Corporate Credentials: Competency – Capability – Capacity

Rolling Stock: Carbody Manufacturing + Furnishing

forward integrating into Coach manufacturing

Taking Manufacturing Excellence

to the next level
DTL/Corp/Prod/R22-19062024

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved.

 About us: DTL Group
• DTL Ancillaries was established in 1988, Born out of 40 years of rich domain expertise Selective Awards & Accolades
• It is a 2nd largest CRF and fabricated rolling stock components supplier to the Railways and
Background Metros in India i.e. Shell kit items, Sidewall, Roof, Underframe, etc.
• ICF handpicked vendor with CRF capabilities to fabricate side wall, roof etc. since 2008.
• MOU signed with SAPA-HYDRO for development of Aluminum profiles for trains.

• Strategically located manufacturing facilities in Pune to optimize the delivery time and
logistic cost.
Location &
Infrastructure • Lean manufacturing concept with capabilities to produce range of components. India SME 100 Awards
• Manufacturing facilities spread over 17.5 acres area comprises of robust production and India SME Forum - 2017
testing facilities including Prototyping and R&D centre.
IndiaMart Leaders of Tomorrow
• Complete range of inspection, measuring and testing equipment.
ET NOW Awards 2012

• Strong customer relationships has led to DTL awarded a significant amount of new Manufacturing Presence
Client business over the past 30 years.
Relationships • Transitioned key clients (ICF/ MCF, BEML, Bombardier) from “Execution” relationship to
strategic partnership.
• Built Credentials as preferred supplier to Alstom, Bombardier, BEML.

Certifications

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 2

 Our Strength in Numbers – Key Highlights

33+ 20+ 2 4 10.5

acres
3+1
acres
(4 Hectares)
years of overall years of railway DSIR Approved R&D manufacturing manufacturing vacant land for
experience experience & Proto Centre units facility area expansion

150+ 35+ 475 ~4700

INR million
100%
plant equipments customers employee current order Promoters
and machinery served strength* book^ owned
Backward integration & New
Development capabilities

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 3

 Rolling Stock: Offerings by DTL
Carbody: Furnishing: CRF & Metro Interiors: Wagons:
o Underframe o Modular Lavatories o Cantrail o Open Wagons
o Sidewall o Ceiling Panels & Side Panels o Solebar o Covered Wagons
o Roof o Sleeping Berths & Ladders o Roof Corrugations o Flat Wagons
o Endwall o Nosecone Mask o Underframe Corrugations o Hopper Wagons
o Nosecone Structure o Driver Cab & Desk o Trough Floor o Container Wagons
o Entrance Doors o Luggage Rack o Saloon Seat & Cab Window
o Door Frames o Saloon Sliding Door o Air Ducts & Cable Ducts
o Water Tank o Partition Panels o Alum HC Ceiling Panels

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 4

 Our Delivery Credentials: Apr’12 – Mar’24

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 Metro Rolling Stock: CRF Kit So far, 2,771 Cars CRF Kit supplied out of 3,334 Cars.

Cantrail Solebar Trough Floor Roof Sidewall Skin

 MRS1: 506 Cars (380 Cars Delivered)

 BMRCL 5RS-DM: 318 Cars (Starting May’24)
 Vande Bharat Sleeper: 160 Cars
Supplies Started from Hyundai Rotem DMRC RS 6 in 2008.

 Delhi-Meerut RRTS: 20 TS (Delivered)

 Agra-Kanpur MRTS: 67 TS (40 Delivered)
 Bhopal-Indore MRTS: 26 TS (16TS done)

Now Alstom  Vienna Flexity Tram: 94 TS (81 Delivered)

 Mumbai Line 3: 12 TS (On-going)

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 6

 Technical Milestones
Evolved from a fabricated supplier for auto to
A leading supplier of comprehensive products to
200 AC-3T
Started Delivery Alstom LACCNE
for orders of SS Mumbai Line-3 Fursnishing;
Railways and Metros. Received vendor station benches and Bhopal – Honeycomb &
approval from Indore MRTS
Bombardier to and enhanced FRP Plant
supply CRF fabrication CRF.
Started plant in components for
Started supplying metros; capacity
Kolkata; 2023
CRF components 2021
Started mill for IIGF invested Rs.
for metro coaches
wagon CRF 250 m in DTL 2019
to Rotem and
Sole supplier for sections; 2017
BEML
Backward 1.6 lakhs vehicles Developed 100+
integration to 2012-2013
panels @ 400 tools for CRF
start CRF roll
sets per day for sections 2010 2024
forming (in
house mill 2022
TATA Ace
2020
Load body assembly) 2008 Vande Metro Shell
production for 2018
2004 Vande Kit, MEMU Coach
DCM Toyota 2015
2000-01 Bharat Furnishing; DETC
2012 Complete Shell Shell Kit Shell Furnishing.
1988-95 manufacturing
2009 Received orders for LHB
(Export);
2005 Received INR shell kit items and Complete coach
2002-03 Received 250 m order corrugated sidewalls; furnishing from
1996-98 Government from Rotem executed trial order RCF; CRF of BEML
Set up mills recognition for MRS1
to supply CRF from Bombardier;
for LHB SS R&D design and Bombardier RRTS,
Additions of 3 Started components received approval from
coach set prototype Agra-Kanpur
CRF mills (all manufacturing to DMRC the MCF for prototype
Shifted to Pune modules for Metro.
CRF components validation interiors of two LHB
as supplier to designed and
ICF
assembled in for Railways designs Coaches.
Tata Motors
house)

