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The Market

The Indian sugar machinery market has always been characterized by intense competition. The need to introduce newer technologies, newer equipments literally drives the industry. As a leading player, KCP has continuously striven to build its reputa-tion as pioneer by introducing new product lines.

KCP - An Indian Pioneer
At KCP the ground rules for the success were laid 5 decades ago, when they began operations.

“Indigenise. Modernize. Never compromise on technology”
To execute this commitment, KCP in 1941 took over a sugar mill of 800 TCD capacity in Vuyyuru, A.P. It soon expanded its capacity and operations to 8500 TCD, and took up another factory in Lakshmipuram, near Vuyyuru, which it refurbished, increasing its capacity first to 2500 TCD and then to 5000 TCD. This second unit is the most modern sugar factory in India. Simultaneously, KCP embarked on a diversification plan. It set up a workshop near Chennai, which has grown into a full fledged engineering division of The KCP Limited, an ISO 9000 certified company. With Technical know-how from FCB, France (Now known as Fives Cail, France), this division has been a long standing supplier of sugar machinery to Indian Sugar Industry. The plant and machinery supplied by it incorporate contemporary technology ensuring optimal energy, efficiency and reliability.

Fives Cail - A global force
Today Fives Cail a FIVES Group Company, has come to quite literally mean engineering excellence in the sugar, cement & mineral industries worldwide. Its ISO certified Sugar Division known as Fives Cail, specifically has been supplier of consistently top quality equipment & technology to the world sugar industry. Right from design of new equipment, Development of process, Automation of plants, Modernisation or Extension of existing sugar factories, Fives Cail’s expertise covers every conceivable need of the industry.

The Right Chemistry for Success
To give a new competitive edge to its indigenization efforts and to serve the industry better, KCP looked at the world leader, Fives Cail, France for the newer technology and equipment. Simultaneously, Fives Cail (formerly known as FCB) looked at KCP as the right partner to give a new dimension to the globalization policy.

The chemistry was just right. Fives Cail’s (formerly known as FCB) globally acknowledged expertise and KCP’s well-acclaimed engineering capabilities. The two came together to set up a new venture called Fives Cail-KCP (formerly known as FCBKCP Limited), operations began on Nov.18, 1995 signaling a new era for the sugar industry.

Fives Cail-KCP : The Engineers to the Sugar Industry
From concept to commissioning, Fives Cail-KCP venture means instant access to cutting edge global technologies. Ensuring a new level of excellence in all activities, whether it is a supply of machinery or executing projects on a turnkey basis for the sugar industry.

Our People
The biggest strength of any organization is best determined by its workforce and their level of commitment. Fives Cail-KCP has a unique set-up of highly qualified engineers and technicians, all specialists in their respective fields, viz., engineering, erection, commissioning or trouble shooting. The company is governed by a Board of seven Directors including a Chairman and administered by the Managing Director. HR of Fives Cail-KCP’s structured organization consists of following:

Our Expertise
Fives Cail-KCP is well-equipped with the design and engineering know-how for the entire range of Fives Cail state-of-the-art technologies and products for the sugar industry. The experience and expertise of Fives Cail-KCP have been well-proved in India and abroad.

Fives Cail-KCP undertakes feasibility study in places specified by the customers, and depending on the cane availability and future potential, sizes-up the plant. Fives Cail-KCP’s spectrum of activities include preparation of general arrangement & layout drawings, process engineering and detailed plant engineering documents including electrical & instrumentation schemes, supply of equipment for domestic and export markets, project monitoring and supervision of erection and commissioning of the sugar and Cogeneration plant to the satisfaction of the customer.

Fives Cail-KCP is enhanced its capability and now operating with two divisions as under.

Sugar Division:
Focusing on business in sugar sector on EPC basis including specialized equipments viz., 2-roller (Millmax), 3-roller and 4-roller self setting mills, continuous vacuum pans, D412, D612 & 2512 automatic batch centrifugal machines and Multi tube Sugar dryer etc.,

Energy Division:
Focusing on business in Energy sector capable to supply Bagasse fired boilers of varying capacities and operating pressures, Multi fuel boilers, Biomass boilers, Spent wash incinerators, AFBC boilers and integrated cogen / power plants. Fives Cail-KCP follows IBR/ISO/ASME to design boilers.

