Corrosion Prevention Products for Caterpillar

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Group Presentation
USA, India – 3 Units, Italy, France,
Thailand – Manufacturing and exports
to 25 countries globally

2. About Us
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! RDM RustX USA
! 12 Years old in USA
! More than 500 customers
nationwide
! All in house manufacturing of
products
! RustX HI Tech International – Largest
and oldest manufacturer of Polymers
inPunjab India
! 8 Group Companies in India
! Existence since 1983
! Tecnoprimaf RustX Italy
! Bucher RustX France
! Tech Store RustX Thailand
! Mercamer RustX Finland

3. q RDM RustX USA – 60,000 sq ft
q Manufactures VCI packaging rolls,
bags, sheets and custom printing
available
q Slits VCI papers into rolls and
sheets
q Holds stocks of various oil grades
q 800 employees globally
q 10000+ customers globally
q 30+ Oem’s
q 20+ customers in steel mills
q Patents and trademarks in various
product technologies
q Reach, ROHS approved
q Presence in 25 countries globally
RDM RUSTX LA,
USA

4. ! Other plants
! Italy 65000 sq ft
! Thailand 25000 sq ft
! France 25000 sq ft
! Finland warehouse 80,000
sq ft
Global Sites
4
North India Plant 150,000 sq ft – 30 year old facility
Delhi Plant 50,000 sq ft, 3 years old Mumbai Plant 65,000 sq ft – 8 years old
Corporate Office Space – Upcoming by Nov 2014

5. q Jaz Manak
q Chairman – RDM RustX USA
q Sid Sareen –Director Technical
q Honors degree holder in Polymer and Chemical Engineering Australia, EE – Harvard - USA
q Mukul Sareen – Director Business Development
q C.Knoop, Australia – Technical Assistance and Chemical Suppliers
Promoters
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6. Our Values
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Integrity Flexibility
Respect Innovation

7. Clients

8. Steel Mills
POSCO

9. Claas Renault–Supplying for
packaging and vendors for
over 10 Years
Tractors
New Holland – Spare
parts, exports of CBU,
SKD, CKD
Mahindra – 25,000 tractors
per month
SONALIKA - Spare parts,
CBU, SKD, CKD, Lubricants
and Washing Medias
Messey Ferguson–
Simpsons – Packaging for
engines and parts
Same Deutz– Complete
Packaging Solutions

10. Trucks
Volvo – Supplier for parts, engines, bodies
and sole vendor in many units across India
Eicher – Supplier to all major vendors for
rustxoils, packaging and lubricants
Mahindra Navistar – Suppliers to parts
manufacturers for exports from India to USA
TATA – suppliers to various divisions
making parts, vendors and for exports

11. Bikes
Suzuki – All CKD and SKD exports packed
and supervised
Yamaha – All CKD and SKD exports
packed and supervised
Bajaj– All vendors apply
RustX oils before
despatch
Honda– All CKD and
SKD exports packed
and supervised
Ducati– All parts
packed in India are
exported to Italy in
RustX

12. q Volvo Eicher Power Train= 100% Share
q Suzuki Maruti Cars = 100% Share
q Slumberger = Major share in some countries
q JCB = Major share in some countries
q Caterpillar Aus, India and others = 100% Share
q Honda MSI = 100% Share
q Suzuki Motorcycle = 100% Share
q CLAAS Renault I Ltd. = 100% Share
q Yamaha I Ltd = 100% Share
q New Holland I Ltd = 100% Share
q Mahindra & Mahindra = 100% Share
q Mahindra Navistar Project = 100% Share
q Volvo E Commercial = 100 % Share
q International Tractors Ltd = 100% Share
q Tata Auto Components I Ltd. = 100% of TACO Vendors
q Ashok Leyland
Business
Share with
OEM’S

13. AQUAFLUSH
VCI Anti Corrosion products
& Industrial Lubricants
Automotive Lubricants
Industrial Cleaning Agents
Moisture Control Desiccants
Brands

