Texmaco

Texmaco | UGL 1

UGL’s industry leading Joint Venture with Indian based company Texmaco provides cost effective, high quality, high precision, steel fabricated components for industrial and equipment manufacturers.

Established in 2010, the JV combines the strength and experience of two engineering powerhouses and offers clients the flexibility to fabricate a wide variety of innovative solutions across multiple sectors.Clients’ benefit from cost reductions in component supply, the flexibility to produce a wide range of fabricated products, a production capacity capability that caters for large volume orders and greater reliability through high quality fabricated components delivered through an advanced production facility that employs the most advanced technology equipment.

For the rail sector, product lines include bogie frames, cabs, platforms and headstocks for passenger and freight rolling stock (diesel electric locomotives, electric locomotives, electric multiple units, coaches and wagons), and flat packed container and other specialist rail wagons for both Indian and international markets.

This fully integrated, high quality, low cost manufacturing base is spread over a 20,000 m2 area, including a purpose-built production facility located in Kolkata, employing approximately 400 dedicated staff and has the capabilities to meet any fabrication requirement where quality, precision, reliability, and repeatability are paramount.

At A glAnce• World class manufacturing centre for rail industry

components for freight and passenger rolling stock.

• Through the Joint Venture, UGL will achieve an optimal balance between local and overseas content with the objective of providing superior value to clients, at the highest quality standards, at a competitive price, delivered through an optimal supply chain.

• Deliver overseas content for UGL’s assembly production lines in Australia to realise lower cost on fabricated materials and components.

• A wide variety of solutions for fabricated components that support multiple sectors including oil & gas, construction, minerals & metals, aviation, shipping, materials handling, defence, water and power.

• Purpose-built fabrication facility for high tolerance, complex sheet metal and large boiler plate fabrication.

2 UGL | Texmaco

The benefits delivered

CREATING SUPERIOR VALUE THROUGH AN OPTIMAL SUPPLY CHAINUGL will achieve an optimal balance between local and overseas content with the objective of providing superior value to clients, at the highest quality standards, at a competitive price, delivered through an optimal supply chain. High quality overseas content delivered through UGL’s Joint Venture will realise lower cost on fabricated materials and components for UGL’s manufacturing assembly line in Australia. Combined with domestic market functions such as quality, design, testing and accreditation, UGL will continue to deliver world class rail assets at competitive prices which are customised to meet unique Australian standards and specifications.

FABRICATION THAT DELIVERS QUALITY OUTCOMES FOR CLIENTSUGL’s Joint Venture has been established to deliver high quality fabrication utilising the most advanced in-house workshop equipment and capabilities for optimised and cost effective fabrication solutions. The Joint Venture’s purpose built facility has been designed, mobilised and is now overseen by UGL personnel with over 10 years’ experience on a rotating basis onsite to ensure that manufacturing processes and quality assurance disciplines match its Australian operations. This is backed by field and welding qualifications and best in class quality control capabilities to meet and exceed the quality standards of clients in Australia and other developed country markets

All supplied material is third party tested at the mill before despatch to UGL’s facility and all material equivalency is approved by a metallurgist with Design Authority within UGL.

COMBINING THE STRENGTHS OF TWO RAIL MANUFACTURING LEADERSBoth UGL and Texmaco have consistently responded to challenges and opportunities with innovation and client driven solutions. With the extensive knowledge and experience of the two organisations combined and available under UGL’s Joint Venture, clients receive turnkey fabrication solutions that provide peace of mind.

UGL’s business evolved from the strength and experience of Australia’s oldest rail sector company, namely A. Goninan & Co, which has a long and rich history dating back to 1899. Today UGL is Australia’s pre-eminent diversified rail service provider covering manufacture, maintenance and operations of locomotives and passenger trains and systems.

Texmaco was established in 1939 and has developed into one of India’s leading engineering and manufacturing companies. Texmaco has consistently been a top performer in the Indian railways industry and has stood out as the market leader for more than 50 years. Texmaco was selected as UGL’s Joint Venture partner for its AAR accreditation and proven track record for delivering high quality, value for money fabricated componentry to Australian customers, including Wabtec bogies. One out of every four freight cars running on Indian railroads is a product of Texmaco. These freight cars comprise both conventional and custom-built wagons catering to specialised products such as petroleum, chemicals, cement, and alumina.