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 7

 Our Journey so far in last 2 decades in Railways domain
Started with CRF &
Fabrication items At Present Going Forward
•Under-frame Assembly •Complete Coach Shell / Car Body •Rolling Stock manufacturing
•Sidewall Assembly •Complete DETC (Tower Car)
• A. COACH
•Complete interior furnishing:
•Roof Assembly •Flooring, •B. WAGON
•End wall Assembly •Sidewall & Ceiling panels, •C. METRO
•Partition frame,
•Front Part Assembly •Seats & Berth (HL 3 compliant)
•End Part Assembly •Window, Doors & Steps,
•Lavatory,
•Partition Frames
•Luminaires & Lighting,
•Door Cut out Assembly •Switches and Charging Points,
•AC Ducting,
•Nose Cone
•Chair Pillar with Upper Berth Climbing
•Cant rail Arrangement,
•PAPIS,
•Solebar •Gangway, Vestibule,
•Rain Gutter •Aluminium Extrusions
•Wagon Building at KULTI Site
•Roof bearer
•Cable Tray and Duct assembly
All Types of Sliding Doors
•All Types of Luggage Racks
•Fuel Tank
•Water Tank

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 8

 Our Foreign Technical Collaborations

Jin Yang Metal

Roll Forming Germany Composites France Metro CRF ToT S. Korea

AC Ducting Czechia Alu Profiles Belgium

These associations of DTL has significantly expanded the reach, footprint and innovative competitive advantage of our product range in Rail & Metro.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 9

 Manufacturing Excellence
o The manufacturing plant of Railway Equipment Division is spread across an area of over 17.5 acres with shop floor area covering 2.59 L Sq. Ft and
houses superior production and testing facilities, inclusive of a research and development centre. 7 acres of Solar site is included.
o The units are capable of manufacturing crucial railway products of high quality. This is further ensured with the involvement of proficient human
resource and technology advancement.
 Lean manufacturing concept with capability to produce multiple technology-based products through engagement of multiple processes.
 State-of-the-art modern facility with Cutting, Bending, Shearing, Welding machines, hydraulic power presses ranging from 10 tons to 1000 tons,
with inhouse toolroom.
 Process design based on FMEA outcomes to achieve optimum process capabilities (SPC).
 24x7 Round the clock working and support.
 Over 475 competent staff across skills. | 60 Certified Welders | Average experience 10 years | Average age 35 years
 Over 100 plant equipment and machinery.
Corporate Office Unit - 1 Unit - 2

1st Floor, Kohinoor Centre, Gat No. 366, Ambethan Road, Gat No. 43, WMDC Indl Area,
Talegaon Chowk, Chakan Chakan Ambethan Road, Chakan

Unit – 3 Unit - 4

Gat No. 43, WMDC Indl Area, Gat No. 2003, Ambethan Road,
Ambethan Road, Chakan Chakan

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 10

 Our Build-up to be a Rail Coach Furnishing Partner
o Successfully established credentials for Furnishing business through delivering in World
Class Interior in 2017 to MCF for proposed tender of 1000 coaches by Rly Board.
o We have established credentials in coach furnishing by participating in World Class
interior in 2017.
o We are one of the two qualified vendor amongst number of participants establishing itself
as a unique player with execution capabilities amongst list of furnishing players in
collaboration with French partner.

This shell is developed w.r.t. furnishing design ab-initio.

o We received development vendor status from the program and which has helped in
receiving our first order of 109 coaches furnishing from RCF for LACCNE, and later 200
more from RCF.
o The current capacity at our premises for furnishing is for 50 Cs/month; being ramped-up
to 75 Cs/month as per Order receipt.
o We have additional land, where we plan to expand the current furnishing operations with
Double Rail-Track for complete turnkey solution covering Shell with Furnishing.

