Established in 1957, ThyssenKrupp Industries India (TKII) is a part of the industrial solutions business area of ThyssenKrupp AG, Germany. Globally, ThyssenKrupp is one of the world's largest industrial conglomerates with three main verticals of business activity: steel, capital goods, and services, in all of which it occupies leadership positions. Over the last five decades, TKII has grown to become one of the most trusted names in the fields of sugar plant and machinery, open cast mining and bulk material handling systems, cement plant and machinery and, steam, and power generation plants. TKII's strategic vision, as a leading contractor executing turnkey projects, is derived from its core strengths of integrated engineering expertise and automation in manufacturing at its Pune and Hyderabad works.

In an exclusive interview with IPF, Sivasubramanian Natarajan, Managing Director, ThyssenKrupp Industries India (P) Ltd elaborates about the company's products, operations and future plans. Excerpts from the interview:

Could you provide details of the specialised material handling systems manufactured by the company?

ThyssenKrupp Industries India (TKII) caters to the complete range of equipment and systems in the field of bulk material handling for core sectors in the field of power, open cast mining, steel plants, refineries and ports. TKII attributes its technological strength to the world-class German technology of ThyssenKrupp Resource Technologies, who are the pioneers in these fields. TKII has access to an extended world-class technology, which includes the technology of Krupp, Buckau Wolf, PHB, PWH, O&K, Demag Lauchhammer, Weserhutte & Robins, which have merged with ThyssenKrupp over the years.

In the power sector we provide total turnkey solutions for complete coal handling systems, right from unloading/receipt of the coal via wagons up to delivery into the boiler bunkers. Our products include belt conveyor systems, wagon tippler and paddle feeders, complete stockyard management systems (stacking and reclaiming machines), crushing and screening units, wagon loading stations, etc. In the open cast mining sector we supply complete turnkey solutions right from excavation of the material up to loading on to the wagons or conveying it to the plant, as the case may be.

Our product range includes bucket wheel excavators, mobile transfer conveyors, shiftable conveyors, mobile and semi-mobile crushing plants, transport crawlers, spreaders, pipe conveyors, downhill conveyors, etc. Our products for the steel plants, refineries and fertilizer plants include fixed and slewable stackers, twin boom stackers, bucket wheel reclaimers, bridge type reclaimers, barrel reclaimers, circular stacker recalimer and blending systems, portal and semi-portal reclaimers. At the heart of any bulk material handling system lies an efficient and robust belt conveyor system. We also pride ourselves in this field of high-capacity overland conveyors and pipe conveyors. Our products, ranging from ship loaders, barge loaders, and continuous ship unloaders to stockyard machines provide an end-to-end solution for the ports sector.

Does the company work on customised equipment to suit specific requirements?

TKII is in the project business and caters to various core sectors. TKII customises equipment/systems to suit the requirements of each of our customers. All customers have specific requirements which are shared with us and we provide solutions meeting their needs. It goes without saying that customisation is an integral part of our business model.

What role does the R&D department play in the evolution of new products? Are any new systems likely to be introduced in 2015-16?

ThyssenKrupp stands for excellence in technology, design and engineering, manufacturing, and providing services for products that we deal with and solutions that we provide. ThyssenKrupp worldwide invests significant resources in R&D activities to provide the customers with the latest equipment in different fields that we are operating in. Our products are designed with a simple philosophy of higher efficiency, lower maintenance and the least emissions. Strong design and engineering, which is our core strength, forms the basis of our business. Our design and engineering team works in close coordination with our global business units, thereby continuously upgrading technology and products in line with international standards.

ThyssenKrupp Resource Technologies have recently launched 'Skip Conveying', a product that could change the way coal is transported from pits. Skip conveying is an efficient way of handling coal. These machines can deliver coal of up to 5,000 tonnes per hour whereas we need a fleet of dumpers together to go through the strenuous journey to achieve the same. Thus the skip conveyor system can increase productivity and efficiency multifold times. In addition to enhanced productivity and efficiency in the mine, CO2 footprint is cut significantly through reduced truck traffic. The skip conveyor system represents environment-friendly technology with minimal noise and dust emissions. It also has the potential to provide high transport availability since it can remain fully operational in conditions such as snow, fog and rain.

