Solutions
HEMSUN ENGG. INDUSTRIES delivers comprehensive Solutions, turnkey plant layouts, tooling design, and automation retrofits from our engineering headquarters in Gujarat. Explore service capabilities, machine specifications, and tooling integration below.
Working principle and engineering architecture
The execution principles behind Solutions follow a structured engineering delivery model: 3D CAD/CAM die design and FEA stress analysis, precision CNC machining, full FAT witness testing, PLC ladder logic and SCADA integration, on-site mechanical and hydraulic erection, and comprehensive operator training. Every machine frame is precision-welded from ultrasonically tested IS:2062 Grade B structural steel plate and stress-relieved to ensure long-term dimensional stability.
Our turnkey solutions integrate production line simulation, automated material transfer conveyors, robotic pick-and-place grippers, and real-time SCADA telemetry. Every tooling set is manufactured from vacuum heat-treated AISI D2 or H13 tool steel with mirror-polished cavities (Ra ≤ 0.15 µm), backed by complete cycle time benchmarking and CMM inspection reports prior to site dispatch. Furthermore, closed-loop proportional hydraulic controls and high-efficiency variable-displacement piston pumps ensure smooth acceleration and deceleration, preventing mechanical line shock during continuous multi-shift production cycles.
Types & Configurations We Build
Sizing and capacity calculations
Solutions covers complete manufacturing infrastructure delivery—from component feasibility review and 3D CAD/CAM tooling design to multi-press automated production line layout, electrical panel integration, on-site commissioning, and annual maintenance contracts (AMC). Engineered to maximize Overall Equipment Effectiveness (OEE) and eliminate bottlenecks across industrial stamping, moulding, and assembly lines. Our Dahegam manufacturing facility integrates structural fabrication, CNC machining, hydraulic power pack assembly, and control panel wiring under one roof to guarantee strict quality oversight and rapid delivery timelines for domestic and export clients.
Sizing & Tonnage Calculations:
Turnkey capacity planning calculates plant OEE, cycle time, and multi-press synchronization:
Formula: Annual Output (Units) = (Operating Hours × 3600 / Cycle Time in sec) × Cavity Count × OEE % × Yield %
Example: For an automated 4-cavity cell running 20-second cycles at 85% OEE over 6,000 operating hours, annual plant capacity is 3.67 Million precision parts. Total power demand is sized with a 1.25 safety factor to accommodate simultaneous multi-axis rapid approach strokes.
Technical specifications and machine parameters
| Parameter / Specification | Standard Range / Feature |
|---|---|
| Engineering Scope | Solutions (Turnkey Engineering & Lifecycle Services) |
| Project Delivery Timeline | 8 to 16 Weeks from CAD Sign-Off to Factory Acceptance Testing |
| Automation Architecture | Semi-Automatic to Fully Automated Robotic Production Lines |
| Quality Standards | In-House Batch Metrology / CE-Marked Electrical Components |
| Warranty & Support | Comprehensive 12-Month Mechanical & Hydraulic Warranty with AMC Options |
| Global Service Reach | Field Engineers Deployed Worldwide from Gujarat, India |
Material compatibility and engineering metallurgy
- Vacuum-Hardened Tool Steels: AISI D2, H13, and EN-31 tool steel for long-life multi-cavity dies and precision punches.
- Heavy Structural Steel (IS:2062): Stress-relieved fabricated frames, conveyor structures, and automated loading elevator gantries.
- Industrial Hydraulic Fluids: ISO VG 68 anti-wear hydraulic oils and high-temperature fire-resistant fluid circuits.
- Siemens & Schneider Automation: Standardized industrial PLCs, color touchscreen HMIs, and variable frequency drives (VFD).
Procurement and tooling selection guide
Evaluating turnkey engineering providers:
- Scope of Delivery: Ensure single-source responsibility covering machines, tooling, hydraulics, thermal piping, and automation.
- In-House Toolroom Capability: Verify manufacturer designs and CNC-machines die sets in-house with vacuum heat treatment.
- Global Commissioning Track Record: Partner with engineering companies that deploy field engineers for on-site erection and FAT witness runs.
- Spare Parts & AMC Support: Verify ongoing availability of replacement hydraulic seals, PLC backups, and technical support.
- Regulatory & Power Grid Compatibility: Verify electrical switchgear matches local 3-phase voltages (415V/50Hz or 380V–480V/60Hz).
Testing, inspection and global commissioning
HEMSUN ENGG. INDUSTRIES manages complete turnkey project logistics, seaworthy crating with internal VCI moisture barriers, on-site foundation anchoring, electrical cabling, hydraulic oil charging, pilot production runs, and maintenance crew training.
Frequently Asked Questions
What turnkey services does HEMSUN provide beyond component supply?
Turnkey plant engineering, hydraulic press fabrication, compression mold manufacturing, fixture design, installation, commissioning, and after-sales support for PTFE and powder molding facilities.
Can HEMSUN support export project documentation?
Yes. IEC-registered export workflows include commercial invoice, packing list, certificate of origin, and inspection reports required by international buyers.
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