Furnishing
Capacity

Coaches/Month Coaches/Month
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 11
 Our Products and Market Segment
COACH FURNISHING METROS WAGONS LOCOMOTIVE

Rail Coach Fabrication Rail Coach Interiors CRF & Interiors RS CRF and Structural kit Complete Loco-Shell

Metro CRF Products

Complete Shell Kit

Side Sill Side Cant Rail Door Cover Upper Panel

Roof End Wall Front Part Side Wall

Key Stone Plate Cant Rail Roof Sheet Rail Gutter

Door Nose Cone Under Frame Paintless Corrugated

Metro Interiors
Side Wall

Saloon Seat Floor Coving & Kick Plate Cab Window

CBC Coupler Retention Tank Water Tank Entrance Door Cubicle Frame Ceiling Panels Work Room Shell Assy
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 12
 Product: Complete CG Mozambique Export Coach
Southern African Mozambique through RITES Customized “Make in India” export oriented world class coaches at MCF. DTL supplied to MCF.
Narrow 610mm
Gauge

Narrow 762mm
Gauge

Meter 1000mm
Gauge

Cape 1067mm
Gauge

Standard 1435mm
Gauge

Broad 1676mm
Gauge

Standard
Railrod
Actual Photo at MCF Tie 2591mm

These coaches are of “cape” gauge i.e. 1067mm, which is a variant in between broad and meter gauge. Customization done in terms of gauge, length and interiors to suit the needs of
Mozambique railways. DTL is supplying for complete shell for AC First class, AC 2nd class, AC 3rd class, pantry cars, generator cars, restroom cars etc.
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 13
 Product: Complete CG Mozambique Export Coach
Southern African Mozambique through RITES Customized “Make in India” export oriented world class coaches. DTL supplied to MCF.

After successfully manufactured and supplied 60 Shells in SS301 material,

an additional 10 shells order received.
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 14
 Product: Complete DETC Coach Shell & Wagon
PLW (DMW), Patiala Part of the ‘Make in India’ initiative, DETC will be able to respond to the damage of OHE equipment. WAGONS @ Kulti Site

BOXNHL

BVCM

BOXNR

The DETC has an elevated platform, an observation dome, room for OHE testing equipment and tools to deal with
accidents.
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 15
 Product: Vande Bharat Sidewall

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 16

 Product: Vande Bharat Underframe, Roof, Endwall, etc.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 17

 Product: Vande Bharat Nose Cone

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 18

 EMU Nose Cone

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 Product: RRTS Carbody

Sidewall Skin Solebar Cantrail Roof Corrugation Under frame Corrugation

14Mtr Tandem Press Brake acquired Exclusively to produce Sidewall Skin for RRTS
on LONG-TERM arrangement with Alstom (Ex-Bombardier).

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 20

 Product: Camp-Coach and Workroom Shell Assembly

Camp Coach,
Workroom Shell Assembly and Steel Components for
LORAM Rail Grinding Machines
supplied vide BEML & SAN Engg.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 21

 Product: LHB AC-3T Coach Furnishing

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 Product: LHB AC-3T Coach Furnishing

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 Product: LHB AC-3T Coach Furnishing

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 Product: FRP Modular Lavatories System
Modular TOILET with Gel coat finish FRP with anti graffiti PU painting, Provision for ANTI-SKID floor, Touch free fittings, Odour controller & dustbin with PFS.
(Pressurized Flushing System MCF's MMDTS 19027)

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 25

 SS Modular Toilet System
LGS / EOG COACHES

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 Product: Furnishing items delivered in Coach Interiors
1st time
introduced
FST
Compliant
as
FST compliant timber free floor, modular berths,
halogen free upholstery, rubber floor carpet, fire
resistant PU foam
Motorised Electric window Venetian
blinds, leather-free FST compliant berths
Interior insulation panels Fire Alarm System World
Class
Coach
interiors
in
2018-19.
IP Camera Passenger Information Center DIVYANGJAN toilet with wheel-chair entry

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 27

 Product: Furnishing items delivered in Coach Interiors

Flooring Seat & Berth Ducting Sliding Door Snack Table, Mobile Holder, Braille Signage
Water Bottle Holder

Fittings & Accessories Chair pillars including ladder Alu HC Partition Frame Light Fittings

Side & Ceiling Panelling Lavatory and Other accessories

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 28

 • Aluminium
Product: AC Ducting • Polyester Fabric

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 29

 • SS Based
Product: Luggage Rack • Aluminum Casting & PC Sheet based

Improved
Luggage
Rack

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 30

 Product: Saloon Sliding Door

Endurance Testing Jig

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 31

 Products: Seat & Berths • Lighter & Modular
• EN 45545 FST Compliant

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 32

 Product: Seat & Berths – PU Foam M/c
The strictest safety regulations apply to
the railways industry. the norm EN
45545 about the fire resistance of parts
and materials used for railways.
The resistance to fire of the foam is
assessed with the following criteria:
o Flame spread
o Ignitability
o Rate of heat release
o Smoke
o Toxicity
This Premix Unit along with chemical
loading system is capable of producing
EN45545 compliant PU Foam at V2S.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 33

