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MIVEN MAYFRAN CONVEYORS PVT. LTD.

Contents

1.COMPANY BACKGROUND ............................................................................................... 2


2.COMPANYPROFILE ............................................................................................................ 3
3. INFRASTRUCTURE ............................................................................................................ 4
3.1 VISION ........................................................................................................................... 5
3.2 MISSION ......................................................................................................................... 5
3.3 OBJECTIVES .................................................................................................................. 5
3.4 PRODUCT PROFILE ...................................................................................................... 6
4. CHIP CONVEYOR ............................................................................................................... 7
4.1 MINI TOTE HINGE BELT CONVEYOR(MT10) ......................................................... 7
4.2 CHIP TOTE HINGE BELT CONVEYOR(CT-20)......................................................... 8
4.3 4 INCH PITCH HINGE BELT ....................................................................................... 9
4.4 SHORT PITCH SCRAPER ........................................................................................... 10
4.5 CT3 SCRAPER CONVEYOR ...................................................................................... 11
4.6 MAGNETIC CONVEYOR ......................................................................................... 12
4.7 SCREW COIL CONVEYOR ........................................................................................ 13
5. CHIP AND COOLANT SEPARATOR, FILTERS ............................................................. 14
5.1 CONCEP 2000 ............................................................................................................... 14
5.2 MAGNETIC SEPARATOR CONVEYOR ........................................................ 16
5.3 PERMANENT MEDIA FILTER .................................................................................. 17
6. CENTRALISED SYSTEM ................................................................................................. 18
6.1 CHIP PROCESSING SYSTEM .................................................................................... 18
6.2 COOLANT FILTRATION ................................................................................... 21
7. PRESS SCRAP AND SOLID COMPONENT HANDELING CONVEYORS
................................................................................................................................................. 23
7.1 SIX INCH PITCH HINGE BELT ........................................................................ 23
7.2 NINE INCH PITCH HINGE BELT .............................................................................. 24
8. MATERIAL HANDLING SYSTEM ......................................................................... 26
8.1 ROLLER CONVEYOR .......................................................................................... 26

DEPARTMENT OF MECHANICAL ENGINEERING Page 1


MIVEN MAYFRAN CONVEYORS PVT. LTD.

1.COMPANY BACKGROUND
Established in Cleveland (USA) by the ethnic German entrepreneurs
Meyfarth and Frantz in 1933, today Mayfran is a global leader in providing solutions
for scrap and coolant management and material handling in metalworking, recycling,
solid waste processing, and other applications. The company is an original outfitter
for machine tool manufacturers as well as machine tool users.
Mayfran’s products convey, filter, separate, shred, briquette and process
materials and fluids for the automotive, aerospace, consumer products, energy, steel
processing, solid waste, pulp and paper, medical products, heavy equipment and
related industries.
Mayfran produces worldwide at locations in the United States, Europe, Japan,
Korea, India and China. The customer service is globally networked via subsidiaries
and agencies. The group employs about 900 people worldwide and 300 employees in
Europe.
Since September 2012, Mayfran worldwide is part of the Japanese company,
Tsubakimoto Chain Group, Osaka, Japan.
In the year 2006 the renowned Mayfran international, started its subsidiary
company as a mavin mayfran convey in sirur family at Hubli to expand their business
through worldwide and with a aim of reduces the transportations cost.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

2.COMPANY PROFILE

Company Name : Miven Mayfran

Conveyors Pvt Ltd.Hubli

Address : Sirur Compound Karwar Road

Hubli - 580024 Karnataka, India.

Phone No : 0836-2212201-06

Fax : 2303265

Email : [email protected]

Year of establishment : 2006

Managing Director : Mr. Vikram Sirur

Product : Chip, Swarf, Scrap

Handling Conveyors,

Design, Manufactures

Sector : India, Private Sector.