14. Rust-X provides a TOTAL solution
VS
Multiple Suppliers causing Incompatibility
Solutions
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Metalworking Washing
Aquaflush
Rust Prevention VCI Packaging
Industrial
Lubricants
RP Oils
Aerosols
Plastics, Papers etc
Desiccants
Rust Removal
Neutrasafe
Neutralizer

15. Packaging in VCI
VCI Works By
q Evaporation & De-activation of
moisture
q Multi-molecuar film onto the metal
q Altering the pH
q Passivating the electron flow
Proprietary VCI
Technology
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Fe2O3 Fe3O4 Fe Fe Fe Fe Fe
SMP Technology
Speedy Moisture Passivation
q 30 second formula vs 12 hours of
competition to make pH of packaging
alkaline (live test available)

16. q The Myth
q VCI works like a sponge to absorb moisture
q VCI is harmful to environment
q VCI is carcinogenic
q Truth
q VCI reacts with moisture to form a bond that is non reactive with Iron
q RustX products are Reach approved and ROHS compliant
q RustX products are recyclable
Lets squash
the MYTH

17. Trademark and
Patents
17

18. Papers Plastics VCI Emitters
ROHS
Compliant
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19. ECO
RUSTX
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¨ Reach approved VCI products
¨ Ecologically and biologically
friendly corrosion prevention
chemicals
¨ Non carcinogenic chemicals
¨ Easy disposal
¨ Minimal consumption

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Equipment
3 Layers vs 1 Layer Plant

21. Sources of
Corrosion
CORROSION
VENDOR
SUPPLIES
DURING
MANUFACTURING
DURING
STORAGE &
EXPORTS

22. ¨ Corrosion during Supplies
¨ Improper Packaging &
protection
¤ Carefree attitude –
¤ Responsibility till gate
syndrome
¤ Cost Issues
¤ Concealment of
corrosion –
¤ paints, coatings, grinding, rust
preventives etc.
Vendor
Supplies

23. ¨ Corrosion in Vendors
Manufacturing process
¨ Shipping in open bins
¨ No use of Rust Preventives
¨ Lack of packaging
knowledge
¨ Poor handling by
transporter
¨ Exposure to rainfall
¨ RESPONSIBILITY TO
GATE syndrome
Incoming
parts

24. Corrosion During
Manufacturing
Water
based
washing
process.
Coolants
after
machining
Moisture
retention
after
casting
Leak
testing
under
water

25. Corrosion After
machining or
washing

26. q Lack of knowledge of packaging
q Poor Storage Facilities
q Exposure to Rainfall or Acidic
Environments
q Irregularity of storage periods
q Under-designed Packaging Solution
q Cost based decisions by suppliers
_________________________________
q Non Sea-Worthy Products
q Pressure on reducing packaging costs
q Knowledge issues
q Water based washing
q LCL Conisgnments subjected to
Rainfall

27. 1 Layer
Plant
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q Conventional Plant
q Single Layer Structure
q Less Tacky film due to lower
impregnation of tacky
additives
q Lower VCI Dosage
q Lower Elongation due to
lesser take up
q Lower production capcity
q Higher Water Vapour
Emission Rates
q Higher Oxygen
Transmission Rates
q Higher blow holes and
puncture points

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`Container Rain
• Where is your container on the ship?
• What is happening inside the container?

29. Permeability

30. Container
Rain

31. q Co Ex Plant
q Outer Layer
q High quantity of strengthening
polymers
q High corona treatment for better
printing adhesion
q Middle Layer
q High moisture and oxygen
barrier polymers that also give
better strength and elongation
q VCI Additives for appropriate
bleeding to the inner layer
q Inner Layer
q VCI Additives in high proportion
q High tacky additives
Co Ex Plant
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32. q Construction of Tuff Film
q Outer layer – Moisture
Resistant film with
printable surface
q Middle layer – High
Density Barrier H20 &
O2
q Inner Layer – VCI Film
q More VCI concentrated
on the inside and can
only MIGRATE
towards the wrapped
component
CoEx vs
1 Layer Film
Layer1
Layer2-Barrier
Layer3
q Adhesive is non
controlled and
bleeds more on
one side
q VCI film is
single Layered
q VCI can migrate
to both the sides
as there is no
High Density
barrier
1- Layer filmCo Ex film