 Product: Rail Coach Interiors Side and Ceiling Paneling

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 34

 FRP Composites Manufacturing: Shop
o A completely newly developed and installed FRP Shop at Unit3 with shop floor area covering 85% and houses superior production and testing facilities,
inclusive of R&D and Prototype Development Validation centre.
o The units are capable of manufacturing crucial railway products of high quality. This is further ensured with the involvement of proficient human resource
and technology advancement.
 Lean manufacturing concept with capability to produce multiple technology-based products through engagement of multiple processes.
 State-of-the-art modern facility with Mould, Fixture/Tooling design capability and Process and Product Validation through in-house facility & tie-ups.
 Process design based on FMEA outcomes to achieve optimum process capabilities (SPC).
 24x7 Round the clock working and support.
 Our team is having expertise is to develop and manufacture
large size FRP engineering and industrial components.
 Processes:
 Controlled Hand Lay-Up (HLU)
 Sheet Moulding Compound (SMC)) – Under Development
 RTM / LRTM – Under Development
 Vacuum Infusion Process (VIP) – Under Development

SMC to supplement Hand Lay-up Process:

Installing 2000T Hydraulic Press as per RCF directives

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 35

 FRP Composites: Fire Testing Laboratory Equipments
To ensure product development as per specification, we have set-up this facility for FRP Components:
Toxicity Tester NCD-1409
Smoke visibility tester UIC 564-2 Apx15
Critical Oxygen Index Testing Instrument with ASTM D2863
Electro chemical Oxygen Analyser
Digital Temperature Controller Muffle Furnace up to 1000 0C
Digital Temperature Controller Oven up to 200 0C
Izod impact tester IS 1998.
Notch Cutter
Resistance to impact test
Specific gravity with density kit accuracy 0.001 g
Toxicity 14 gas Tube and Pump
Digital UTM (upto 2.5 ton)
Thickness Gauge
CMM 3-axis
Spread of Flame Tester UIC 564-2 Apx11
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 36
 FRP Composites: Fire Testing Laboratory Equipments
To ensure product development as per specification, we have set-up this facility for FRP Components:

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 37

 Aluminium Honeycomb Core Production Plant
o A completely newly developed and installed Aluminium Honeycomb Core production
Shop at Unit-3.
o The units are capable of manufacturing Partition Frames and Ceiling Panels.
o State-of-the-art modern facility includes:
 Gluing Machine
 Hot Pressing
 Core Sawing and cutting machine Essential Backward integrated for Quality Furnishing

 Core Expander
 Laminating Press
 Vacuum Bagging

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 38

 Aluminium Honeycomb Core Manufacturing Plant
Gluing Machine Hot Pressing Machine Core Sawing Machine Expander Machine

Core Cell Sizes: Hot Pressing up to Core Bunch of Capacity: Sawing up to Core Expanding up to
3.2 MM, 4.8 MM, 6.4 MM, Length 2600 mm X Width 600 mm Length 2700 mm x Width 600 mm Length 3800mm x Width 3000mm
9.6 MM, 12.7 MM, 19.2 MM

Cold/HOT Pressing Machine Expanded Core Sawing Machine CNC Router

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 39
 Aluminium Honeycomb Core Testing Laboratory
Applicable Tests
S. Test Ref Actual specified
Testing Parameter Test Method
No. Std value of product
Bare compressive strength APPENDIX B of
1 ASTM C365 9.4 Mpa
and modulus test IS 11642
Stabilized core compressive APPENDIX C of
2 ASTM C365 9.8 Mpa
strength and modulus IS 11642
L direction strength : 4.8 Mpa

Core shear strength and APPENDIX D of L direction modulus : 0.9 Mpa

3 ASTM C273
modulus test IS 11642 W direction strength : 3.0 Mpa

W direction modulus : 0.4 Mpa

Node-bond strength of APPENDIX E of

4 ASTM C363 5.0 Mpa
honeycomb core material IS 11642
ASTM D1781
ASTM D
5 Drum peel strength ASTM D 1781 1781
Min 60 [Link]/cm
6 Bending load ASTM C 393 ASTM C 393 Min 2.0 Mpa

ASTM C393
ASTM C365

ASTM C273 ASTM C363

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 40

 Honeycomb Application in Metro & Railways
o Carbody / Bulkhead

o Ceiling Panels

o Partition Frames

o Driver’s Cab partition wall

o End Wall

o Sidewall and Door

o Sidewall Flap

o Roof Sections

o Floating floor panels

o Anti-skid access ramps

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 41

 Metro Interiors: SS Seat for Mumbai Metro Rolling Stock

Suitable for MEMU.