Number of Employees : 250

ISO Certification : ISO 9001

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

3. INFRASTRUCTURE

Fig. 3.1-head office


Complementing our engineering expertise, the use of advanced manufacturing
techniques helps us produce high quality equipment. Using high precision equipment
such as CNC turning centre, CNC Vertical milling center, CNC bending machine,
state of the art paint booth etc., Miven Mayfran is geared to cater to the varying
requirements of a demanding market.
At Miven Mayfran ,quality is a way of life. An ISO 9001 company, we believe
that relentless pursuit of excellence is the only way to achieve customer delight
One of our core strengths is a 120 plus strong, skilled and motivated
workforce which being aligned towards a common vision of growth and customer
satisfaction, has executed several complex projects in record times.
One of the key areas of focus at Miven Mayfran is technology. Our design
department uses the advanced Solid Edge package for 3D modeling of our equipment.
This has led to considerable shortening of our delivery times and enhanced our output
quality.

DEPARTMENT OF MECHANICAL ENGINEERING Page 4


MIVEN MAYFRAN CONVEYORS PVT. LTD.

3.1 VISION
To be globally reliably reliable partner in providing solutions to all stakeholders.

3.2 MISSION
To provide globally highest standards in service, delivery and reliability by
identifying and understanding stakeholder needs and to continually improve upon
these for greater stakeholder comfort.

3.3 OBJECTIVES
Strictly maintain the time schedule.

Acquire, utilize and maintain machinery and equipment and keep in to good order

Obtain the best quality of raw materials and equipment.

Produced quality products

Provide proper and adequate service as to keep the flow of production smooth and
efficient.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

3.4 PRODUCT PROFILE

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

4. CHIP CONVEYOR
DEFINITION
A conveyor system is a common piece of mechanical handling equipment that
moves materials from one location to another. Conveyors are especially useful in
applications involving the transportation of heavy or bulky materials. Conveyor
systems allow quick and efficient transportation for a wide variety of materials, which
make them very popular in the material handling and packaging industries.Chip
conveyors are used to transfer broken crushed metal chips from place of machining to
the bin.

CHIP CONVEYORS FOR MACHINE TOOL


4.1 MINI TOTE HINGE BELT CONVEYOR(MT10)

fig 4.1- MT10 conveyor

These conveyors use a hinged steel belt moving inside a metal casing to
effectively remove metal chips and they come in four basic profiles Straight ( Style
A ), Inclined ( Style B ), Straight & Inclined ( Style C ) and Goose Neck ( Style D ).
The hinge belt surface can be plain, perforated or dimpled in accordance with
application requirement.
APPLICATION:
This light duty conveyor finds application in small machine tools due to its compact
design. It can handle long, short, curly chips, wet or dry that can be easily compressed
by hand. These conveyors can be applied on lathes and smaller sized machining
centers with a spindle horse power of 15 KW( Nominal ).

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

DIMENSIONS
Nominal Belt width :150 to 500mm,
Chain Pitch :31.75mm,Max. Length :5 to 10M.

4.2 CHIP TOTE HINGE BELT CONVEYOR(CT-20)

fig 4.2- CT -20 conveyor

These conveyors use a hinged steel belt moving inside a metal casing to
effectively remove metal chips and they come in four basic profiles Straight( Style
A),Inclined ( Style B ), Straight & Inclined ( Style C ) and Goose Neck ( Style
D).The hinge belt surface can be plain, perforated or dimpled in accordance with
application requirement.

APPLICATION:
These are medium duty conveyors and cover a wide spectrum of applications.
They can handle large quantity of long, curly, bushy chips wet, dry or hot. These
conveyors can be applied on machining centers, turning, milling, boring and
special purpose machines with a driving power of upto 50 KW.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

DIMENSION:
Nominal Belt width: 152 to 610mm,

Chain Pitch: 63.5mm,

Max. Length: approx. 20M.

