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Inoxview
9
NOV 12
special
INDIA
the INOXPA newsletter
current situation and objectives
manufacturing plant
India
INOXPA in the world.
INOXPA in India.
There is a tendency for people to believe that the sole reason that companies decide
to internationalise their operations is to reduce production costs. Decentralisation is
seldom viewed as a means of improving manufacturing quality which could have a
positive impact on costs at the same time.
With its many years of international experience, INOXPA has demonstrated that the
search for new markets provides strong consumer guarantees and the company
now owns branches in 12 countries, comprising a network of more than a hundred
distribution networks worldwide. This represents a comprehensivemodel of competitiveness in which being competitive is not exclusively the result of offering the
lowest price but also investing in the design and production of a quality product
and with better service.
It is for this reason and as part of our commitment to quality that INOXPA has
started operations in India, and in this issue, we intend to explain what this new
manufacturing plant means for us and for our valued customers.
Inoxview special INDIA
current situation and future objectives
manufacturing plant
Current situation
Growth forecasts
In the 2000s, INOXPA started a slow but progressive slowdown of the production of pipe fittings and unions to outsource this
production to Asian countries. Ten years later the company changed its strategy, adapting to the new market needs and, faithful
to its commitment to quality and service, restarted it’s own manufacturing of these components,but now in its new facilities of
INOXPA INDIA.
In this new production plant in the Asian continent INOXPA is able to produce and guarantee a competitive end product of
optimal quality by implementing in the production and quality control processes the same guidelines that INOXPA has used for
the past 35 years, and directly control production and distribution. At the same time, the quality standards are maintained but
with lower production costs, thus allowing the company to access new markets.
The short term growth forecasts for the INOXPA INDIA plant are:
• Expand the facilities by 2800m2 to a total of 7.000 m2 dedicated exclusively to production.
• New pipe fittings manufacturing line.
• Incorporation of 4 new CNC machines (1 machining centre + 3 CNC lathes with automatic loading system).
• Expand the workforce to 150 employees, of which 105 are direct production staff.
Features of the production plant INOXPA INDIA:
Total area of the facilities: 4300 m2
3 production lines:
• Machining line: 16 CNC machines: 3 machining centres, 7 double-head lathes with automatic loader and 6 CNC lathes.
• Cold forming line: Triple action 400-200-150 mT hydraulic press.
• Assembly and control.
• 118 workers, of whom 80 are direct production staff.
• Creation of a Product Development and Innovation Department.
• Consolidate the entire production of the following product lines:
- Single seat multiway valves
- Filters
- Hyginox and Estampinox centrifugal pumps
- Pipe fittings.
Currently manufactured products:
Butterfly valves, ball valves, check valves, overflow valves, pneumatic actuators, and some
pump components.
Installed capacity for the manufacturing of +
150,000 valves and + 10,000 pumps.
Quality and traceability
Objectives
The goal is simple: to be able to consistently offer the product required by our clients at a competitive price and with the guarantee
of INOXPA.
One of INOXPA’s main concerns is to have total control of the manufacturing process of the products marketed; from the purchase of
the raw materials to the delivery to the customer. In order to achieve this, the following structure is required:
Production centre: for the manufacture and assembly of the basic lines offered in the INOXPA catalogue, such as valves (butterfly,
ball, overflow, etc.), centrifugal pumps (Hyginox and Estampinox), as well as pipe fittings and unions.
Group Logistics Centre for the Near and Middle East areas as well as South-East Asia, with a special interest on the ASEAN countries
(Association of Southeast Asian Nations).
the INOXPA newsletter
The products manufactured by INOXPA INDIA are made from
selected raw materials, from first tier suppliers, which meet all
composition, manufacturing quality and traceability standards according to the international specifications and certifications.
The traceability of the materials is maintained throughout the manufacturing process, up to the finished product.
At the end of the production process, the products are tested.
INOXPA INDIA is INOXPA
INOXPA,
S.A.
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the INOXPA newsletter
India
Geographical
location
Representative products:
Butterfly valve
A particularly significant product for INOXPA is the butterfly valve.
