vacuum control
SCADA Screen shot
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CORE STRENGTH HIGHLIGHTS
Mould temp & vacuum monitoring
SCADA Screen shot
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CONTACT US
HEAD OFFICE:
413, Phase-II, GIDC Industrial Estate, Vatva,
Ahmedabad-382445, India. +91-70-65452678
WORKS:
Plot nos 547-548, Manjusar GIDC, Savli ,
Vadodara – 391775. India +91-02667 290183
Mr. H.V.BENNUR
Managing Director
[email protected]
+91-9825778877
Mr. SIVARAJ CHETTIAR
CEO
[email protected]
+91-9724465523
THANK YOU
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