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Unity Engineers is a technology driven company which undertakes tasks of providing Turnkey Engineering Solutions, tailor made to client’s specific requirement. We not only provide solutions to Engineering problems on consultancy basis but also undertake manufacture, supply, erection & commissioning work in respect of suggested solutions.
A typical assignment or a project could involve one or all of the following activities:-    Conceptual Design of a machine or an equipment    Detail Engineering    Manufacturing and Testing   System Integration, Erection & Commissioning We also undertake tasks of Technology up-gradation of existing old machines in light of new Advances in Control Automation and Motion Control Technology as well as Supervisory Control and Data Acquisition Systems (SCADA). Towards this end we do re-engineering & retrofitting of select parts / assemblies, manufacture them and integrate them into the rest of the system for enhanced performance, quality and safety.
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Nature of Business

Manufacturer

Year of Establishment

1988

Reactors for Chemical Processing Plants
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We have designed, manufactured and supplied Reactors for various applications. The Reactors have been designed to sustain the required pressure, provide efficient agitation as well as heating / cooling through jacketing or limpet coils.

 The choice of material of construction is done depending upon the chemical properties of the reactants and the product.

The Stirrer design, gearbox and motor choice is done considering the load parameters which are derived from the viscosity and other physical properties of the product.

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Mineral Processing Equipments
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We have developed import substitute Air Classification Plants for processing various minerals to produce micronized grades of minerals like Calcite, Dolomite, Talc, Barytes, China Clay (Kaolin), Mica, Silica etc.

These plants are designed to efficiently separate the fines and coarse oversize particles from the feed material of 300 to 500 mesh powder. The conventional mechanical grinding using either a Pulveriser or a Raymond mill can economically produce powders up to 300/500 mesh size only which generally have a top cut of 50 to 35 microns and average particle size of 20 to 15 microns. Our plants are capable of producing complete range of micronized mineral grades having top cut of 20, 10 and 5 microns having mean particle size of 5, 3 and 1.5 respectively with sharp cut accuracy. Micronized grades of various minerals have good demand in various industries like Paints, Power Coating, Ink, Plastics, Paper, Rubber, Pharmaceutical, Ceramics, Cosmetics, Construction Chemicals etc. In all these industries, the finer the powder the better it is from the processing point of view as well as for the quality of the end product. The process have twin benefits, the Classified products are sold at much higher price to the conventional ground minerals powders (feed product to the Classification Plant), whereas the coarse separated from the fines is sold as a coarse product. Hence, practically no wastage or by product is generated in the Classification process.

These plants are designed to efficiently separate the fines and coarse oversize particles from the feed material of 300 to 500 mesh powder which generally have a top cut of 50 to 35 microns and average particle size of 20 to 15 microns. Our plants are capable of producing complete range of micronized mineral grades having top cut of 20, 10 and 5 microns having mean particle size of 5, 3 and 1.5 respectively with sharp cut accuracy. Micronized grades of various minerals have good demand in various industries like Paints, Power Coating, Ink, Plastics, Paper, Rubber, Pharmaceutical, Ceramics, Cosmetics, Construction Chemicals etc. The process have twin benefits, the Classified products are sold at much higher price to the conventional ground minerals powders (feed product to the Classification Plant), whereas the coarse separated from the fines is sold as a coarse product. Hence, practically no wastage or by product is generated in the Classification process.

Air Classification Plant INTEGRATED with Continuous Ball Mill (CCG)For optimization of the Classification plant performance by way of better recovery of micronized grades and reduce the generation of the coarse material, we recommend our Continuous Ball Mill (CCG) having Close Circuit Grinding System duly integrated with the Air Classification Plant.

 

Commercial as well as Qualitative advantages

??? Compared to a Pulveriser or a Raymond mill grinding system, a Ball Mill generates 15-20% extra fines.
??? Being Close Circuit Grinding system, the coarse rejected from the Classification plant are redirected to the Ball
Mill for further grinding. Hence, the low value coarse reject from the Classification plant is reutilized.
??? Lower Primary grinding cost as as instead of grinding 500 mesh only 300 mesh grinding would be required
for feeding to the Ball Mill. Also the production would be higher.
??? Overall production cost per MT would go down, due to less initial grinding required in present system, more percentage of fines being generated in the Ball Mill and minimization of coarse generation.
??? In case of product blending/coating a more homogeneous and consistent mixing is achieved with Ball Mill
compared to conventional grinding/mixing system.

