Infrastructure Design – Tricolite
Family standing in front of metro.

WORKING QUIETLY
FOR YOUR SMILE.

Use of state of the art, modern and latest technologies has always been the mantra for building infrastructure for Tricolite. Every plant that has been designed has incorporated elements of lean manufacturing, sustainability, digitalization and ergonomics.

Electrical Design

The Electrical Design department, spearheaded by an esteemed woman leader, stands as a testament to the organization's commitment to technical excellence and innovation. This department is renowned for its technical prowess and is considered a cornerstone of the organization's success. The team's dedication to maintaining high standards of quality and reliability is evident in their approach to design, which serves as a wellspring of innovation and fresh perspectives.

The adoption of cutting-edge technology is a strategic move to ensure fail-safe operations and standardization across processes. The overarching goal is to create products that are not only future-proof and communicable but also intelligent. These smart products are designed to empower customers by providing them with insights into their energy consumption patterns, thereby enabling them to optimize their operations for greater efficiency.

The design process is comprehensive and forward-thinking, encompassing:

  • Future-Ready Smart Panel Designing: Crafting panels that are equipped to handle the demands of tomorrow's technology landscape.
  • Utilization of World-Class Software for Drawing Preparation: Leveraging advanced tools such as Pro Panel, E-Plan, and Pro E to create precise and detailed designs.
  • Online Electrical BOM Generation: Streamlining the creation of Bill of Materials (BOM) through online platforms for enhanced accuracy and efficiency.

This meticulous approach to electrical design not only sets the stage for the development of innovative products but also reinforces the organization's position as a leader in the industry. The focus on creating smart, communicable, and efficient solutions reflect the organization's foresight and its unwavering commitment to excellence.

Mechanical Design

Mechanical design is a critical component in the engineering of durable products, particularly for companies like Tricolite that aim for a product lifespan of at least 30 years. The selection of high-quality raw materials and their processing with precision is fundamental to achieving such longevity. Tricolite’ s commitment to this principle is evident in its investment in cutting-edge machinery for fabrication, including globally recognized cutting, punching, and bending machines, as well as an advanced automated conveyorized paint-shop.

The integration of 3D designing software is a strategic move that bridges the fabrication and painting departments, streamlining the production process to ensure accuracy from the first attempt. This integration is not only a testament to Tricolite’ s innovative approach but also enhances the efficiency and quality of the output.

At the heart of Tricolite’ s operations are its design engineering team, which is the driving force behind the creation of futuristic and user-friendly systems. The team's expertise in utilizing the latest 3D modelling software enables them to design systems that are not only precise but also tailored to meet customer requirements. The design process at Tricolite includes:

  • Future Ready - Smart Panel Designing: Focusing on creating panels that are adaptable to future technological advancements.
  • 3D Simulations for Mechanical Designing: Employing simulations to visualize and test designs before physical production.
  • World Class Software for Drawing Preparation: Utilizing top-tier software such as Creo and Product Designer PD to prepare detailed and accurate drawings.

Moreover, Tricolite maintains digital archives for all drawings, ensuring that designs are preserved and can be referenced or reused efficiently. This practice not only safeguards intellectual property but also allows for consistent quality in production.

In summary, Tricolite’ s approach to mechanical design is a comprehensive process that emphasizes quality, precision, and future-readiness. By leveraging advanced technology and software, along with a skilled design engineering team, Tricolite is well-positioned to deliver products that meet the highest standards of durability and functionality. The company's dedication to mechanical design excellence is a clear indicator of its commitment to providing value to its customers and maintaining its competitive edge in the industry.

Manufacturing

Manufacturing infrastructure based in Delhi NCR is spread over 2.0 lac sq. ft. of area equipped with state-of-the-art technology & tools for precision workmanship. It is one of the best facilities in the country that can be held up to any global standard.

This is divided in four units, which houses fabrication, paint-shop and assembly. All shop floors are laid out as per flow manufacturing and TQM requirements to minimize non-essential movement of man and material. We are now consciously making our shop floors digital and smart to eliminate paper and communicate through web enables technologies.

CNC Machine

CNC Machine

We have installed world class Fiber Laser cutting machine, this machine has latest features like:

  • Laser Beam mode converter
  • Auto nozzle changer
  • I- Optics Sensor: Auto check for the condition of Protection Glass for smooth laser cutting.
  • I- Process Monitoring: Automatic control of Beam to ensure proper cutting.
  • Automatic prevention of cutting head damage control.
  • Can process sheets from 0.4 to 22mm of wide range thickness.

The offline software Production Designer- (Intelligent, Interactive, & Integrated)

This software has latest features like:

  • It will create 2D to 3D automatically.
  • It will create auto unfold of each sheet metal part from the enclosure assembly.
  • It will do auto programming and nesting for CNC machines.
  • It will create automatic bending programs.

We have also expanded our bending capacity by installing hybrid HRB series press brakes from Amada Japan.

Busbar Shop

Busbar Shop

Automated Bus Bar Making Linking, Punching & Bending

Centralized bus bar shop that feeds the entire plant works on flow manufacturing principle.

  • EHRT CNC Busbar cutting & punching Machine from Germany
  • Euromac Busbar Bending Machine from Italy
  • Insulation Options available in Epoxy, PVC Sleeving, Bare & Tinning
  • 36 Stage Inspection Check for Link Making & Fitting
  • 100% Online records of all Mechanical Designs for easy and fast retrieval
  • 36 Stage Inspection Check for Link Making & Fitting

Automobile Grade Paint Shop

Automobile Grade Paint Shop

PAINTSHOP POWDER COATING PROCESS

In our plant the paint shop process starts from a ready fabricated material from fabrication department of various materials like CRCA, GI, GPSP, Alu. Zinc & Stainless steel. Powder coating is a type of coating that is applied as a free‐flowing, dry Powder.