4.3 4 INCH PITCH HINGE BELT

Fig 4.3- 4 inch pitch hinge belt conveyor

These conveyors use a hinged steel belt moving inside a metal casing to
effectively remove metal chips and they come in four basic profiles Straight (
Style A ), Inclined ( Style B ), Straight & Inclined ( Style C ) and Goose Neck (
Style D ). The hinge belt surface can be plain, perforated or dimpled in
accordance with application requirement.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

APPLICATION

These are heavy duty conveyors that can handle large quantity of long,
curly, bushy chips and find application in machines that generate heavy chips/
swarf as in wheel turning lathes. These conveyors are also used as collecting
conveyors over larger distances.

DIMENSION:
Nominal Belt width: 305 to 915mm,
Chain Pitch: 101.6mm, Max. Length: approx. 50M

4.4 SHORT PITCH SCRAPER

Fig 4.4- Short pitch conveyor

These are designed for handling small, powdery chips such as cast iron and
find application in machines/metal cutting operations that generate small/powdery
chips such as milling. They can handle wet or dry chips. When used for handling
wet ferrous chips , a magnetic deck can be provided to help arrest flowing of chips
with coolant.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

APPLICATION:

Metal cutting operations that generate short, coarse powder chips such as CI chips
generated during turning or steel chips generated during milling.

DIMENSION:
Nominal Belt width: 150 to 500mm,
Chain Pitch: 38.1mm

4.5 CT3 SCRAPER CONVEYOR

Fig 4.5- CT3 Scraper Conveyor

These are designed for handling small, powdery chips such as cast iron and
find application in machines/metal cutting operations that generate small/powdery
chips such as milling. They can handle wet or dry chips. When used for handling
wet ferrous chips , a magnetic deck can be provided to help arrest flowing of chips
with coolant.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

APPLICATION:
Metal cutting operations that generate small, short, coarse powder chips such as CI
chips generated during turning or steel chips generated during milling.

DIMENSION:
Nominal Belt width: 200 to 800mm,
Chain Pitch: 63.5mm

4.6 MAGNETIC CONVEYOR

Fig 4.6- Magnetic Conveyor

 Magnetic conveyor is widely used in broaching gear, hobbling gear, shaping and
milling machines.Handles ferrous swarf only.Plain sheet acts as an ideal separator
to filter ferrous fines from cutting oils.Magnetic Plain Sheet type conveyors use a
band of magnets that moves inside a watertight casing under a non-magnetic slider
plate. As the magnets mounted on endless chain moves, the chips are dragged on
the slider plate, elevated and ped into chip trolley.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

APPLICATION:
Magnetic conveyors are ideally suited for small chips, especially when they are
required to be separated from cutting oil. Some machines where magnetic
conveyors find application are broaching, gear hobbers, gear shapers and milling
machines.

DIMENSION:
Nominal Belt width: 200 to 500mm,Chain Pitch: 15.875mm.

4.7 SCREW COIL CONVEYOR

Fig 4.7- Screw oil conveyor

Screw conveyor is the simplest and oldest form of chip


conveying. Screw flights welded on a central shaft push the chips along screw axis
when made to rotate at a constant speed. Coil conveyor is similar to screw
conveyor in working concept though the construction varies. Steel square section is
formed into coil which, when rotates, pushes the chips along the coil axis.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

APPLICATION:
In machines where chips are required to be cleared from the machine bed in
a narrow space, screw or coil type conveyors are used. The best example is vertical
machining centres where screw or coil type conveyors are applied to collect chips
from either side of the machine bed, which are then discharged into a hinge belt or
scraper type conveyor for elevating and discharging into chip trolley. Screw
conveyors also find application in multi-spindle automats which generate large
volume of long, coily chips. Coil type conveyors also find application on band saw
machine to handle powder chips mixed with coolant
.
DIMENSION:
Screw: 100 dia x 100 pitch, 150 dia x 150 pitch, 165 dia x 150 pitchCoil: 100 dia x
125 pitch.