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UNIBLEND continuous kneader is a high performance, broad spectrum Compounding Machine which operates on a unique Synchronous Reciprocating Screw principle, which sets it apart from all other screw type compounders, either twin screw or single screw. As in all contemporary high technology compounding systems the polymer is charged in the machine from the first inlet port and the fillers, fibres, additives etc. are charged through subsequent ports in the barrel into the already molten polymer stream .

 

What differentiates UNIBLEND from other machines is its screw, which is recessed at 90 or 120° interval all along the periphery, and performs an axial stroking movement simultaneous with the rotation, completing one stroke with every revolution. Correspondingly, the barrel is fitted with four or three rows of kneading pins, which are also spaced at 90 or 120° inside the barrel, The excellent dispersion of unmeltable compounds into the molten polymer matrix is achieved due to shear generated between the flanks of the screw flights and the stationery kneading pins. The synchronous back and forth movement of the screw also provides a high degree of product exchange in the axial direction. thus producing an outstandingly ‘Uniform Blending’ over a remarkably short process length.

A significant advantage of this kneading system over twin screw is that no pressure peak or high radial pressure is generated during the kneading process. The matrix is sheared, dispersed and simply reoriented or refolded several times. This makes the UNIBLEND Kneader especially suitable for compounding of heat and pressure sensitive polymers as well as formulations containing high filler proportions or reinforcing materials like glass fibre.

 

SPECIAL FEATURES OF UNIBLEND KNEADER 1. AXIALLY SPLIT BARREL2. SEGMENTAL SCREW AND SLEEVED BARREL 3. INDEPENDENT DISCHARGE SYSTEM4. ELABORATE DEGASSING FACILITY5. PRECISE TEMPERATURE CONTROL6. GENTLE PRODUCT HANDLING7. LOW ENERGY CONSUMPTION8. LOW SPACE REQUIREMENT9. THE ECONOMY FACTORAPPLICATION AREAS OF UNIBLEND KNEADER

Due to its unique operating principle as well as flexibility of design UNIBLEND stands out as the most versatile machine which can be tailor- made to handle with ease and efficiency a wide range of applications such as

Engineering Plastics

Filled and Reinforced Thermoplastics
Polymer Blends and Alloys.
Automotive Compounds.
Thermoplastic Elastomers.
Magnetoplastics

Cable Compounds

PVC,XLPE
Sioplas Flame Retardant Compounds.
Telecomunication Cables, Fiber Optics.
Semiconductives.

PVC Pelletizing

Rigid PVC Pipes, Fittings, Window Frames,
Flexible PVC hoses, Shoe Soles, Seals,
HouseHold Appliances.

Masterbatches

Black, White and Colour.
Additives

Thermoset Plastics

Phenolics, Ureas.
Epoxy Moulding Compounds,
Unsaturated Polymers

Powder Coatings

Epoxy, Acrylic, Urethane and Polyester Resins.

Toner Compounding

Toners for copiers and laser Printers 

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Automatic Conveyor Transfer System
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This system offers the ease of handling of their heavy products effectively from one Product Assembly Line to another without manual intervention. The project involves an innovative and indigenous design as well fabrication and complete reengineering of control automation system.

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Industrial Pipe

Industrial Pipe

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Steel Pipe

Steel Pipe

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Steel Pipes

Steel Pipes

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Industrial Pipes

Industrial Pipes

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Industrial Rod

Industrial Rod

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Flexible Polyurethane Foam Plant
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The OPTIFOAM V7 is a Slabstock Continuous Flexible Polyurethane Foaming Plant designed to produce consistent quality of highly regular, flat topped foam blocks.
It operates on Low Pressure Downward Foaming Principle.The individual chemicals from the tanks are metered in to high speed Mixing head by accurate Positive displacement pumps, which are controlled by microprocessor drives.