33. Pores
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1 Layer cast film has higher permeability of
moisture and oxygen compared
to a CO Extruded film
1 layer Co-EX Films

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Complete Knock Down (CKD)
Semi Knock Down (SKD)
Complete Build Unit (CBU)
Engine Packaging Solutions

35. All CKD, SKD, CBU
packed by RustX
Oils, VCI Packaging,
Desiccants , Emitters
CKD Packaging
at Suzuki

36. Heavy Equipment engines in RustX VCI, Oils and Desiccants and Emitters
Engines
VCI SMP Action starts within 1-5 minutes V/S 12 Hours of nearest competitors of placing the engine on pallet
(2400% improvement).
Neutralizes the shop floor humidity stuck in the packaging very quick
Can be checked using Red Litmus Solution

37. Long Block Dry
Packing
Step 1 Step 2 (Wrap with VCI non Woven sheet) Step 3
Step 4 (Place in VCI Pallet Bag) Step 5
5 years
Corrosion
Prevention
Dry
Packaging
Elimination
of oiling and
washing
process
before
painting
No Oil yet
excellent
protection
Step 8 ( Raincoat Bag) Global Team
Step 6 ( Desiccants + Emitter Combo)
Step 7 ( Heat Sealing)

38. q Aluminum Foil Packaging for
Heavy machines
q Spray RP Oil on the non
painted parts
q Add Desiccants and Emitters
q Heat Sealing
q Vacuuming
Aluminum
Barrier Film
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q Only manufacturers in
the world to provide
Aluminum Foil with VCI
in the inner layer
q No extra VCI film or
papers required before
using Aluminum Film
q Saves at least 30% cost
and time.

39. Shrink
Packaging
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q Shrink Packaging for Heavy
machines and equipment's
q Spray RP Oil on the non
painted parts
q Add Desiccants and Emitters
q Heat Shrinking
q No Vacuuming Required
q Only manufacturers in
the world to provide 3
Layer shrink with outer
white and inner blue with
VCI
q No extra VCI film or
papers required before
using Aluminum Film
q Saves at least 30% cost
and time.

40. q Step 1 Dress the poly bag to individual
fitment
Crankshaft
Packaging

41. q Place the bottom fitment ( 1st Layer ) and dress the VCI
bag over the fitment
q Place 3 parts in to the given slot ( Refer the images )
q Seal the VCI bag properly
Step 2

42. • Put the another fitment dressed with poly bag & Dress the common
VCI bag from out side
• Repeat the same up to 3rd Layer
• Seal the VCI bag properly
Step 3

43. q Strap the complete pallet with Pet strap
Step 4

44. q Place raincoat cover and ready for export
Step 6

45. For open
storages

46. q TUFFPAULIN - HIGH STRENGTH UV PROOF COVERS
Tuffpaulin

47. q Heavy equipment packaging
Tuffpaulin

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Castings
Forgings
Sheet Metal Parts

49. q Process
q Place VCI Bag in pallet
q Place support separators of Styrofoam, wood or corrugation covered with plastic
q Place components after oiling with RustX VCI Oil
q Heat seal the bag
Forgings / Castings
Master
Packaging
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50. q Advantages
q No individual packing of big parts
q Dry to touch oils , so no cleaning required before assembly
q Engine oil compatible rust prevention products – No contamination
q Saves time of packaging and un-packaging

51. q Forgings and castings
packed in VCI Paper or VCI
Plastics
q Placed in VCI Master bags
q Place desiccants and
emitters in pallet
q Heat the Master VCI bag
Other
Packaging's
q Provides long term corrosion prevention of upto 5 years
q For parts requiring custom packaging, custom vci bags
with or without zip available

