POLYMER BUSINESS

Varroc is a leading tier 1 supplier to all major OEMs in two-wheelers, three-wheelers, four-wheelers and commercial vehicles. With the PAN India presence of 15 plants and 2 R&D centres and infrastructure of moulding machines ranging from 250 T to 3500 T with captive tool room and full fledged paint shop, we cater to high quality demands of Indian and global needs. Our quick turnaround time for new products with quality and differentiation through innovation and customer centric attitude makes us a preferred partner for our customers. At Varroc Polymer, we emphasize on design-driven technology by amalgamating the needs of our clients with the aesthetic flair of design and the technical finesse of engineering A full-fledged Research and Development Centre with attached analytical lab to provide solution for engineering in interior and exterior system, body parts, mirror assemblies and advanced clean air filter solutions across PV, CV, 2W and 3W segment. We are working extensively on lightweighting by replacing large sheet metal parts with polymer and also by introducing light weight micro-cellular polymers & composites in trims and other body parts. We are also working on advanced technologies like 2K molding for injecting two materials in one shot, 3i technology for high-gloss paint finish and reduced wall thickness, and battery protection for electric vehicles. To achieve lightweighting of vehicles to a standpoint of becoming a benchmark for the auto industry, in terms of design and profitability. With the acquisition of Bangalore-based Team Concepts Pvt. Ltd., Varroc has forayed into the genuine vehicle accessories segment. The company is pre-empting the needs of the ever-evolving industry with prime focus on Quality, Cost, Delivery and Differentiation in order to provide innovative solutions.
ENQUIRY
1
Yes
Detail,List
1
8
Name…
/businesses/polymer/
Thumbnail

Categories:

Engineering Capabilities

ADVANCED DESIGN & ENGINEERING

  • B2P & Full system supply
  • FSS/Build to print or reverse engineering
  • +40 3D CAD systems (VS/UGX)
  • FMEA

CAE SIMULATIONS

  • FEA – strength
  • Mold flow
  • CFD

PROTOTYPING

  • Prototype tool design & manufacturing (In-house)
  • Testing & validation

TOOL ROOM

  • Tool design, machining, assembly, tool management & support
  • Single column & double column vertical CNC milling machine
  • Continuous 5-axis CNC milling machine
  • 6-axis deep hole drilling & milling machine
  • High-speed graphite milling machine
  • Spotting press for 100T & 500T

R&D FACILITY ACCREDITED BY NABL (IS/ISO/IEC 17025-2005)

  • Raw material, product performance validations
  • 3D White light & blue light scanners
  • CMM / FARO ARM CMM
  • Meteorology lab
  • Linear and profile measurements
  • Universal testing machine
  • Spectrometer for checking colour & gloss
  • HDT, VST, impact tester & vibration shakeer
  • Conditioning chamber, climatic chamber
  • Oil seal lip opening pressure & air filter leak testing
  • Ageing oven & muffler furnace
  • Performance testing for painted parts
  • Gap and flush analysis

 

Manufacturing Capabilities

INJECTION MOULDING

  • +200 injection moulding machines 350T to 2500T
  • In-house testing facility
  • Gas injection moulding
  • Sequential gating, hot runner
  • Hot & Cold moudling
  • Pour in place foaming

PU FOAM MOULDING

  • 10 automated lines for PU foam moulding
  • High & low pressure system
  • Robotic pouring
  • Seat assembly lines

SEAT ASSEMBLY

  • High & low density foam
  • PVC cover stitching
  • Dual hardness seats
  • Integral PU skin seats

PLASTIC WELDING – ROBOTIC VIBRATION / ULTRASONIC

PAINTING

  • Seven paint lines for PU painting of plastic parts
  • Painting automation

MIRROR MANUFACTURING

  • In-house glass cutting & metalising facilities
  • Automated strip cutting
  • CNC glass marking machine
  • Edge grinding and glass convexing
  • Aluminum metalising and curtain coating
  • Infrared, laser marking and assembly line

AIR FILTER ASSEMBLY

  • Paper filter element – pleating & vertical moulding
  • PU foam integration
  • Heat stacking and hot plate welding
  • Performance and leak testing

 

Polymer Design Process

Know what goes into the making of our world-class products.