R&D

R&D AND CONTINUED PRODUCT IMPROVISATION POLICY

RAPL is committed to the need of continuously improvising the design and manufacturing methods and process to enhance the performance standards of RAPL equipment SPECIALLY designed for LPG Bottling plant needs. As an extension of this policy, RAPL has introduced the concept of standardization of sub-assemblies components wherever practicable, with able and vigilant guidance of a highly skilled and experienced team of foreign-trained engineers.

All the equipments that are developed and supplied by us are thoroughly checked at our inhouse Test bench, where a model chain conveyor system is available.

All our equipments are now being designed and compatible to work with PLC based systems with very minimal and in some cases no manual intervention. PLC’s have been introduces in most of the filling hall equipments such as (Purging unit, Auto cap hammering unit, Auto Evacuation unit etc.) as well has Degassing and Statutory testing equipments such as (Valve screwing/unscrewing unit, Degassing Unit, Hydro pressure testing unit, Pneumatic pressure testing unit etc).

DRY CHAIN

RAPL is one of the leading manufacturers of Conveyor Chain (wet type) fabricated out of Flats and rods of MOC carbon steels. In the past, wet chain was used at conveyor to move the LPG cylinders for its process from one place to another at the refilling plants with the help of lubricant. RAPL has developed a patented Dry chain which can run without using soap lubricant in place of wet chain in LPG Bottling plants. All over India we are the foremost company to obtain zone1 IECex/Atex approval for the drychain.

AUTO RQC – RANDOM QUALITY CHECKING SYSTEM FOR LPG CYLINDERS

Our "Automatic RQC Unit" plays a pivotal role in ensuring the quality of LPG bottling processes by Randomly Checking for leakages in the filled LPG cylinders. This advanced equipment is specifically designed to perform the following critical functions:

Random Quality Checking: The Automatic RQC Unit randomly selects filled LPG cylinders and meticulously checks them for potential defects like variations in net weight of LPG, leakages in the valve area, the bung area, and the integrity of O-rings within the valve.

Statistical Reporting: The equipment not only identifies defects but also compiles statistical data based on the random quality checks. This data provides valuable insights into the overall quality and safety levels of the LPG cylinders within the bottling plant.

Compliance with ATEX/PESO Standards: We are proud to highlight that all electrical components used in our Automatic RQC Unit are rigorously sourced and fully compliant with ATEX and PESO regulations for operation within Zone 1 hazardous areas. This ensures the equipment operates safely and efficiently in environments where explosive atmospheres may be present.

Data Logging and Reporting: Comprehensive data logging is an integral part of the Automatic RQC Unit's operation. It maintains detailed records of all random quality checks and statistical data, which can be used for regulatory compliance, auditing, and process improvement.

Complete Automation of equipments used for Statutory testing of LPG cylinders. Recently we have successfully commissioned inhouse STP unit at IOCL -TIRUNELVELI bottling plant. This plant is equipped with all statutory testing equipments such as PLC based online Degassing unit, shot blasting machine, internal cylinder vaccum cleaning unit, PLC based online 10 head hydro pressure test unit, primary and secondary painting booth with cylinder rotation arrangement, valve changing machine powered by VFD, PLC based online pneumatic testing unit, cylinder tare weight punching machine and foot ring marking machine. Overhead conveyors about 800 meters for STP shed, repainting shed and for cylinder handling between STP , repaiting , filling and degassing sheds. automated through PLC based systems with minimal manual intervention.

Route Card Automation – ERP based tracking (using QR code) of LPG cylinders undergoing various tests inside the Statutory testing plants.

Further the company is meticulously working to implement affixation of QR codes on LPG cylinders as part of Track and Trace solutions which is a cloud based tracking system introduced by Indian oil Corporation Ltd.

RAPL is working to introduce the concept of clinching where in the SS QR tags will be affixed on the Stay plate of the cylinders inside the bottling plant before filling. With the assistance of QR reads, vision unit with AI based cameras installed at various stages inside the botting plant ensure smooth traceability of assets i.e cylinders.

IECex/ATEX

The company has obtained IECex/ATEX approval for components such as :
RAPL Dry chain
RAPL Guide Wheels(Pulley)
RAPL Drive Wheels (Sprockets)
The above components are certified for to use in zone1 Hazardous areas.