Bony Polymers Private Limited

2. Bony Group of Companies
Metallic
Flexible Hoses
Extrusion
Division
Compounding
Business Segments
- Rubber
- Non
Asbestos
Friction
Material
- O Rings
- Rubber
Moulded
Parts
- Rubber to
Metal
Bonded Parts
- Brake Blocks
(Rail)
- Turbo
Charges
Hoses
- Air Clean,
Radiator &
Coolant
Hoses

- Fuel Hoses
- Brake Hoses
- Press Work

- Fabrication
Moulding
Division
LED
Division
Bus
Aggregate
Division
Sheet Metal
- Cross Over
Piping
- Convolutions
- Sign
Boards
- Street
Lights
- Coach
Lights
- Air
Conditions
- Rear
View
Cameras
- Fleet Mgt.
Prime India
Polymix (P) Ltd.
Bony Polymers (P) Ltd.
Saket Fabs (P) Ltd.
Bony Systems &
Technologies Ltd.

4. Bony Polymers (P) Ltd. is a reputed name in the field of
Manufacturing Rubber Moulded Parts, Rubber to Metal
Bonded Parts, Non Asbestos Friction Materials, Hoses,
Hose Assemblies & Fuel Tubes for automotive and non
automotive sectors.
Bony Polymers (P) Ltd. was established in the year
1981 & our specialised products have been utilised by
renowned OEM’s.
The aim is, to make the Bony Polymers (P) Ltd. and its
products a benchmark at all levels of International
Standards.
Introduction

5. Technical Collaboration between Becorit GmbH (Germany)
and Bony Polymers (P) Ltd. for manufacture of
Non Asbestos Friction Materials
Bony Polymers (P) Ltd.
Becorit GmbH
K Type Brake Block L Type Brake Block

6. Agreement between Meiji Flow Systems Co. Ltd. (Japan)
and Bony Polymers (P) Ltd. for Licensed Assembly and
Testing of Hydraulic Brake Hoses
Bony Polymers (P) Ltd.
Meiji Flow Systems Co., Ltd.
Hydraulic Brake Hoses

7. In Technical Association with
EATON FLUID POWER INDIA.
An Association you can rely on……
An Association of Quality
Bony Fluid Power System
(A Division of Bony Polymers (P) Ltd.)(
Technical Association

8. Agency Agreement between TES and BPL
for selling in India
Bony Polymers (P) Ltd. (TES)

9. 　
Our Vision

To achieve world class
standards in Quality of Products,
Services and Human resources

10. Overall Man Power
Category Strength
Production 817
Quality Engineering
(Planning & Assurance)
28
Engineering (Product Dev. & Tool Engg.) 21
Research & Development 22
HR, IR, Govt. Liaising & Security 15
Others 10
Total 913
Total Staff = 220
(Junior Mgt. to COO)
Total Operatives= 693

11. Organization Strength
 Extensive R & D and Product Testing Facility
In-house R & D recognized by Govt. of India,
Ministry of Science & Technology
 Technical Expertise to meet Global requirement
 A Fast Growing Company which has a growth
Rate of 25 to 30 % every Year for the last 10 Years
 Certified Quality and Environment Management
Systems

12. • An ISO/TS-16949:2009
•An ISO – 14001:2004 (EMS)
Quality Certification & Approvals
• VDA 6.3
by : MANN & HUMMEL,SIEMENS VDO
& KNORR- BREMSE
• Govt. of India
Ministry of Science & Technology
recognition for In-house R&D
units
(Recertification under new version)

13. Customer Awards for Excellent Performance

14. Environment
•Registered with IMDS
(International Material Data System )
The IMDS is the automotive industry material data system.
In the IMDS, all materials used for car manufacture are
archived and maintained.
•Certified ISO 14001:2004 Company.