2-Seater
3-Seater
4-Seater
5-Setaer
8-Seater
Option available.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 42

 Metro Interiors for Rolling Stock

Cubicle Frame Floor Coving

Pilot
Cab Window

Floor Coving
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 43
 Product: Urban Furniture: Railway Platform SS Benches
Model no : DTL-UF-ARB-41 DTL benches at MUMBAI CST
Model no : DTL-UF-ARB-10
Sheet Metal Bench with Backrest with seat partition. Sheet Metal Bench without Backrest.

o 10 Seater Bench, SS 304grade o 4 Seater Bench, SS 304grade

o Matt finish o Matt finish

o L-2720mm, W-976mm,H=825mm o L-1742mm, W-525mm,H=460mm

o Made of Sheet metal and Pipe. o Made of Sheet metal and Pipe

o Turret Punching Hormone Pattern Seat. o Turret Punching Hormone Pattern Seat.

o 2 legs made of 3mm thk SS Pipe fixed with the help of Welding o 2 legs made of 2mm thk SS Pipe fixed with the help of Welding

Model no : DTL-UF-ARB-42
Sheet Metal Bench with Backrest and with seat partition.
o 4-Seater Bench, SS 304 grade
o Matt finish
o L-1800mm, W-676mm ,H=796mm
o Made of Sheet metal and Pipe.
o Turret Punching Hormone Pattern Seat.
o 2 legs made of 3mm thk SS Pipe fixed with the help of Welding Model no : DTL-UF-ARB-43
Sheet Metal Bench with Backrest and
without seat partition.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 44

 Exclusive CED & Painting Plant
This World-class facility is built
with a capital investment of
₹ 25 Cr in 2011-12
comprising
 Semi Automated all SS
Constructions CED Plant
 Top Coat Line
 Capacity: 32,000 SqM per Day

Maintained by:

Executed by:

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 45

 Underframe Front Part for Indian Railways – CED Coated

o Simple process eliminates dependence on skilled manpower. Fully automatic o We have installed electrodes at the bottom of the CED tank to take care of
PLC based plant requires less human efforts, film thickness can be controlled. uniform DFT in the bottom of the component.
o Uniform coating. There is no Runs, Sags or Solvent boils. o Able to coat highly recessed areas.
o Better coverage in interior / complex surfaces & sharp corners. o Able to coat complex shapes with a very high degree of accuracy and
o Better corrosion resistance, & @ 100 % utilization of paint therefore cost repeatability.
effective. o The deposited film is reproducible from part and from day to day.
o As coating is done using aqueous process which has less risk of fire in o The same salt spray life is a norm for Auto majors like Maruti & Hyundai.
comparison to solvent coatings, Better in anti-pollution, safety, health hazards.
o The surface salt spray life resistance lasts for more than 1200 hours as per
ASTM B117; against conventional process which offers 250 hrs.
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 46
 Metro Carbody Trough Floor – CED Coated

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 47

 Metro Interiors: Driver Desk

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 48

 The Number says it all – Salient Facts of our CED Plant

PLC 3 4 900 Kg
Jobs per hour
Controlled Transporters Weight Job each
(3,000SqM / Day)

13 5.75 Mtr 2.75 Mtr 3.25 Mtr

SS Tanks Tank Length Tank Width Tank Height

50000 Ltr 13 7.5

x Mtr 33900 ft2 35 Mtr
Tank Capacity each CED Oven Size CED & Paint Shop Area Length Top Coat Line

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 49

 4-Stage Plenum filtered Air downward draft Paint Booth
Completely made in SS
with
Flash-Off
&
Oven

Paint Line Length: 40 Mtr

Capacity: 3,000 SqM/Day

Existing Dimensions
Size in Mtr. L W H

Paint Booth 15.92 2.90 3.28

Flash Off 14.11 2.90 3.52

Oven 14.11 2.90 3.04

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 50
 Our Capabilities: Complete CRF items (1/2)
Tool designing by using
Copra Software
Coach Metros Wagons
Customized mills
Mill 1-4 Mill 5-6 Mill 7-10
Type # Type # Type #

105/90* 32 stage 2 105* 18 stage 1 165* 16 stage 1

75* 20 stage 1 90* 12 stage 1 105* 16 stage 2

75* 16 stage 1 75* 16 stage 1

In house developed tools

Technical and manufacturing capabilities excellence achieved by DTL over the years….

Developed 22m laser Developed spot

In-house tooling Developed all
machine bed and jumbo welding machine
for coach CRF CRF mills
mill for large CRF parts for 22m sidewall

Added 32
Added 4KW laser Added 2 CNC 22 mtr Process for paint less
stages, 105 dia Developed paint-less
cutting & laser bedspot welding coaches
mills for coaches
welding machines machines
metros

Technological capabilities and commitment to innovation has given success in order conversion

We have successful track record of completing new product testing and approval in cost effective and efficient manner

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 51

 Our Capabilities: Complete CRF items (2/2)

