Sitra Plant
Our Sitra manufacturing set up has a production planning, feeder department, assembly line, chest freezer line and a maintenance department.
Manufacturing Set up - Sitra
Area: 50,000 Sq. Meters
Installed production capacity: 0.6 million / annum
Models breakup
- Window (RAC)
- Split indoor, outdoor units & chilled water fan coil units
- Ducted (Hideaway) units
- Top discharge outdoor units
Departments in manufacturing of Chest freezers, Visi coolers
Production planning
Feeder departments
- Press Shop
- Powder coating shop
- Coil Shop
Assembly lines
Chest freezer line
Maintenance & Utilities
Production planning and control
Functioning of PPC begins to derive annual plan from marketing forecast based on available capacity. Later marketing releases the confirm customers orders for production in form of memos on month wise basis.
Confirmed orders before scheduling for production is released from planned stage and estimated material is maintained in ERP system according to the customer requirement. Then it is planned for production based on line capacity considering priority and availability of material.
Warehouse orders are raised to draw material to meet daily production activities for assembly as well as for feeder departments. Based on daily production plan, delivery dates are informed to marketing through shipment schedule for the customer updates.
When order quantity is fully delivered, then production orders are completed and closed in ERP system to complete material transactions. Planned quantity may vary from 1# to 1000# per day with different varieties of models between 40 ~ 60# in a day.
ERP package LN (Version 6.1) is operated on a day to day basis for smooth functioning. Another tool i.e. PREACTOR is used to derive daily production plan and shipment schedule to give the delivery dates.
Feeder Departments
Press Shop
Press Shop at Awal Gulf is equipped with specialized machines (SEYI, SPC-Taiwan) power presses to meet our high quality requirements & standards.
High corrosion resistant material using materials like Galvanized Iron (GI), Pre coated (PCM) & Polyvinyl coated (PVC) for enhanced corrosion resistant life of the unit. Fully automated material feeding in power presses with help of ROBOT feeders. 3+1 axis CNC machines to cater units based on specific customer requests with maximum accuracy like Amada-Japan, LSK-Finland, LVD-Belgium and Yangli-China.
Material transferred to customer departments through overhead conveyor to avoid handling damages & manual interference.
| Details of Vide Range of Machines in Press Shop | |
| Power presses 60T ~ 400T | 15nos |
| 3+1 axis CNC brake presses | 6nos |
| 3 axis CNC turret presses | 3nos |
| 2 axis CNC shearing machines | 2nos |
| Automated cut to size machines | 2nos |
| Resistance welding machines | 13nos |
Powder coating shop
Powder coating shop is having wide range of very specialized process equipment.
Pre-treatment system an even distribution of chemicals, mineral water rinse & the components pass through a dry-off oven under dust-free conditions to remove all traces of oil, moisture & dust particles. The powder painting equipment supplied by Nordson is equipped with automatic electromechanical oscillators, for even powder deposition. Using Polyester powder - suitable for out door applications - provides the maximum protection against extreme UV deterioration and corrosion. Components are passed through a temperature regulated curing oven to achieve desired gloss & surface hardness.
Having dedicated ETP (Effluent treatment plant) for powder coating shop to ensure that water drained from plant will be under acceptable PH limits & this is one of the important aspects in our ISO 14000 (EMS Module).
Parts powder coated can withstand max 1,000 hours in a salt spray chamber test hours.
Coil shop
Sophisticated coil shop having the advanced world class machines from USA, Korea & Taiwan. The Burr OAK coil line produces energy efficient heat exchangers. Automated coil brazing line from SK Brazing- Korea for maintaining constant quality parameters for brazing standards with leak proof joints. Having copper tube ranging from 7mm, 5/16”, 3/8”, ½” & 5/8” with option of Inner grooved copper tubes for better heat transfer.
Coil length ranging from 200mm ~ 5000mm with Conveyor system & no manual interference for coil handling.
Dedicated tooling for making copper, aluminum (hydrophilic, golden epoxy, black epoxy) fins.
100% quality checking in coils for leak with 450psi in addition to testing for fine leaks with Helium leak detector machine. Can detect leak 2gms/annum.
100% coils are passed through baking oven with temp range from 125℃ ~ 130℃. All coils are flushed with nitrogen to avoid oxidization and the resultant impurities from contamination. Having modernized Herasite coating facility.
| Details of Vide Range of Machines in Coil Shop | |
| Fin presses | 8 nos |
| Mechanical expander | 6 nos |
| Hair pin bender | 4 nos |
| Baking oven | 1 no |
| Auto brazing | 2 nos |
| Coil bending machines | 3 nos |
| Return bend mfg machine | 2 nos |
| Helium leak detector | 1 no |
| Herasite paint booth | 1 n |
Assembly lines
Equipped with state-of-the-art Assembly setups, we have dedicated automated assembly lines for products like RAC, Outdoor, Indoor & Central air conditioning units. Automated lines are setup in such a way that changeover can be done in least possible time. Products are assembled sequentially on automated conveyor using torque controlled pneumatic tools and specially coated corrosion resistant hardware which provides firm locking. Brazing process is carried out in an inert atmosphere to avoid oxidation and resultant impurities from contaminating the refrigerant system. System tubing’s are made using 3 axis CNC copper tube bending machine from Finland to fabricate wrinkle free tubes, to match exact dimensions for perfect stress free fit. Harness is prepared using world class automated wire cutting and crimping machines from USA.