15. Expertise in the development & processing of the
following Elastomers:
 NATURAL RUBBER (NR)
 STYRENE BUTADINE RUBBER (SBR)S
 POLYBUTADINE RUBBER (PBR)
 ISOPROPYLE ISOBUTYENE RUBBER (IIR)I
 CHLOROPRENE RUBBER (CR)
 NITRILE BUTADINE RUBBER (NBR)
 HIGH NITRILE BUTADINE RUBBER (HNBR)
 POLYACRYLIC RUBBER
 FLUORO ELASTOMER (FKM)F
 CHROLROPRENE SULPHONATED MONOMER (CSM)C
 EPICHLOROHYDRIN (ECO)E
 SILICONE
 AFLAS
 NBR/PVC
 EPDM
 OTHER SPECIALIZED ELASTOMERS.
Our Expertise

16. Versatile with following international standards :

• ASTM D 2000 for automotive components
• SAE 100 R, SAE J-1403, SAE-30R6, SAE 30R2,
SAE20R4 for hydraulic hoses, radiator hoses,
engine coolant hoses vacuum brake hoses and
hoses for CNG application.
• JIS 6403 Standards, JASO F404 for O-Ring
• DIN standards
• ISO standards
• Customer Specific standards
Our Expertise

17. Product Range

18. Segments Catered
Two Wheelers 45% Cars 10%
Construction & Agri.
Machinery 15%
Trucks & Buses 10%
Railways 18%
Power Plant 2%

19. Our Products
Anti vibration mountsAnti vibration mounts

20. Buffers & Transmission Mountings Buffers & Transmission Mountings
Our Products

21. O - RingsO - Rings
Seals & GasketsSeals & Gaskets
Our Products

22. Grommets for wiring harness
Our Products

23. Dust Covers & Cover Ball JointsDust Covers & Cover Ball Joints
Our Products

24. Boots & BellowsBoots & Bellows
Insulators for CarburettorsInsulators for Carburettors
Our Products

25. •Suspension bushesSuspension bushes
•Bush swing armBush swing arm
•Bush engine hanger & Bush engine hanger &
•Silent blocksSilent blocks
Our Products

26. Isolators & Exhaust Hangers Isolators & Exhaust Hangers
Our Products

27. For Locomotive & Coaches
Our Products

28. Our Products
Vacuum Brake Hoses
Radiator & Coolant Hoses Heater & Water Hoses
Inter Cooler & Turbo charger (Silicon) Hoses

29. Fuel Tubes
Our Products
CNG & LPG Hoses – ARAI Approved

30. High Pressure Hydraulic Hose Assemblies
Our Products

31. High Pressure Hydraulic Hose Assemblies
Our Products

32. Anu Industries
Denso India Limited
FCC Rico Limited
Hero Motors
Lifelong India Ltd.
Munjal Showa
A.G.Industries
 Autofit Pvt. Ltd.
 Magnum Components
 Munjal Auto
 Multilink
 Napino Auto
 Rico Auto
 Majestic Auto Ltd.
 Pricol Ltd.
 Wings Auto
Hero Honda
HMSI.
Yamaha Motors
Suzuki Motorcycles
Esteemed Customers : Two Wheelers
OEMs Tier 2

33. Maruti Suzuki India Ltd.
 Honda Siel Cars India
 Mahindra & Mahindra
Arvin Meritor
 Nissan (Delphi Packard)
 Delphi steering
 Tata (Minda)
 Hyundai (Motonics)
 Land Rover (Mann &
Hummel)
 Mag Filters& Eq. P.Ltd.
Toyota (Tata Yazaki)
Toyota (Toyoda Gosei)
 Ford (Yazaki Wiring)
 Ford (Cooper Standard)
 SKH Metals Ltd.
 MGI Coutier Exotech
 Sun Vacuum Formers Ltd.
Esteemed Customers : Car
OEMs Tier 2

34. Toyo Spring
QH Talbros
Jamuna Auto
Alkraft
Banco
Tata Toyo
Ashok Leyland
Swaraj Mazda
Tata Motors
Mahindra Navistar
JCB India Limited
Escorts Agri machinaries
Claas India Limited
Eicher International Ltd.
 L & T Komatsu
Telcon
Esteemed Customers: Commercial &
Construction Equipments
OEMs Tier 2

35. Esteemed Customers

36. Bony Group Plant Locations
Mixing (Plant 1)
Molding & Extrusion
(Plant 3)
Friction Material
(Plant 2)
Molding
(Plant 4)
Manesar Sheet Metal Plant
(Saket Fabs.)
(Plant 7)
Haridwar
(Plant 5)
Lucknow
(Plant 6)
Existing
Under Construction
Prithla
(Plant 8)