INOXPA INDIA is located in Pune, in the state of Maharashtra.
Pune boasts an excellent infrastructure which meets the needs of the engineering
companies, and benefits from a favourable geographical location: Pune is only
150 km from Mumbai, the seaport and the international airport.
Furthermore, Pune has its own airport, which has links to the major cities like
Delhi, Ahmedabad, Calcutta or Chennai and Bangalore, and which provides 2
international flights to Dubai and Frankfurt.
The largest OEMs and related engineering groups have been based in Pune for
many years already. The corporate headquarters of multinational giants such as
Volkswagen, TATA Motors, SKF, Atlas Copco, Kirloskar, Sandvik Asia Limited, and
Mercedes Benz are also located in Pune.
General characteristics:
• Design complies with the requirements of the food processing industry.
• Compact and robust valve.
• Butterfly disk and half bodies are made from AISI 316L stainless steel forgings.
• Internal surface finish: Ra ≤ 0,8 μm.
• Low pressure loss.
• Low operating torque.
• Various types of easily interchangeable handles and pneumatic actuators available.
• Traceability of components.
• The gasket material complies with the specifications of the FDA regulations.
LVB.
Mixproof double
butterfly valve
with leakage detection
• Double safety system.
The two butterfly disks
share a common mechanism with a single actuator.
• The products on either
side of a closed valve
cannot mix as they are
always separated by a
safety chamber with leak
detection that prevents
accidental mixing in case
of gasket failure.
Sandwich type
butterfly valve
• Flanged connections.
• Design allows easy installation or removal of the
valve without the need to
separate the pipes.
• Welding to the pipeline
does not require complete
valve disassembly.
MBV.
Multiway double
butterfly valve
• Two butterfly disks are
actuated simultaneously
by a common actuator
(manual or pneumatic).
• Simple flow divert system, sanitary design
and easy to open system compared to other
3-way valves.
New C-TOP+
• We have completely
upgraded the internal
components and connection systems in order
to offer a more advanced
technological solution.
• It features the smallest
and most compact control head on the market
in its category.
Butterfly valve
production
process
What advantages does Pune offer?
Pune is the eighth largest urban agglomeration in India and the second largest in
the state of Maharashtra, which is the second most populated state in India, with
more than 110 million inhabitants.
The city, with a population of almost 5.5 million, is small in comparison to the
cities of Mumbai and Delhi which have more than 15 million inhabitants. For this
reason, transport and logistics can be more easily managed in Pune.
The cost of living and the overall costs of the company are lower.
Pune also benefits from an excellent climate all year round and has a reputation
for its highly regarded universities and technical colleges.
Features of the country
and the Hindu society
Firstly, Hindus are educated people, with advanced technical skills and a positive attitude, and with much willingness and dedication.
They are comfortable within the structures and hierarchies of an organisation
and they adapt easily to working as part of a team.
In India, a large percentage of young people possess intermediate or higher
education qualifications and they speak English fluently. Furthermore, there is
a large workforce available for the Technical and Engineering sectors.
India has a growing population and the main challenge it faces is to reduce
social and economic inequalities. Poverty continues to be one of the India´s
greatest problems although it has improved considerably since the country
became independent.
Current estimations suggest that 25% of the population live below the poverty line.
Continuing inflation is also a serious economic problem.
Packaging is one of the key elements to ensure maximum protection during transport and storage of the product. The new design is lighter and more practical
and offers distinct advantages with respect to protection and resistance. The box
material (corrugated cardboard) is recyclable and biodegradable, i.e. 100% environmentally friendly.
the INOXPA newsletter
the INOXPA newsletter
Inoxview special INDIA
manufacturing plant
Inoxview
India
special INDIA
Market features. Trading.
The Indian market has huge potential.
With a population of more than 1,1billion inhabitants and a lot of food to be processed, thereis
huge potential for growth.
The country has a good cash flow as a result of considerable foreign investment and the arrival
of manufacturing plants that supply the demand of Indian consumers.
Another advantage of this country is that it also serves the markets of Bangladesh, Nepal and
Sri Lanka as well as the markets of East Asia such as the Philippines or Indonesia. It should be
noted that there is almost no trading relationship between India and Pakistan and thus all sales
are diverted through Dubai.