  • 20,000 sq. feet paint shop.
  • Fully automatic Conveyorized spray pre-treatment line with 8 spray tanks.
  • No two sheet metal components come in contact, ensuring 100% Phosphating on surface area of sheet metal.
  • Rinsing through DM water.
  • Conveyorized Camelback Oven, with GEMA
  • Electrostatic Guns for Powder Coating.
  • Ovens for drying of pretreated parts is carried out at 120 deg C and for baking powder at 200 deg C.
  • Temperature is uniformly maintained in both ovens by monitoring thru Time Temperature Report test.

Assembly LV and MV

Assembly LV and MV

The assembly shop of LV and MV Panel is equipped with the latest Pneumatic tools to ensure the proper fitting of the components as per the latest IEC standards and Norms.

The manufacturing infrastructure based in Delhi NCR is spread over 2 lac sq. ft. of area equipped with state-of-the-art technology & tools.

The complete modular construction of the panels is standardized to ensure faster, reliable and safer assembly and delivery of the panels.

PLANT-1 MANESAR
LV ASSEMBLY
PLANT-2 MANESAR
MECHANICAL MANUFACTURING
& LV ASSEMBLY
PLANT-3 MANESAR
6.6 KV TO 33 KV
MV ASSEMBLY
PLANT-4 SAHIBABAD
LV ASSEMBLY

Quality and Testing

The organization is certified for
ISO 9001: 2015 Quality Management System.
ISO 14001:2015 Environmental Management System.
ISO 45001:2018 Occupational Health & Safety Management System.

Tricolite dedicates itself to Total Quality. It has pledged to achieve excellence in product, process and service. Every product goes through four stages of manufacturing, each of which has stringent in-process quality checks in place. Total Quality methods have been deployed such as Lean & Flow manufacturing, work as per defined SOPs, 5S storage systems to eliminate searching time, Kaizen schemes for continuous improvement, to name a few. Any error found is run though the 8D Root Cause Analysis done by a cross-functional team to make systemic corrections for its non-repeatability.

Monthly manufacturing excellence reviews are held to collectively discuss challenges, their probable solutions and new ways to upgrade technology.

Quality Assurance

  • Stringent In-process Quality Checklist for >200 points
  • All Raw Material bought from OEMs Directly
  • Aluzinc Sheets used for Better Heat Dissipation & Mechanical Strength
  • Special Tests conducted:
    • In-house Temp Rise up to 8000 A
    • Salt Spray for Corrosion Resistance upto 500 hours
    • Conductivity Test for Busbar
    • Lug Pullout Test for Crimp Strength Validation
    • Millivolt drop for contact resistance
  • Routine Tests as per IEC Standards
Quality Assurance

Digital Testing

High Voltage Tester

Purpose:

The primary purpose of high voltage testing is to assess the insulation resistance and dielectric strength of the LT electrical control panels. It helps identify any potential weaknesses or defects in the insulation system that could lead to electrical breakdowns or hazards during operation.

Kit Specifications:

Model:
HVT-05-Portable
Test Voltage:
0 To 5.0KV AC Variable
Tripping Current Range:
10mA, 25mA,100mA, 200mA.
(Accuracy ± 1.0% of Set Value)

Feature:

Digital Meters and PLC are available for the purpose of producing automatic reports, graphs and output voltage and Leakage current measurements in kV and mA respectively.

CRM Test Kit

Purpose:

Contact resistance refers to the resistance encountered at the point of contact between electrical conductors, such as terminals, connectors and circuit breakers. High contact resistance can lead to overheating, voltage drops, and ultimately, failure of electrical equipment.

Kit Specifications:

Model:
CRM 100B+
Resistance Range:
0-200μΩ ,2000μΩ,20mΩ
(Accuracy Value ± 2% ± 1 Digit)
Printer:
In built Thermal Printer

Feature:

  • CData CRM kit are Stand alone and Windows based PC Controlled downloading & Analysis report.
  • Get early warning of developing hot spot, save cascading effect.
Primary Current Injection Test Kit

Purpose:

This test is a type of electrical testing used primarily in the field of power systems and electrical installations. It is conducted to verify the operational characteristics and performance of protective relays, circuit breakers, and other protective devices within a power system.

Kit Specifications:

Input Voltage:
415V
Output Voltage:
12V
Capacity:
125KVA
Output Current:
8000A

Feature:

  • Digital timer: Can measure tripping time
  • Zero start interlock: Can provide safety
  • True RMS digital metering.
  • Provide fully isolated and distortion free outputs

Salt Spray Lab

Test performance in paint shop to ensure quality of paint.

  • Salt spray test done as per IEC 60068-2-11 batch wise as powder received.
  • For determining the resistance of paints and coatings to separation from substrates,Perform cross-adhesion test on a coated sample for each job by utilizing a tool to cut a right angle lattice pattern into the coating, penetrating all the way to the substrate. Record is being displayed upto six month in lab.
  • To determine resistance against impact, a coated plate (metal plate 0.8 mm thick) is placed under a indenter with a fixed diameter. Then the weight is dropped freely down along a guide tube from a variable height.Its qualification check as per its TC recommended.
  • To check elasticity, adhesion and elongation of paint on sheet metal, a coated plate (metal plate 0.8 mm thick) is bent over a conical mandrel and the coating observed for cracks and discolouration. Its qualification check as per its TC recommended.
  • All chemical tank is being titrated before start paint process,report made on daily basis. Every week Chemical supplier also verify concentration of chemical by taking sample from tank for titration and submit report.
  • Powder supplier also audited powder curing oven quaterly, To verify temprature-time distribution on part inside curing oven for proper curing of paint all over the parts.