37. 　
BONY POLYMERS (P) LTD. (PLANT-1) PLOT NO. 9E/6 (FBD)
• R&D
• COMPOUND
PREPARATIONS
Existing Units

38. Friction Materials for
Railways and
Automotives
BONY POLYMERS (P) LTD. (PLANT-2) PLOT NO. 77/6 (FBD)
Existing Units

39. •Corporate Office
•Moulding Shop
•Extrusion Shop
A state of art facility which has a shop floor area of about 70,000 Sq. Ft., Which will accommodate
Moulding and Extrusion operations.
BONY POLYMERS (P) LTD. (PLANT-3) PLOT NO. 37 P/6 (FBD)
Injection Moulding Unit Hose Section Moulding shop Extrusion shop
Existing Units

40. 15000 Sq. Feet
BONY POLYMERS (P) LTD. (PLANT-4) 34/3, IMT MANESAR, GURGAON
Existing Units

41. BONY POLYMERS (P) LTD. (PLANT-5)
PLOT NO. 6, INDUSTRIAL PARK IV, BEGUMPUR VILLAGE, HARIDWAR
Existing Units

42. Manufacturing
Facilities

43. Mixing

44. Computerized Ingredients Weighing System

45. Mixing & Pre Blanks Preparation

46. Moulding

47. Injection Moulding Machine
BARREL VOLUME UPTO 10000 CC
CLAMPING FORCE UPTO 400 TONS
No. of Injection Moulding Machine: 50
(38+12)

48. Capacity :300 tons Capacity :200 tons
Vacuum Compression Moulding Machine

49. 14 Tanks Metal Pre-Treatment Line
Surface Preparation

50. AN AUTOMATED ADHESIVE APPLICATION SYSTEM
Adhesive Application

51. Extrusion

52.  High- Precision Fuel Tubes
 Pressure Hoses and
 Long Length Air Pipes.
Co-Extrusion

53. Hose Braiding & Knitting Machine

54. Hose Extraction & Proof testing Machine

55. Hose Assembly

56. Crimping Machines

57. Crimping Machines

58. Fully Functional Laboratory
Testing Facilities

59. Parameters We Meet
High Tensile and Elongation
High Compression Resistance
Oil Resistance/Fuel Resistance
Electrical Resistance
Ozone Resistance / Weather Resistance in open atmosphere
High Temp. Resistance /Low Temp. Resistance
Static and Dynamic Stiffness
Axial, Radial and Torsion Test
Shear & Fatigue test
High Air Pressure Resistance &Vacuum Resistance
Other critical Metallurgies of Engine & Transmission parts

60. For testing of compound
curing behaviour
Rheometer and Rubber Process Analyzer
For testing of viscous and elastic
components & dynamic
characteristics of rubber compounds

61. Vibration Simulator
Testing Equipment
For measuring Dynamic
Stiffness or tan-delta ( loss factor )
of mounts at high vibration
frequency

62. Universal Testing
Machine
(15 tonne Instron)
Testing Equipment
For measuring
deflection at load of
Metalastic ant vibration
mounting

63. Life cycle testing :
•Engine mounts
•Mount rubbers
•Shock absorber components.
Endurance Testing Machines
Capacity:30 tons
Testing Equipment

64. Fatigue Testing
Machine
Testing Equipment
Measures resistance of metalastic
antivibration mount to repeated
compressive load cycling at
defined frequencies

65. Cordinates Measuring Machine (CMM)
Measuring Equipment
Profile Projector

66. Testing Equipment
Ozone Chamber
For simulating weather
resistance upon exposure
of a stressed rubber component
to high ozone concentration

67. Testing Equipment
Torsional Fatigue
Testing Machine

68. Testing Equipment
Dust Cover Mud
Endurance Test
Rig

69. Testing Equipment
Humidity Chamber

70. High Voltage
Tester
Low Temperature
Testing up to –70°c
Measuring cold
flexibility of Hoses &
Rubber Components
Testing Equipment

71. IRHD Hardness
Tester
Resilience
Tester
Dispersion
Analyser
Abrasion
Tester
Mooney
Viscometer
MICRO HARDNESS
TESTER
ELECTRONIC
DENSIMETER
Testing Equipment

72. Hose Leakage Testing
Under water with air pressure
Testing Equipment

73. Hose Durability
Testing Machine
Testing Equipment
Measure resistance of
Vibrating / radiator / heater
hoses to air circulating
hot coolant under
simulated
engine condition

74. Hose Bending Test Machine
Testing Equipment

75. Hose Flexure Testing machine
Measure resistance of Air
Brake Hose to high stress
flex cycling
Testing Equipment

76. Tool Design
Software used: -
•CAD 2005
• Pro-e (wildfire)P
• Uni-Graphics NX3
• Iron CAD
• Delcam
• Solid Edge
• Catia
• Tools made on CNC Machines
Tool designing -In house