52. Rust
Removers

53. q Observe the rust being removed and extracted into the liquid by the
q Changing colour of the liquid from transparent to yellowish brown
q 5-15 minutes required to convert complete corrosion
Rust Remover
used on
Castings

54. q 2mm thick steel after
Rust
Remover

55. q 2mm thick steel before
Rust
Remover

56. q No effect on Copper only the rust is
removed within 3-4 minutes
Rust
Remover

57. q 6 month old component
q Rust Removed in 3 minutes
Sheet Metal

58. q Holographic packaging for spares
Spare Parts

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Steel Mills
Coil Packaging Automated
Coil Packaging Manual
Sheet Packaging Manual
Steel Rods Packaging

60. Automated Coil
Packing using
VCI Stretch
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61. 1. Cross Linked Polymers for Higher Tensile Strength
Advantages of
RUSTX Films
2. Highly tacky stretch films for higher adhesion
Fe
4.) Co – Extrusion Film for better elongation and
strength
Layer 1
Layer 2 - Barrier
Layer 3
3. Patented SMP VCI Technology for upto 5 years
protection

62. Demonstrable Proprietary
technology provides higher strength
in low gauge films
q Type of Polymers used distinguish a film
q Cross Linking increase functional strength
q A film made on a Co Ex plant is 30% stronger than
made on 1 layer plant or cast line
q Better polymers with lower MFI are used to
strengthen a film
q VCI additive in the inner film maintain a ph of 8-9
inside the packaging
q Tackiness on both outer and inner enable better
adhesion of the film layers
q High elongation up to 900% results in lesser
tearing at the edges.
Specialty of
RustX Films

63. Multi Colour
Printing
q RustX films can be printed to upto 6 colours on roto gravuere machines
q All printing is done free of cost
q I.E. make your brand visible to many people

64. q Moisture during transportation –
100% RH with Temp of 45 - 48 C
q Breathing of the Packaging –
Changes in Temperature & Volume
of Air
q Removal Of Oil from the surface by
absorption
q Absorption of Humidity or water
retention by Interleaving Paper
q Rainfall during transportation
q Improper Storage Conditions
Causes of
Rust
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65. q Snow causing seepage of water inside
the coils
q Poor tacky adhesives can lead to gaps
q Poor VCI is a major cause of non neutral
environment in packaging
q Rain Water, water at ports or sea can
seep through the edge of protectors
Only a good quality tacky
stretch can result in tightly
wrapped coil
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Causes of
Rust

66. q Poor Stretch wrapping causing moisture to go inside
packaging
Causes of
Rust
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Navy and Army

68. q VCI Shrink Packaging with outer white and inner VCI Shrink
Aircraft and
Marine
Preservation

69. q VCI Zipper pouches in LDPE and Aluminum Bags
q Ammunition without VCI protection
Ammunition
Packaging

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Cutting Oils
Rust Preventive Coolant Additives
Lubricants
Chemicals

71. q Water based cutting oil 5% in concentration to be used in CNC/VMC/HMC
Machines
q 6-12 months tank life
q Biocides present for good bacteria to eat bad bacteria to keep tank foul free
q Rust Preventives added for upto 7-15 days corrosion prevention after
machining
q More lubricity (oil viscosity 50cst) for better surface finish
q Low cost per gallon and cost per component
Cutting Oil

72. q Water based washing
q 3% conc in water
q Millipore values less than 2
q Heating may or may not be
required
q No corrosion for upto 5 days
after washing
q Non flammable
q Biologically friendly
Aquaflush

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74. Batch
Cleaning

75. RPA4500

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77. q Neutrasafe
q Neutral rust remover
q Non Acidic
q Safe for eco and bio
q Patented product
q Converts rust to metal in 5-10
minutes
q No mechanical action required
Rust
Removers

78. q Observe the rust being removed and extracted into the liquid by the
q Changing colour of the liquid from transparent to yellowish brown
q 5-15 minutes required to convert complete corrosion
Rust Remover
used on
Castings