Machine / M&P
Man / Experience

Material / Compliance
Method / Home Grown CRF Technology
•We are supplying Cold Formed •Infrastructure to produce 22 meter •Refined by German Know How being •We have 100% capability to meet
products for Railways since long single piece carline, 2 meter our speciality, including tooling; we and produce desired CRF items in
2001 and diversified into Metro width with laser tracker for control have developed in-house tool Stainless steel as well as Corten
items from 2008 prominent among of profile and dimensions to 15 design, simulation, validation skills; steel.
other orders are Hyundai-Rotem
DMRC RS-9 300 cars, BEML’s MRS1 Micron to a meter accuracy. erected Two 32 stages CRF mills
506 cars and Bombardier RRTS & designed and made in-house. •All CRF items for all sorts of rail
Agra-Kanpur totaling 411 cars •Also last but not least a 1 Ton each coaches (ICF self-propelled, LHB,
project. 10 MTR long centre sill BoxNHL •Over 150 plant equipment and metro and RRTS) are produced.
Wagon IRSM 44 etc. necessitated machinery
•Recently executed projects for RRTS developing a Jumbo Mill as Import •CRF items manufactured by us are
/ DEMU / MEMU / EMU / T18 substitute to 3.5 Million USD to •Dedicated unit-2 for Roll Forming Cantrail, Middle duct frames,
coaches. name just a few. Technology. Keystone plates, Cover door, Upper
cover, Trough floor, Longitudinal
•Over 500 competent staff across beam, Rain gutter, Sidesills, Outside
skills. sill, Upper panel, Roof cantrail, Roof
•30 Certified Welders EN 15085 panels, Corrugated panel, Sidewall
•Average experience 10 years cantrail,
•Average age 35 years

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 52

 CAD – CAE Software (Latest Versions)
COPRA® FEA RF 2020

SINUMERIK 828D

COPRA® RF 2021

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 53

 Design and Tooling Capabilities
o We are dedicated ourselves in designing and manufacturing of press tools, trim dies, punches, sheet metal press tools and moulds with the goal to
become the best in the industry.
o Having in-house tool room as well as trusted supplier-customer relationship, we get the dies & tools made with desired precision timely.
o We have hired an adroit team of employees, which keeps themselves abreast with advanced manufacturing techniques and designs.
o Further, we also have a quality control unit, wherein, we check our entire range on defined parameters like design, quality and finish.
o All units and equipped with all the essential tools, machine, and technology in order to manufacture a high-quality range of products.

o This enables OEMs to draw attention towards to us:

o Quicker-Smarter-Better solutions
o Client-centric approach
o Moral business ethics
o International quality standards
o Economical prices

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 3D Robotic Laser Cutting – 7 Axis for CRF Profiles

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 Laser Cutting-cum-Welding & Seam Welding M/c

Bed Size: 2 X 22 M | Power: 3KW Maximum welding speed of

Thickness: 12 MM (SS) 3 mtrs / min.
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 56
 Salient Facts of our CRF Credentials
Production Capacity:
No. of Mills: No. of Stations: Job Thickness:
7500 T / Annum;
10 2 – 36 Forming stations 0.5 – 10 mm
Capacity can be twice.

Sheet Width: M/c Working Speed:

Cutting Type: Hydraulic Power:
1500 mm Max. 6m/min; vary w.r.t.
Hydraulic 80 T to 100 T
(1mill with 2m wide) profile complexity

Coil Bore:
Roller Diameter: Coil Weight: Yield Strength: 965 MPa
500 ID Min.
600 mm Max. 6T–8T UTS: 1050 MPa Max.
650 OD Max.

Driven Type:
Profile Depth: Motor: Motor Power:
Individual +ve type Heavy
200 mm Single Drive 75 HP
Duty Gear box

SS RM Grade: Design, Simulate and Validate Tolerance:

Temper Rolled Grade: Flower Diagram of
301L, 301LN, 304, 304L & LT, DLT, ST, HT As per EN 10162
400 Series, HS Alloy Steel Sections: COPRA Also Customer Specific

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 Design R&D
Designed & Developed Designed & Developed First time in India 22-meter-long weld less ready to fit CRF
Paint-less SIDEWALL Sidewall carline with true profile.
for the 1st time in India Seam Welding We have been an exponent of CRF technology since 2001.

DSIR Certified
Dept. Of Scientific and Industrial Research

Continual Development of Sub-systems components

SS Saloon Seat for

Mumbai Metro Rolling
Stock
(BEML)

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 Paint-less coach production: Concept to Creation
Paint-less coach production: Concept to Creation First 2 trains corrugated paint-less LHB SS coaches
Antyodaya running successfully
PRESENT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1

FUTURE

4 prototype coaches 409 m corrugated sidewall sets

delivered to MCF

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 Next in Line: Aluminium Coach production India-Italy-Belgium
MOU signed with SAPA-HYDRO for development of Aluminum profiles for trains

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 Next in Line: Aluminium Coach manufacturing India-Italy-Belgium

Converting the Side wall, Roof in Aluminum vide Friction Stir Welding and use bimetallic insert welding to join with SS underframe and End wall.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 61

 Next in Line: Complete Carbody with sub-systems
Strategic focus on NPI/NPD: MOU & TOT signed for below sub-systems to remain ahead in the race and Future-ready.
MOU Signed Under Discussion
Rubber Floor Covering Aluminum Extrusions for Coach / Trainset Vestibules Air Springs
(2mm & 3mm)