77. Tool Manufacturing Facilities
EDM-1
Vertical Milling Machine
Center Lathe
Polishing Machine
Surface Grinder
Drilling Machine
Vertical Milling Center (VMC)

78. Training & Education

79. •Advance Product Quality Planning (APQP)
•Production Part Approval Process (PPAP)P
•Measurement System Analysis (Gage R&R)
•Process FMEA
•Statistical Process Control (SPC)
•Total Productive Maintenance (TPM)
•Kaizen
•Small Group Activities
•Jishu Hozen
Quality Practices
Continual Improvement Activities being followed:

80. Future Plan
A RUBBER MIXING
LINE FOR CAPACITY
OF 5000 METRIC TON
PER ANNUM, WHICH IS
“ A FOURTH
GENERATION MIXING
TECHNOLOGY”

81. Future Plan
New Plant coming up in 12000
sq Ft. for supply to TATA Motors
(CMV) Lucknow
Plant In Lucknow )

82. Plant Available for Future Expansion
18/3, AJRONDA , MATHURA ROAD,
FARIDABAD
15000 Sq. Feet

83. Saket Fabs (P) Ltd.

84. • Presses ranging from 20 tonnes to 600 tonnes
• Self supporting tool room
• Spread over an area of 8000 sq. Yards
A Press Metal Company
Introduction

85. • An ISO 9001:2000
• An ISO/TS-16949:2002
• An ISO – 14001:2004 (EMS)
• Approved by
 RDSO (Ministry of Railway)R
Quality Certification & Approvals
• Direct On Line to
HHML

86. Esteemed Customers
Major OEMs Tier-2

87. Overall Man Power
Category Strength
Production 72
Quality 4
Engineering and R&D 3
Administration 4
Others 2
Total 85

88. Products We MakeProducts We Make
(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)((
•Four Wheeler Products
•Railway Products
•Two Wheeler Products

89. Cabin Parts
Back Panel
Seat Pans

90. Plates Set IN LH-RH Plates Set OUT LH-RHCross Member LH-RH
Chassis Parts

91. Panel Front Lower
Piller B-Out LH-RH Hing Assembly
Body Parts

92. Mounting PadsCorner Bracket LH-RH
End Plate
Other Parts

93. Products We MakeProducts We Make
(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)((
•Four Wheeler Products
•Railway Products
•Two Wheeler Products

94. For Locomotive and coaches
Our Product Range

95. Products We MakeProducts We Make
(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)((
•Four Wheeler Products
•Railway Products
•Two Wheeler Products

96. Engine Parts

97. Fuel Filters

98. Body Parts

99. Manufacturing Manufacturing
(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)((
•Manufacturing Facilities
•Testing Facilities
•Tool Design & Tool Room

100. Manufacturing Facilities
Press Shop

101. Press Shop
Manufacturing Facilities

102. Weld Shop
Manufacturing Facilities

103. Manufacturing Manufacturing
(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)((
•Manufacturing Facilities
•Tool Design & Tool Room
•Testing Facilities

104. Tool Design
Software used: -
•CAD 2005
• Pro-e (wildfire)P
• Uni-Graphics NX3
• Iron CAD
• Delcam
• Solid Edge
• Catia
• Tools made on CNC Machines
Tool designing -In house

105. Tool Manufacturing Facilities
Center Lathe
Surface Grinder
Drilling Machine
Profile milling
Turret milling

106. Manufacturing Manufacturing
(Sheet Metal & Fabrication)(Sheet Metal & Fabrication)((
•Manufacturing Facilities
•Tool Design & Tool Room
•Testing Facilities

107. Testing Facilities
Salt Spray Testing Chamber
Cupping Test Machine

108. Testing Facilities
Hardness Tester Microscope

109. Group Mid Term Plan

110. Group Sales Trend & Forecast
17
26
32
42
58
80
100
115
140
190
300
500
0
50
100
150
200
250
300
350
400
450
500
550
600
650
Value (in Rs. Crore)
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
2007-08
2008-09 2009-10 2010-11 2011-12
Tentative Plan
1 US$ = Rs. 47
40
Million $
63
Million $
106
Million $
30
Million $
20
170
220
30
50
300
50
150
Bony Polymers + Prime India
BSTL
Saket Fabs