Industrial sectors
Facing a highly competitive local market with a wide offering of products at very low prices,INOXPA
is gradually penetrating all of the industrial sectors. The pumps,valves, blenders, mixers and agitators have been well received
by some industries which are already demanding quality products and want to rely on suppliers that inspire confidence and
innovation.
Food-processing sector
The consumption of processed food is increasing, and this generates growth
in the food-processing sector. A large number of industrial companies are
diversifying and now focussing on processes within the food sector.
In India, food sector processes are in the
early stages of enormous expansion and
this sector will be the primary area of
focus over the next few years.
Cosmetics and pharmaceutical sector
Our range of products and prices are
of particular interest to the cosmetics
industry and the pharmaceutical sector.
Wine sector
The wine sector is another market
undergoing expansion in India, on a small
scale however. It is concentrated in the
area between Nasik and Bangalore. This is
a very premature market, with a history of only 8 to 10 years and it is still in the early stages of development.
There is a growing appreciation of wine amongst India´s upper classes, however, in Hinduism, alcohol consumption is not
viewed favourably and wines are expensive due to the high sales tax.
Dairy sector, derivatives and soft drinks
The dairy sector is also growing rapidly. Looking at the country´s size and population, India could be considered as a continent.
This has an impact on the type of business and market in each state. For example, the Government of Gujarat is promoting
the expansion of the dairy sector by means of public tendering. By contrast, other states, with fewer dairy farms, are offering
assistance with the reconstitution of milk.
Alcohol-free soft drinks represent another continuously growing market, amongst young people in particular.
Alternatives such as iced tea, milk drinks and energy drinks are especially popular.
The small size of the packaging is particularly remarkable. Containers of 1.5 and 2 litres are only available in certain places while
supermarkets and shops sell smaller containers, whether it be cans or cartons (Tetra Brik).
Companies like Coca Cola, Pepsi or Aje have several manufacturing plants in India.
the INOXPA newsletter
With 1,1billion
inhabitants
and a lot of food
to be processed,
there is huge
potential
for growth.
The marketing process is carried out from the headquarters in the Maharashtra state. The distribution
networkis expanding and the brand already has distributors in Gujarat and New Delhi.
Foreign investment and
the setting up of plants
supplies the demand of
Indian consumers.
The structure of the organisation is also growing and currently includes a technical sales team of seven
people, in addition to engineers, warehouse managers and assemblers, and the selection process for
technical sales persons is currently open in Calcutta, Mumbai, Gujarat and Hyderabad.
INOXPA has also created a microsite in India which supports the company´s trading activities
by providing information on specific products and services: http://www.inoxpa.in/.
Trade shows
Celebrations
DAIRY
UNIVERSE
GANESH
CHATURTHI
DASERA.
KANDE NAVMI PUJA.
INOXPA participated in the Dairy
Universe 2012 trade show (September
11-13) dedicated to the dairy industry
in Mumbai, India.
http://www.dairyuniverseindia.com/
On the 15th of September, the Hindus
celebrate the birth of the elephantheaded god Ganesha, son of Shiva and
Parvati. The Ganesha Festival remains
one of the most important cultural
events of the year.
Navaratri (nine nights) is one of the
most important Hindu festivals.
It symbolises the triumph of good over
evil. Navaratri is celebrated at harvest
time at the beginning of October
and, as the name suggests, lasts for a
period of nine days. The tenth day of
the festival is called Dasara (Dussera).
The Dairy Universe trade show
offers solutions for the production
and processing of dairy products,
ingredients and packaging.
Dairy Universe is the only event in
India dedicated to the dairy industry.
This trade show covers all aspects of
processing, packaging, storage and
distribution of dairy products.
FOODEX
INOXPA took part in the Foodex
2012 trade show (August 24-27) in
Bangalore.
http://www.indiafoodex.com/
Representations of the god are
displayed and worshipped during
a period of ten days. This year, the
festival took place between the 1st
and the 15th of September. Every
year, hundreds of Ganeshas are carried
through the streets. The processions
are accompanied by enthusiastic
dancers and musicians. Each step
taken by a Ganesha representation is
viewed as a promise of prosperity for
the inhabitants of the town.