Additionally, Mega Pipe is another product which has been launched. This is a new technology wherein we will be able to transport the material at an inclination of 35 degrees from the pit, using a pipe conveyor with a special belt. This technology has been developed jointly by ThyssenKrupp, Siemens and ContiTech. With new environmental regulations in place and the need for optimised systems, we are focusing on our products like flow dividers, twin wagon tipplers, transfer platforms and pipe conveyors to help optimise the system requirements.

What scope does TKII foresee in the mining sector in the years to come?

In the open cast mining sector we supply complete turnkey solutions which include excavation of the material, sizing to the required product size, loading on to the wagons or conveying it to the plant, as the case may be. Our product range includes bucket wheel excavators, mobile transfer conveyors, shiftable conveyors, mobile and semi-mobile crushing plants, sizers, transport crawlers, spreaders, pipe conveyors, downhill conveyors, etc. We also plan to introduce new technologies like skip conveying and mega pipe to various mine owners and showcase the benefits of these equipments with regards to efficiency and productivity.

Did the ban on mining affect the performance of ThyssenKrupp Industries India? If so, to what extent?

TKII is a diversified player and has presence in mining and material handling, power, cement, sugar, oil and gas and petrochemicals, infrastructure, etc. We looked around for opportunities in other countries and we picked up a few good orders outside India. We bagged some orders in Southeast Asia. Now we have a good presence in Malaysia where we are doing two large projects. One is for a 1,000 mega-watt power plant where we are doing the complete coal handling plant. We are also executing a urea handling plant in Malaysia as well. We also have some presence in power plants with our CFBC boilers in Indonesia and Philippines; thus, the shortfall in India was compensated for by orders from overseas.

Could you elaborate about the after-sales and maintenance aspects that are unique to the company?

Through our after sales services we are committed to creating value for the customers throughout the life cycle. Besides the supply of spares for our own manufactured equipments and technical expert support services, we offer the following services to our customers to reap multiple benefits. 

• Integrated asset management (performance-based operation and maintenance contracts): This is a value-creating service aligned with customers' business objectives. It offers a synergistic combination of several years of equipment manufacturing, construction and project management experience and a proactive, systematic and holistic approach towards asset management. This service solution is offered based on mutually discussed and defined operation and maintenance contracts. 
•  Reliability improvement and life extension solutions: Through this we provide solutions for repairs and replacements, retrofits, modifications and upgrades, and rejuvenation of customers' aging assets so that customers can get a life extension of such assets by investing an optimum additional cost. 
• Productivity improvement: We support our customers for improving the productivity by identifying bottlenecks in processes. We help remove those by optimising the processes and upgrading old manual, obsolete systems by adding or upgrading automation. 
• Asset management consulting: We conduct assessment of customers' assets and suggest them performance improvement plans and also support them in implementation. 
• Training: We provide operation and maintenance training for our customers.

What are the company's expansion plans for the coming five years?

TKII has two manufacturing units, one in Pune and second in Hyderabad. These factories are flexible to cater to all our four verticals. Our sales and execution teams are centralised in Pune. We also have our design and engineering setup in Pune and Kolkata. Depending on the market requirement, we will be able to expand whenever required.

Does TKII cater to the neighbouring countries?

All the divisions of TKII contribute to the export business in cooperation with ThyssenKrupp Group companies in various regions. The machinery and equipment for cement plants have been exported to various countries like Sudan, UAE, Mozambique and Kenya. The equipment for material handling has had a major concentration in the Southeast Asian market wherein the exports have been mainly to Malaysia. We are presently focusing on the SEA and SSA markets for our power and sugar divisions.

Could you name some of your major clients?

Just to name a few, our clientele includes state-owned companies like Neyveli Lignite Corporation, NTPC Ltd, Damodar Valley Corporation Ltd, Bharat Petroleum Corporation Ltd, National Mineral Development Corporation Ltd, National Aluminium Company Ltd and most state electricity boards. Among private companies, some of our major clients are Reliance Industries Ltd, Adani Group, Tata Group, Aditya Birla Group, Jindal Power Ltd, Alstom Power Systems, etc.

Has the new government's policies, such as the 'Make in India' campaign, made an impact on the company's manufacturing plans?

The 'Make in India' campaign by the Government of India will provide a boost for the manufacturing sector of the country once the government implements the initiatives as planned. TKII being part of the worldwide ThyssenKrupp Group has opportunities to export equipment and systems manufactured in India for worldwide projects. We are exporting our products and systems to South America, Europe, Africa, the Middle East and Southeast Asia.