Texmaco | UGL 3

The facility boasts the latest in steel manufacturing technology including:

• Koiki high tolerance plasma machine with second head and bevelling capability

• Plate blasting and straightening facilities

• CNC cutting machines including laser, plasma and oxy

• Laser guided CNC presses – 105T and 500T

• IGM robotic welders

• Semi-automatic, water-cooled MIG welders with routine calibration

• Bridge mill machining centre

• Stress relieving furnace

• A variety of heavy lift facility cranes

• All-weather enclosed production line, blasting and painting facility

Fabrication capability

4 UGL | Texmaco

World class equipment

Airless plate blasterMeCShoT BLASTING eqUIPMeNT PVT LTD

• Airless shot blasting machine used for blast cleaning and de-scaling of carbon steel plates prior to fabrication processing

• Processing of carbon steel plates up to 10m long x 2.5m wide in thickness range 5-40mm

• Cleaning steel plates by shot blasting prior to fabrication processes. Improved quality and appearance of subsequent parts

Laser cutter BySTroNIC LASer AG

• Large format 4kW CO2 laser cutter

• Processing of carbon and stainless steels as well as aluminium in material thickness from 1-20mm. Maximum plate size is 2.5m wide x 6.5m long

• High quality and precision cutting of plate profiles and holes prior to fabrication processing

Plasma cutter KoIKe SANSo KoGyo Co LTD

• Dual gantry, multi-head plasma cutter with bevel cutting feature

• Cutting of plates from 5mm to 50mm thickness with bevel cutting at up to 45 degrees

• Profile cutting of parts for fabrication. Bevel cutting weld preparations.

Plasma robot IGM ROBOTERSySTEME AG

• 3D cutting of sheet, plate, angle, channels, tube or folded parts

• Cut depths up to and including 50mm

• Processing of ‘Weld Preps’ which could otherwise be a much slower ‘milling’ process. Also able to process structural sections such as angles, channel and tubes which cannot be handled by conventional plasma processing

Press brake - sml BySTroNIC LASer AG

/ BEyELER GMBH

• Sheet and plate bending for materials from 1 to 20mm thick and lengths up to 3.1m

• 150 tonne machine with 3100mm table

• High precision bending of sheet and plate due to advanced features such as; laser bend correction, automatic crowning, material thickness compensation combined with multi axis cnc control

Texmaco | UGL 5

Press brake - lg tandem BySTroNIC LASer AG / BEyELER GMBH

Welding fixtures TAL MANUfACTUrING SoLUTIoNS LTD

• Capacity: C44 & KAZ bogie frames, C44 platforms

• Manufacturing aids to assist with quality control during fabrication and welding

Welders MIG/MAG/TIGLorCh SChweISSTeChNIK GMBh

• Digital MIG/MAG twin pulse welding with TIG option

• Welding at 400A 50% duty cycle

• World class welding due to latest German digital technology

Welding robotsIGM ROBOTERSySTEME AG

• Robotic welding work cells

• Initially setup for locomotive bogie side frames and transoms. Alternative products can be processed through introduction of suitable fixtures.

• Automated welding processes via full integration of robot, welding machine and multi axis rotators

• Sheet and plate bending for materials from 1 to 20mm thick and lengths up to 6.2m per machine or 12.4m when operated in tandem synchronised mode

• 2x 500 tonne machines with 6200mm table - giving total capacity of 1000 tonnes at 12,000mm when in use in tandem synchronised mode

• High precision bending of sheet and plate due to advanced features such as; laser bend correction, automatic crowning, material thickness compensation combined with multi axis cnc control

6 UGL | Texmaco

World class equipment continued

CranesDeMAG CrANeS

& CoMPoNeNTS PVT LTD

• Various types of overhead cranes for lifting and materials movement

• Dual 15 tonne - heavy fabrication / despatch bays Dual 10 tonne - plate blasting shop Multiple 5 tonne - CNC / medium fabrication areas Multiple 2 tonne - light fabrication areas

• Handling and movement of sheet, plate, components, sub assemblies and finished goods

Air compressorsINGerSoL-rAND

/ UD MArKeTING PVT LTf

• Part of compressed air system which includes; multiple receivers and filters combined with desiccant dryers for all air and refrigerant dryers at particular critical points of use

• 160kW, 1025cfm, 8.5 bar, air cooled

• Provision of compressed air for blasting, painting, air tools and CNC machines

Shot blasting and painting line

MeCShoT BLASTING eqUIPMeNT PVT LTD

• An overhead conveyor system passing through six stations for the facilitation of: product loading, shot blasting, primer painting, finish coat painting, paint baking and product unloading

• Booth size suits products uo to: 12m long x 3.5m wide x 3.5m high. Overhead conveyor supports products: up to and including 5000kg (per station)

• World class blasting, priming and painting of various products in accordance with individual customer specifications

Bridge millNICoLAS CorreA S.A.