Over head material movement conveyor: Dedicated over head conveyor for material movement from feeder shops & raw material warehouse to Assembly line to reduce transit damages, manual handling & storage space.
Over head vacuum carousal system: Equipped with world class vacuum pumps Galileo-Italy. Best in class gas charging machine from Galileo-Italy is used for charging various refrigerant with precision.
Dedicated online testing facility: Each machine is run tested for performance, electrical safety parameters and tested for leaks using high sensitivity leak detectors.
Automated packing and robotized over head finished good conveyor: Automated online packing system using automatic taping and strapping machine. Our finished goods are directly transferred to finished good warehouse using over head conveyor. Units are placed on pallets with the help of ROBOTS.
Using upgraded IT systems: Each unit is bar coded for traceability. We are extensively using ERP systems.
| Details of dedicated product assembly lines. | |
| Line-1 | Window units |
| Line-2 | Ducted units |
| Line-3 | Outdoor units ≥ 36K |
| Line-4 | Top & Side discharge outdoor units ≤ 36K |
| Line-5 | Indoor units |
Chest freezer
Our dedicated manufacturing facility for making Chest Freezers & Visi-coolers works with High Pressure Foaming Machine to inject environmentally sound polyurethane foam with latest technology from Canon.
The complete process of injection is microprocessor controlled to ensure precise quality and ratio of mixture with constant density to produce polyurethane foam of high quality. Specially engineered carousal cabinet foam fixtures are used from Canon-Italy to produce proper foamed cabinets that have uniform K factor. Custom made designed coil winding machine to ensure proper contact between sheet and tube to get better heat conductivity & cooling. Automatic gas charging machine & precision leak detectors to produce high quality and leak proof products.
In house thermoformed door lids are made using thermoforming machine from Canon-Italy.
Chest freezer doors are puffed using six mould door drum fixture from Canon-Italy.
Details of products
| Details of dedicated product assembly lines. | |
| Chest freezers | 100L, 250L, 350L, 450L and 550L |
| Visi coolers | 350L & 450L with glass door |
Maintenance & Utilities:
Maintenance Team - Awal Gulf Maintenance team has highly qualified and Skilled & competent technicians & Engineers for maintaining all the facilities available in the company.
Maintenance
Machines & Spare parts: All the machines are maintained through computerized maintenance management system and well developed stores and Inventory systems are in place for maintaining the Spares inventory. All necessary spare parts are maintained in a proper manner in order to have a ZERO Break Down of machines.
Preventive & Predictive Maintenance: As a manufacturing company we cannot afford lose production due to machine break down. Hence, our maintenance team is fully focused on Planned Maintenance system to have ZERO break down. Hence more attention and focus is given for Preventive Maintenance systems.
Utilities
Air Supply: Awal Gulf Manufacturing has 10 Screw Air compressors of total capacity of 1500 CFM @ 10 bar working pressure. The compressors have advanced air treatment system which gives Moisture, water & Oil free Air supply for manufacturing Processes.
Reverse Osmosis Plant for Water Treatment: We are proud to mention that we have own Reverse osmosis treatment plants for Generating Sweet water for drinking & process. The plant has the capacity of Generating 3000 Gallons per day.
Safety SystemsWe are mainly focus on Safety of Human, Factory. In order to have safe working environment company has the following Safety systems.
Fire Alarm Systems: Advanced Fire alarm systems are installed in all the locations of factory by installing Fire break Glasses, Beam detectors etc., and also the fire panel has direct link with civil defense.
Fire Pumps, Hose reels & Sprinkler systems: We also installed advanced Fire Pumps for Fire Hose Reels & Sprinklers which can be operated with electricity & Generators.
Nitrogen & Oxygen Gas plants: We have our own Nitrogen & Oxygen gas plants which can generate PURE Gases for our regular production.
Unique points of AWAL GULF- Manufacturing
- Using latest ERP software (LN) & PREACTOR for production planning & adhering shipment schedules of our valued customers.
- Flexible manufacturing system & batch size varies from 1# to 1000#. Different varieties of models between 40 ~ 60# in a day with product changeover time minimum as 1min in all assembly lines.
- Fully automated material feeding in power presses with help of ROBOT feeders & following SMED (Single minute exchange of tools) practices.
- Automatic electromechanical powder coating oscillators, for even powder deposition. Parts powder coated can withstand max 1,000 hours in a salt spray chamber test hours.
- Having dedicated ETP (Effluent treatment plant) for powder coating shop in compliance with Environmental regulations & systems.
- Automated coil brazing line for maintaining constant quality parameters for brazing standards with leak proof joints
- Dedicated computerized online units testing facility and bar coding.
- Automated packing and robotized palliating system.
- Specially engineered carousal cabinet foam fixtures to produce proper foamed cabinets that have uniform K factor.
- Having Nitrogen & Oxygen Gas generator plants.
- Modern automated material handling systems