For the first time, the Ganesha god
was carried through the INOXPA
plant which took place over a five-day
period. Ganeshais the supreme god of
wisdom, prosperity and good fortune.
The main purpose of this celebration
is to call upon Shakti, the Goddess of
power, so that she may grant wealth,
good prospects and prosperity for
humankind.
In modern day celebrations, factory
machinery has become an object of
worship.
This festival was celebrated on the
6th of October, 2011. It is the second
year that it will be celebrated in the
INOXPA INDIA plants. The machinery
will be worshipped and given a kind
of blessing.
the INOXPA newsletter
the interview
Marc Pons
Responsible for the China and India Implementation Project.
Marc Pons started working for INOXPA in January of 1996, just at the time
when INOXPA was entering its major expansion phase after the crisis of 1992.
Always associated with a technical environment, and with pumps and valves
in particular, he worked for many years in INOXPA (pumps), CANDIGRA (valves) and the united INOXPA Group. He was head of the Product Technical
Department for almost 4 years, until the end of 2009, when he became fully
committed to INOXPA´s industrial implementation project in INDIA and CHINA,
benefiting from his previous years of product experience.
Would you consider that the implementation phase has now been
completed?
Generally speaking, no. Right now there are several product lines in different
stages of development. On the one
hand, there are products which are
90% developed (such as butterfly valves and related accessories).
On the other hand, there are products
(or their components) at an intermediate stage of development, such as
the Hyginox and Estampinox centrifugal pumps.
INOXPA aims to make rapid progress
in the implementation phase over the
next 8-10 months and to complete this
phase by the end of 2013 for the initially planned products.
Have the logistics or communication systems proved to be complicated?
Regarding logistics, the first thing to
take into account is the fact that India
is a country under construction (or a
subcontinent as they themselves like to
say, and they are not wrong). In India,
new infrastructures are being constructed almost everywhere; but one of
the problems with this country, which
is part of its idiosyncrasy, is that they
know when to start but they do not
know when to stop.
Could you highlight a competitive
advantage of trading in the Asian
markets?
INOXPA´s strategic location, and the
fact that it is an EOU (Export Oriented
Unit), will make it the centre of operations for the countries of Southeast
Asia (particularly the members of
ASEAN), and of the Near and Middle
East.
An advantage of INOXPA INDIA is that
it is a production centre and it is therefore able to adapt the Group’s products to meet the specific demands
of these different markets, which is a
competitive advantage over other manufacturers.
Have these emerging markets been
affected or negatively impacted by
Europe´s current economic crisis?
Yes, but only partly. For these markets,
depending on the country of origin
you want to consider, Europe represents the main market for technological and manufactured products.
Luckily, there are currently two areas
of high economic growth on the global scale and, in these areas, it is the
internal market which acts as the main
driver of growth and this is also where
INOXPA has decided to project its future.
What are the company´s future objectives, for both the short and the
long term?
Considering the real sense of “starting
from scratch” that you have when you
arrive in this country, the potential for
growth is huge, provided that things
are done properly.
The energy of the people and their willingness to get things done is refreshing, although, in comparison to the
neighbouring countries and cultures,
this population is less ambitious and
they are more content with what they
have. This does not in any way detract
from their desire to progress as a people and a country.
The most important objective in the
short term is to consolidate the production of the initially planned product
range, to consolidate the organisation
in terms of personnel, and to achieve
full economic self-sufficiency.
The introduction and consolidation of
our products in the Indian market is
our challenge in the medium and long
term.
INOXPA SA
C/ Telers, 54
17820 Banyoles (Girona) SPAIN
Tel. +34 972 57 52 00 · Fax +34 972 57 55 02
[email protected]
www.inoxpa.com
Dipòsit Legal: GI.1381-2008
The plant is already four years old.
What stage of production is it currently at?
INOXPA INDIA started mass production
during the second quarter of 2010.
Now, just over two years later, there
are five different production lines.