Empowering the customer:
In addition to commissioning plants, Fives Cail-KCP provides extensive training to the customers’ engineers / technicians in the operation, maintenance and trouble shooting. It also deputes its experts to customer’s factories who are planning expansion or are graduating to modern equipment for increasing efficiency or for rejunevating the plant or equipments. The experts chalk out a comprehensive programme for expansion / modernization and suggest the equipments to be modified/installed anew. These experts co-ordinate with the plant engineers in the layout modifications in carrying out the above.

Our Engineering capability:
Fives Cail-KCP has with it 50 highly qualified and experienced professionals in the design of plant and equipment for manufacture of sugar and in the respective fields of process, mechanical, electrical, instrumentation, civil and structural engineering who are conversant with sugar engineering and technology. Some have been trained at Fives Cail, France in the latest trends in equipment design.

Design and drafting operations are carried out on Local Area Network (LAN) with a high end server connected to 45 nodes operating under client / server architecture.

Latest versions of software with “Concurrent Engineering” approach, representing the state-of-the-art in today’s computerized engineering analysis are used to enhance productivity in designing, analyzing and drafting.

• Auto Cad 2012 (Inventor / Mechanical)
• Finite Element Analysis software to analyze critical structures and components, shock load and thermal behaviour.
• Feature based parametric solid modeling software.
• Manufacturing resource planning & scheduling application employing RDBMS.

The Quality Assurance Team comprising of highly qualified engineers, chalkout the quality assurance plan for each and every project right from design to commissioning and also the level of acceptance.

The highly committed Project Monitoring Team equipped with modern project management software, coordinate with various agencies, internal as well as external, right from design to manufacture, procurement, erection and commissioning of products and projects.

An expert advisory panel:
Fives Cail-KCP has a regular advisory board, comprising experienced consultants, including Indian Institute of Technology (IIT) whose guidance is sought for optimization by stress analysis which is used in designing and sizing of critical equipments.

Our Manufacturing Capability:
Fives Cail-KCP utilises KCP’s Heavy Engineering Division to manufacturing critical components. This unit is an ISO 9001 and ASME certified engineering complex and is one of the largest, well integrated workshops of its kind anywhere in the world with facilities for casting, fabricating and machining heavy and large sections of steel machinery. The versatility of its engineering facilities is achieved through:

• A modern steel foundry which can pour upto 30 T of liquid metal a piece in a single casting of varying chemical compositions, with heat treatment furnaces capable of accepting 60 T of load, in dimensions upto 5500 (W) x 8500 (L) x 3500 (H) mm.
• Large fabrication bay with facilities to cold bend up to 150 mm, and hot bend upto 180mm thick steel plates, submerged arc-welding, dishing and flanging facilities with cranage facilities to handle upto 200 T loads.
• Machine shops with large gear cutting (upto 8M dia) machines, CNC lathes, horizontal boring machines (upto 200mm dia), vertical boring lathes (upto 7.2m dia), plano-milling machines, dynamic balancing facilities and a host of light, heavy and extra duty machines.

The Engineering unit of KCP is qualified to manufacture boilers as per the above international accredited codes. Fives Cail-KCP has a carefully selected list of sub-contractors and sub-suppliers for supplying equipments matching the specifications and quality standards set by it.

Our Quality - A Critical Ingredient
Fives Cail-KCP’s commitment is well demonstrated by the numerous quality audits it undertakes at every stage, right upto despatch. A well-qualified complement of quality assurance engineers carry out these operations at the testing facilities of KCP which has a full-fledged material testing laboratory, including x-ray testing. Fives Cail-KCP (formerly known as FCB-KCP) can supply equipments subject to specifications of third party inspection agencies like LRSI / BVQI / SGS etc. in accordance with customers’ requirement.