OPTIFOAM V7 has seven chemical streams – Polyol, TDI, Silicon, Amine, Stannous Octoate, Water and Methylene Chloride. Additional lines for pigment and additives dosing can be incorporated optionally. The mixture is led from the Mixing Head into a Foaming trough through a pair of flexible hoses. A diaphragm Valve located at the outlet of the Mixing Head enables accurate control of the mixing head pressure and thus the cell structure of the resultant foam. The chemical mixture spills over the edge of the trough onto the first of a series of metallic fall plates. The number of the fall plates may be 4 or 5 depending upon the machine. The slope of the fall plates is adjustable from the control panel. Almost 70% of rising takes place over the Fall Plates and the rest over the horizontal, metal slat conveyor. The regular and uniformly flat topped foam train reaches the end of the foaming tunnel over the conveyor, where it is cut off by a block cutter to obtain regular rectangular shaped foam blocks. The width of the Foaming Tunnel is variable between 1.4 mts. to 2.1 mts. and can be set by a powered system from the operating platform. 

Good Reasons to opt for OPTIFOAM V7???  Flat Topped Regular Foam Blocks with minimum wastage/scrap.
???  Greater block heights compared to conventional machines.
???  Better ILD values.
???  Hassle-free and easy to operate plant with low manpower cost.
???  Low specific power consumption, hence economical in operation.
???  Flexibility of foaming width due to variable Foaming Tunnel width.
???  Reliable and customer-friendly service backup. 

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Ring frame Spinning Machine
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Unity Engineers is a technology driven engineering company specializing in development of high end import substitute Plant & Machinery.

The company has joined hands with ATIRA (Ahemedabad Textile Industry Research Association) which is a widely reputed textile research institute engaged in the service of textile industry since 1949.

"UNITY ATIRA MARK-I" is a technologically advanced, Innovatively designed and Energy Efficient Ring Frame Spinning machine. The machine has a unique patented "Integral Twin Ball Bearing Spindle System".

The robust design, precision machining and Power Saving features of the machine give Spinning Mills a cutting edge as they increase the overall

Efficiency and Profitability. The machine has many distinct features which make it different from the available conventional Ring Frame machines,

offering ease of operation, least maintenance and educed replacement cost.

Salient Features

1. Introducing the first Ring Frame Spinning Machine in the world having Spindle with Twin Ball Bearing system. As a result, unlike conventional Spindles where Spindle & Bolster have to be discarded upon wearing, MARK-I spindles can be continued in use by simply changing the bearings.

2. The only Ring Frame Spindle in the world to have 16 mm dia. wharve enabling it to achieve Higher Speeds with Better Power Efficiency.

3. No need for periodic Oil Lubrication as the sealed Bearings are lubricated for life. Big saving on the maintenance as well as cost of Lubricating oil. Also increases the production as down time for oil change is eliminated.

4. Electronically controlled up-down building motion of the Ring Rail employing encoder based feedback system for precision & infinite flexibility in setting the chase length as well as traverse speeds, without any mechanical changes like cams, gears etc. thereby enabling Optimal Package Shape and Yarn Content for all yarn counts.

5. Completely new Simplified Driving System avoiding massive gearing. Hence, lower power consumption, lower inventory & maintenance cost and simplified maintenance. Over all higher productivity and increased profitability.

6. New Pneumafil System having damper system for controlling suction as desired, saves on the power.

7. State of the art integration of Spindle Speed with Ring Rail movement and Drafting system through AC Frequency Drive and PLC for achieving better & consistent product quality.

8. E-drafting : Allows user to change TPI & draft directly from the Control Panel enabling speedy change of product quality.

 

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Domestic Oil Expeller
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Domestic Oil Expeller

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Domestic Oil Expeller is designed with the objective of having decentralised oil expelling at the village level, instead of bringing seeds to the oil mill.

Domestic Oil Expeller is designed with the objective of enabling small farmers to produce highly value added products with simplistic and economical machine. The oil as well as the cake yield much better value than oil seeds and have ready use in day to day life.

The machine is also suitable for Urban domestic use as it ensures the availability of the pure unadulterated oil.

The unconventional design makes the machine user friendly in operation and very easy to maintain. The alloy steel Screw is hardened for better wear resistance and the Barrel is made from special graded cast iron.

The machine is equipped with a built in Filter Press which operates on a vacuum pump.

All in all, it is a Compact, Rugged, Reliable and User Friendly Mini Oil Expeller.

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TFO Machines For Tyre Cord
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Unity Engineers successfully undertook the project of converting the conventional Tyre Cord Twisting Machines into state of the art Direct Cable Twisting Machines. These machines provided complete cost saving Twisting Solution for high denier yarns

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