5. CHIP AND COOLANT SEPARATOR, FILTERS


In machine cutting operations where a large quantity of coolant is used, a
chip conveyor alone cannot be effective. The used coolant is required to be
continuously cleaned of metal particles so that it can be re-circulated. Mayfran's
CONSEP 1000, CONSEP 2000, ALUMINIUM SEPARATOR CONVEYOR and
MAGNETIC ROLLER SEPARATOR CONVEYOR are proven equipment’s in
this category.

5.1 CONCEP 2000

Fig 5.1 - Concep 2000

DEPARTMENT OF MECHANICAL ENGINEERING Page 14


MIVEN MAYFRAN CONVEYORS PVT. LTD.

CONSEP 2000 coolant cleaning separator is the perfect solution for chip
conveying and coolant cleaning in a single unit using little floor space. It is
engineered to process virtually every chip type with minimal return of chips or
fines to the coolant tank. Its modular design makes it simple to add additional
components for extended coolant cleaning requirements below 50 microns.
ConSep 2000 is a combination of steel belt conveyor, a filter drum and a drag type
(scraper) conveyor that makes it suitable for handling any type of chips -long,
curly, bushy, small and fine. The primary conveyor removes all chip types and
sizes including strings and balls. The lower drag-type separator conveyor removes
fines that are passed through and carried back into the system by the primary
conveyor A permanent self-cleaning media drum separates fines from the coolant
to 50 micron nominal ConSep 2000 II is an improved version of ConSep 2000. The
drag type conveyor has been replaced by a unique inner chip handling system with
a spiral conveyor at discharge. The filter drum can be indexing type or continuous
rotation type.

APPLICATION

ConSep 2000 is the best and most economical method to dedicated chip handling
and coolant cleaning for machining centers and automatic multispindle lathes.

DIMENSION:

Nominal Belt width: 300 to 800mm,

Chain Pitch: 31.75mm/50.8mm/63.5mm

Capacity: Up to 800LPM

DEPARTMENT OF MECHANICAL ENGINEERING Page 15


MIVEN MAYFRAN CONVEYORS PVT. LTD.

5.2 MAGNETIC SEPARATOR CONVEYOR

Fig 5.2- magnetic roller separator


Magnetic Roller Separator conveyor is an ideal separator for filtering ferrous
fines from cutting oil. Its superior design features ensure an effective conveying
and filter less cleaning simultaneously. It can handle high volume of ferrous chips-
small, free flowing and broken chips upto 75mm long generated during milling,
broaching, hobbling, gear cutting operations. A series of stainless steel rollers, each
with a permanent magnetic core fitted along the length of the conveyor, are made
to rotate axially. The strength of each magnetic core diminishes gradually in the
rotational direction of the roller. Swarf is attracted by the magnetic core to the
roller surface. As the roller rotates, the swarf moves into a progressively weaker
magnetic field. The stronger field of next roller then pulls the swarf onto its
surface. Through repetition of this process the separation and conveying is
achieved. The swarf is discharged into chip trolley at the end of the conveyor and
the coolant flows into tank.

DIMENSION:
Nominal Width :150 to 500mm
Capacity :60 to 600 Kgs/Hr (Steel).

DEPARTMENT OF MECHANICAL ENGINEERING Page 16


MIVEN MAYFRAN CONVEYORS PVT. LTD.

5.3 PERMANENT MEDIA FILTER

Fig 5.3- permanent Media Filter

This filter is based on the build-up of a filter cake which is periodically


removed through rotation. During the periodic rotation, the coarse particles
deposited in the filter housing are also carried out by special cleats.
Simultaneously, the accumulated filter cake is removed by the brush, and the filter
mat pores are additionally cleaned using a separate clean coolant (flushing) pump
from inside to outside. This lowers the coolant level and completes the cleaning
cycle.