Station Escalator Seats & Berths Aluminum Honeycomb Panel – Automatic Sliding Access Door systems
Developed in-House@DTL for AC compartment

Platform Screen Door Fire Detection and Suppression System FRP Modular Toilets Plug Door - Single Leaf Automatic Sliding
Main Entrance

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 New Capability: 5-Axis CNC Milling M/c
Applications:
o Loco Shell – WAG9 Underframe X: 7200
o Bogie with Bolsters (VB, Fiat, WAG9, Metro & MEMU)
o Coupler Adapter Weldment Assy
Y: 4300
o Bolster Adapter Weldment Assy Z: 1400
o Many more jobs

Under Development
[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 63
 DTL’s UNIQUE in-House Manufacturing Facilities
Fabrication (Ferritic as well as Austenitic) Furnishing Complete interiors
o CNC Laser Welding & Cutting – 24mtr long o Seat & Berths PU Foam based
o 360o Robotic Laser Cutting M/c – 24mtr o Interior FRP Paneling
o Aluminium Honeycomb Partition Frame
o CNC Robotic Spot Welding – Gantry 45mtr long
o Liquid spray Painting
o Cold Roll Forming Mills – width upto 2mtr
o CED Coating
o CNC Milling and Machining Centres – 5-axis
o Modular Lavatory paneling & assembling
o CNC High Definition Plasma Cutting – 24mtr long o Fabrication for Chair Pillars, other assy
o CNC Press Brake – 14mtr o Testing Lab for FRP, Alu-HC Core and Metal items.
o Hydraulic Press – Up to 500T Railway Furnishing Product - Mix
S. No. Sub-Systems Source Share
o Shearing and Bending – 4mtr 1 Flooring Developed Source 2%
o Roof Arch Section Rolling 2 Seat & Berths in-House 22%
3 IC Sliding Door in-House 2%
o FARO Laser Tracker 4 FRP Panelling in-House 8%
5 Alu HC Partitions in-House 5%
o Punching Machine
6 Chair Pillar – SS/MS in-House 7%
o MIG, TIG and MAG Welding complete set-ups 7 Modular Lavatory - ePFS in-House 14%
8 AC Ducting - Alu In-House 5%
o Plate Straightening 9 Passenger Amenity in-House 4%
o Radial Drilling 10 Lettering & Stickers Developed Source 1%
11 CCTV Developed Source 2%
o Shot Blasting and Sand Blasting Booths 12 PAPIS Developed Source 9%
o Paint Booth with Drying Oven 13 FDS Developed Source 6%
14 Lighting & Switches Developed Source 4%
o Portable CMMs 15 Hardware Developed Source 1%
16 Control Panel Racks in-House 1%
o Mechanical and Chemical Testing Lab
17 Transport in-House 4%
18 Installation in-House 3% 64

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 Quality Engineering
o Our relentless focus on quality as a business process has facilitated development of standard operating procedures that stabilize and
standardize our operational efficiencies. In our journey of transformation, we have followed global best practices and consequently
developed our own excellence model to set new benchmarks in quality standards.

o Our comprehensive testing system ensures that each product which is produced is able to set a benchmark for quality standards.

o Our testing facilities include:

 State-of-the-art calibration facilities and standard room, including 100kN UTM and other facilities selected on principles of MSA

 Fully-equipped testing laboratories to carry out detailed examination in accordance with IRIS, RITES, RDSO specification

 A modern, full scale high pressure shower test Roof Leak Testing/Underframe Inspection

 Dedicated team with a Culture of process design and control to achieve zero defect and QMS objectives

 Complete range of inspection, measuring and testing equipment for destructive and nondestructive inspection and analysis of
products including components, sub-assemblies, assemblies and system solutions.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 65

 Systems for Controlling, Scheduling & Effectiveness

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 Environmental System - Our Go Green Practice
o We have all the certifications necessary to run a world-class facility as well as we are certified for ISO 9001-2015
QMS & ISO/TS 22163:2017 IRIS & IATF/TS 16949:2016.
o Life Membership with Maharashtra Enviro Power Ltd for waste disposal.
o Plant is Certified by Maharashtra Pollution Control Board .
o Chrome Free processes approved by MPCB.
o Equipped with Effluent treatment plants.
o Non air polluting process.
o Plant for Zero Discharge.
o 7 Acres hilly area.
Reimagining Tomorrow, Acting Today!
o Installing 2 MW Solar power Plant

1kWp ~30 tonnes* ~50 teak trees*

= =
Solar System Carbon Emission Plantation
abatement

*Source: Govt. of India calculator at [Link]

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 67

 End to End Capabilities in CRF and Fabrication Process

Bending Finishing &

Has 3 laser cutting Has 1 laser welding, 4
Design and machines and two plasma Has 12 mtr 1 CNC spot welding, 3 seam Assembling
Development cutting machines, 2 CNC bending machine, 1 welding machines, 5 Finishing include
In-house tooling shearing machines, 1 CNC roller bending machine, arm spot gun sandblasting, priming
capabilities drill machine, 3 CNC lathe 2 mechanical power Machine and painting product.
machine break, 7 hydraulic press DTL follows stringent
Approved inhouse quality checks
R&D units by throughout the
Department of manufacturing process.
Scientific and Laser & Plasma
Industrial Research, Cutting Machines Welding
GoI