• Large format milling machine

• Table capacity of 25 tonne. Axis travel; x=6000 y=3800 z=10000

• Final machining of completed locomotive bogie frames

Texmaco | UGL 7

Forklifts - side loadBAUMAN S.r.L.

• Side loading forklift - diesel

• 10 tonne with 7000mm support provided by four tyne configuration

• Movement of long sheets, plates and manufactured items

Forklifts - std VoLTAS MATerIAL hANDLING PVT LTD

• Conventional forklift - diesel

• 3 tonne, 3 stage mast - 2750kg @ 4500 lift

• General material movements and container loading

Bandsaw INDo TeCh INDUSTrIeS PVT LTD

• Mitre cutting bandsaw

• 450x250mm cutting size with digital mitre angle control and adjustable 3000mm length stop

• Cutting of structural sections such as angles, channels and tubes

8 UGL | Texmaco

LOCOMOTIVE PLATFORMS

• Australian standard and narrow gauge locomotives

• Indian broad gauge locomotives and passenger cars

• other International locomotives and passenger cars

BOGIE FRAMES

• Australian standard and narrow gauge

• Ge Transportation’s global locomotive requirements

• Indian broad gauge locomotives and passenger cars

• other International locomotives and passenger cars

CABS & CAB STRUCTURES• Australian standard and narrow gauge locomotives

• Indian broad gauge locomotives and passenger cars

• other international locomotives and passenger cars

ELECTRIC MULTIPLE UNIT BOLSTERS AND HEADSTOCKS• Australian standard gauge bogie frames and bolsters

• Australian electric-multiple-unit headstocks

• Indian broad gauge passenger cars

• other International locomotives and passenger cars

WAGON COMPONENTS• Australian standard gauge iron ore

• Indian broad gauge container wagons

• All types of wagons and wagon components for global railways.

GLOBAL FREIGHT ROLLING STOCK• CIS, South America, Middle east

• Support tier one multinational manufacturers

GLOBAL PASSENGER ROLLING STOCK• Support tier one multinational manufacturers

GENERAL STEEL FABRICATION• Across water, power, defence, resources

(minerals & metals, oil & gas), aviation (aero) and transport & technology systems sectors

• off high way equipment

• Component manufacture of scale

• Industries requiring precision component manufacturing

• Niche markets

Products

Locomotive bogie framesfACILITy DeSIGN CAPACITy 450PA

Locomotive platform segmentsfACILITy DeSIGN CAPACITy 50PA

Locomotive cab setsfACILITy DeSIGN CAPACITy 50PA

Services

QUALITY MANAGEMENT• A quality Management Plan implemented by experienced

UGL personnel that ensures the delivery of consistent and repeatable high quality fabricated product

• Managed and coordinated specialist subcontractor services

• Structures and roles providing balanced activities for quality Management, quality Assurance and quality Control Disciplines

• quality risk assessment

• Defined regime for inspection, witnessing and monitoring

• qMS Audit model that delivers structured programs across business process and supplier management systems

• Continual improvement through proven methodologies and techniques

SUPPLY CHAIN AND TECHNICAL SERVICES SUPPLY• Procurement for new rolling stock sub assembly fabrication

• Logistics

REFURBISHMENT AND UPGRADES• engineering, planning, procurement, preparation and

execution services for product refurbishment and upgrades

• Managed and coordinated specialist subcontractor services

PROJECT DELIVERY• Project delivery of new fabricated components

• Lean Six Sigma practices

• Budget preparation, planning and management

• Management of sub-contract services

12 UGL Limited

www.ugllimited.com

UGL is a global diversified services company delivering critical assets and essential services that sustain and enhance the environment in which we live.

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