Advantages:

 1. Works without disposable filtering media


 2.Without vacuum
 3. Double cleaning of stainless steel filter clothe
 4. Compact and of modular design
 5.Low on maintenance

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

6. CENTRALISED SYSTEM

When the amount of chips and coolant to be processed is large, centralized


systems are a more economical option. Specially in cases where the process
parameters don’t change/minimally change, centralized systems add immense
value due to the inherent ability of achieving a high level of automation.
With vast experience in the demanding markets of Europe, North America and
Japan, the centralized systems from Mayfran are known for their ruggedness and
high degree of reliability. The Viavent, which is a patented, new generation chip
and coolant transportation system from Mayfran, is the ultimate solution to all the
trench-based system problems.

6.1 CHIP PROCESSING SYSTEM

6.1.1 VBU

Fig 6.1.1 –VBU machine

Present day machining practices make use of expensive oils which, without
processing would result in a substantial increase in the cost factor, not to mention
the increased threat to the environment. The VBU-200 helps recover this expensive
oil which can be reused either directly or after filtration depending on the
machining activity. The relatively dry chips produced as a result fetch a much
higher value during sale.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

APPLICATION:
• Small centrifuge units fir single or small group of machines.
• The capacity of 50 kg/hr is a very cost effective solution especially for gear
cutting shoops.
• Units with capacities of upto 1000 kgs per hour also available.

6.1.2 CHIP CRUSHER

Fig 6.1.2 Chip Crusher

Based on the type of chips and application, Miven Mayfran offers a versatile
product range of chip crushers to suit individual needs.

Crushing of chips has some significant advantages

ps) and
recovery the coolant from the chips
dling in over the floor-mounted
transport of chips and coolant
d them into briquetting presses

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

Miven Mayfran crushers can run in automatic mode and are easy to service
and repair due to over-dimensioning of bearings, shafts and couplings and this in
turn ensures an extended lifetime of the equipment.

The Chip Crusher models offered are :

 1.TA crusher-suited for small quantities


 2.MA crusher-suited for pump-stations for chip and coolant
 3.MSA crusher-for large clusters of hard and brittle swarf.
 4.SG crusher-for intermittent (batch) supply of chips.

6.1.3 RECLAMET 3000

Fig 6.1.3 Reclamet 3000

Wet chips coming out of the machine have to be properly dried before
storage to ensure prevention of soil pollution by the coolant. An additional benefit
is that expensive coolant can be reclaimed resulting in enormous cost savings. With
more stringent pollution control laws being implemented, the Reclamet-3000 is
best suited to cater to your chip processing needs by enhancing coolant lifetime
which ensuring compliance with the environmental regulations. The Reclamet-
3000 is an integrated turnkey solution with a shredder, tramp-material separation,
swarf de-oiling and pneumatic conveying of dried swarf compact assembly. That

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

we have more than ?? proven installations working satisfactorily in India, speaks


volumes about the reliability, quality and the value that it delivers to the customer.

6.2 COOLANT FILTRATION

6.2.1 Vacuum Based Paper Media Filter – ECONOVAC

Fig 6.2.1 vaccum based media filter

This filter works on the principle of suction of coolant through the filter media.
Once a filter cake is formed on the surface of the media, a vacuum is created which
triggers the indexing of the filter media. Advanced engineering and manufacturing
techniques ensure that the vacuum seals are maintained intact.

Hydro-Vac can be equipped with either permanent or disposable filter media


depending on applications. Continuous and fully automated, Hydro-Vac can be
installed in above or below floor locations.This equipment is ahead of the pack
when it comes to price performance ratio and space requirements.

APPLICATION:

For flow rates from 100 to 2000 lit/min. To be used both for single machines
and for machine groups. The high flow rate optimizes filtration for machining,
grinding, honing, polishing and other metalworking operations.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

