Production of Storage tank

1. Yachiyo India Manufacturing Private Ltd.
By – Lalit Chambyal
1902857

2. Yachiyo India Manufacturing Private Ltd.
Name of the place
Yachiyo India Manufacturing Private Ltd.
Outline
Production of Fuel Tanks
Establishment
April, 2008
Operation Start-up
September, 2012
Production capacity
Plastic Fuel Tanks
250,000 sets/year
Location
SPL-1(C), TAPUKARA INDUSTRIAL AREA,KHUSHKHERA, DISTRICT ALWAR 301707,RAJASTHAN,
INDIA

3. Plastic Fuel Tank
HDPE 4261 AG – HONDA FUEL TANKS
HDPE HS213Q – MARUTI FUEL TANKS

4. TANKS TYPE
MONOLAYER (3 layer)
• HDPE (outer)
• Recycle
• HDPE(inner)
MULTILAYER (6 layers)
• HDPE (outer)
• Recycle
• Adhesive (outer)
• EVOH
• Adhesive (inner)
• HDPE(inner)

5. Material used and Percentage
Composition
• HDPE(4261AG)- High Density Polyethylene – (71-87%)
(Honda)
• HDPE(HS213Q)- High Density Polyethylene-(60-86%)
(Maruti)
• EVOH(F10103)- Ethylene vinyl Alcohol-(0.1-2.2%)
• LDPE(LJ400)- Low Density Polyethylene-(9.5-27%)
• Admer(GT-7)- used to clean the pipes and nozzles after
production

6. PRODUCTION LINE
• PRIMARY PRODUCTION line ( moulding of fuel
tanks)
• SECONDARY PRODUCTION line ( attachment
of child parts)

7. PRIMARY PRODUCTION LINE
RAW MATERIAL (HDPE,LDPE,EVOH,Admer etc)
Raw Material is stored in pre-assigned place and transferred to the storage tanks according
to the requirement of the production.

8. LDPE Storage tank HDPE storage tank Recycle Material Storage
tank
Each type of Raw Material is filled in a separate storage tank, from the storage tanks
material is taken out by the Moulding Machine according to composition set for the
production.

9. EVOH Storage tank

10. MOULDS
Moulds are used for casting of fuel tanks,
Moulds of different shapes and sizes are used in casting of Fuel Tanks for different
Models of different companies

11. Moulding of fuel tank on Moulding Machine
A high pressure air is used to cast fuel tank.

12. Moulding of fuel tank on Moulding Machine

13. Storage area for finished product of PRIMARY PRODUCTION LINE
Casted Fuel tanks are stored in a Storage area.
Fuel tanks are stored in storage area at least for 48hrs then after they are transferred further
to the SECONDARY PRODUCTION LINE for the installment of child parts.

14. Child parts such as BREATHER NECK, FILLER NECK, FUEL GUAGE etc are installed in the
SECONDARY LINE using plastic welding technique .
A Temperature of 150◦C-200◦C is maintained for welding of child parts.
Child parts are installed using Fully Automated Machines/ Robots.
SECONDARY PRODUCTION LINE

15. Random fuel tank from the SECONDARY PRODUCTION line is take out by the quality
control department for the quality check.
3 Tanks per batch are inspected and checked by the quality control department.
1st tank is taken out at the starting of production of the batch, 2nd is taken in the
middle and 3rd is taken out at the last, for the quality check.

16. Quality tests such as
1) Penetration test
2) Flower test
3) Tensile test
4) 3D measurement test
5) Welded joint inspection
are done by the quality control department using various machines

17. Machines used for the profile inspection of the fuel tank

18. Profile of the fuel tank ( welded joints)

19. Machines used for the test of tensile strength and weld-joint strength .

20. The batch of fuel tanks cleared by the quality department is further
transferred to the store department, store department further dispatch
the stock to the customers.
STORE DEPARTMENT use formula of
FIFO
(First IN First OUT)
For the maintainace of stock