6.2.2 Vacuum Based Permanent Media Filter – PERMAFLOW

Fig. 6.2.2 Vaccum based permanent media filters

Mayfran Permaflow drum filters have proven their efficiency time and over
again due to their reliability, the flexible installation options, as well as their low
operating costs for filtering the emulsion or the coolant. In most cases, they don`t
need any precipitation of the chips in the fluid and are therefore particularly well
suited for the integration in a chipdisposal system and easy to retrofit as expansion
or upgrade of the filtering capacity. The configuration of the Permaflow vacuum
filter offers a higher percentage purity without the use of filter auxiliary
consumables. This in turn drastically lowers the operating costs.The filtration takes
place through the cake formed on an indexing drum. The indexing and
backflushing mechanisms ensure an uninterrupted flow of clean coolant and this in
turn does away with the requirement of a clean coolant tank.Perma-Flow offers
complete versatility in liquid-solids separation, with units available from 3.5 square
feet up to 140 square feet for a custom match to your application.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

Perma-Flow offers strainer type separation using either continuous or


pressurized incremental backwash, and allows positive cake removal. Fine
filtration of less than ten micron is a reality with Perma-Flow, and its modular
design provides for parallel operation on large system, or total square capability.

APPLICATION:

 For central, fully automatic filter systems from 600 to 50,000 l/min. - oil
and emulsion.
 For majority of mechanical processes such as lathe working, drilling and
milling, though only conditionally for grinding.

7. PRESS SCRAP AND SOLID COMPONENT


HANDELING CONVEYORS

7.1 SIX INCH PITCH HINGE BELT

Fig. 7.1 Six inch pitch hinge belt

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

This conveyor finds application in stamping/ sheet metal press shops where
the scrap generation rate exceeds the handling capacity of a 4 pitch conveyor. The
conveyor frame can be open type made from heavy structural steel sections or
closed type made from heavy gauge steel plates. The steel belt is of proven
Mayfran design and due to its unique roller-bush-link chain feature is known to last
for years. Modular construction of the conveyor makes it possible to add or remove
conveyor segments at a later date depending on requirement.

APPLICATION
Used in chip handling from heavy chip generating machines such as wheel turning
lathe, Press scrap handling, Component handling application.

DIMENSION
Chain Pitch: 152.4mm,

Width range: 305mm to 1219mm,

Length: 60m (depending on elevation angle & height).

7.2 NINE INCH PITCH HINGE BELT

Fig. 7.2- Nine inch pitch hinge belt

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

This rugged conveyor is available in both the open type frame and closed type
frame. The discharge chute can also be customized to suit the site conditions as
well as specific customer requirements. The design also incorporates several safety
features such as pull-cord for emergency stoppage, overload relay for motor etc.

The heart of the system is the patented Mayfran hinged steel belt. This steel belt is
constructed of die-formed 1/4" or 3/16" nominal thickness low carbon steel.

Some of the other special features are:

Do1.double row high carbon die-punched side bars.

2.Plain or anti-friction bearing rollers.

 3.Pin and sleeve hinge construction (steel or optional UHMW polyethylene tubing
liner over pin through belt hinge joint).

 4.Hardened single flange rollers.


 5. 3/16 ", 1/4" or 3/8" thick formed interlocking side wings welded to hinge links.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

8. MATERIAL HANDLING SYSTEM

8.1 ROLLER CONVEYOR

Fig. 8.1- Roller conveyor


Gravity Roller Conveyors are built on slight inclined. Since there conveying
power is simply the force of Gravity. The inclination depends upon the type of
material that is being used. When the material is placed on the conveyor, the roller
revolve, thus moving the material in the direction of incline.

Powerised Roller Conveyors are used to carry load at controlled speed. Roll to
Roll chain driven live roller conveyor are used where dirt, oil, grease and other
contaminations are present. The driving chain or chains are at ends of the rollers
and are shielded.

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MIVEN MAYFRAN CONVEYORS PVT. LTD.

LEARNING EXPERIENCE

Miven-plant training carried out at miven mayfran conveyors pvt .ltd has
indeed proven to be a great opportunity in using my learning skills. In this fast
paced business environment, practical usage of skills is very important.
We had knowledgeable experience in in-plant training programmed. Be it the
personal of the Miven, the workers of its environment, they all have invested their
precious time in helping us to get the practical knowledge.

DEPARTMENT OF MECHANICAL ENGINEERING Page 27

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