CNC Bending Machine Laser Tracker

Copra Software Laser Cutting Machine Laser Welding Machine

DTL has the capabilities to work across processes with minimal outsourcing

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 68

 We are a leading player in the Rail & Metro industry
Established in 1988, Started Railway business in
2000, Now IRIS certified company

Built Credential and successful contract wins

ICF handpicked vendor with CRF capabilities to
with deepened footprints in rail rolling stock
fabricate side wall, roof etc. since 2008
market in India

Strategically well-located manufacturing Led by first & second generation

facilities in West (Pune) to optimize the entrepreneur having combined
delivery time & logistic costs experience of more than 80 years

Transitioned key clients for CRF (ICF/ MCF,

BEML, Bombardier. Alstom) from “Execution” Well invested organization backed by robust
relationship to “Strategic Partnership”. Adding business practices to give optimum growth
new clients CAF (audit) & Siemens (initial RFQ)

Track record of value creation & new product

development in SS , MS , FRP , Aluminum
Honeycomb for Railway Shell & Furnishing etc.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 69

 Smart Procurement: Proto Development & SCM
Sourcing, a key cost reduction driver:
Make vs Buy configurations are being taken. An illustration below.

o We develop proto, and standardise the production; then outsourcing on Job work basis.
o Cost competitiveness depends on the availability of raw materials required for component manufacturing in adequate
quantity and of required quality at a reasonable price.
o In the case of Aluminum technology, although India has a large production & assembling capacity, the availability of
certain raw materials (quality and quantity) is doubtful. Hence, there is a dependence on overseas suppliers.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 70

 Leading DTL’s growth story with following key team
o Lean organization structure with streamlined cost methods has made DTL to successfully manage rail supply market cycles.
o Seasoned Management Supported by Strong Bench of Managers.
Managing Director
• Future Business Strategy
VIJAY MOHAN JAIN
• New Businesses & New Product Development Satellite Team: Customer SPoC
• Selvakumaran D. – Chennai
• Finance and Company Legal matters • K. N. Pandey – Raebareli
• Cost Reduction Overview. Jt. Managing Director • Mrityunjay Prasad – Kapurthala
• Tender’s scrutiny before submission. OPERATIONS • Vimal Bhasin – Delhi
• M. R. Lakshmi Venkatesh - Bengaluru
SIDHARTH JAIN

Operations
OSD
SADANANDA
Avinash

NPD & NPI Sales, Engg, Design Production Materials Commercial Manufacturing Company
New Business Marketing Development Planning Logistics Coordinator Secretary QA, QC Management
SADANANDA SADANANDA THORAT, Control GUPTA NITIN Systems Systems
VERMA, RAKSHE RAKSHE RAKSHE
VIKRANT Rail Fab Cold Roll Paint Shop
CFT Finance
Co-ordinator THORAT Forming MUMTAJ
SUNIL
ABHILASH Furnishing VERMA
Maintenance Accounts
CFT: Cross
FRP- Special
Accounting NARAYANAN ROY
Functional Team Purchase VIKRANT Processes
based on Product & SHINDE PRASHANT Honey comb RAKSHE
Client from Engg,
Production,
RINKU RAVI
Materials, Logistics,
Etc.
Bank Company Safety Human Resource
Liaison Secretary MUMTAJ Development
Administration
*Cross communication at various levels will be avoided but wherever it is necessary,
NITIN
we should not restrict in the interest of overall result oriented approach.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 71

 DTL’s plan to supply Fully-Furnished-Painted Shell
Shell Furnishing Way Forward
At Present: At Present: Fully Furnished-Painted
DTL is supplying below T18 Shell DTL is executing AC-3TE Shell for Rolling Stock
sub-assemblies to ICF. Furnishing on Turnkey basis PUs. VB or T18 or LACCNE.
PO from ICF to DTL Our in-house manufacturing facility are: Over period of time, we will add:
NDTC • Seat & Berths PU Foam based • 150m of Track for furnishing on
Coach Type vs Sub-assy DTC MC TC • Interior FRP Paneling
/EC dummy bogies at Unit-3 Annexe.
Underframe     • Aluminium Honeycomb Partition Frame • Painting Booth and Shower Test at
Sidewall     • Liquid spray Painting Unit-4.
Roof     • CED Coating
• Bogie and other electrical items
Endwall     • Modular Lavatory assembling
can be sourced as necessary.
• Fabrication for Chair Pillars, other assy
Nosecone Structure  - - - • Production Rate: 6 Cs/Week
• Testing Lab for FRP and Metal items.
Solebar & Centre Sill    
DTL having supplied below shells and Furnishing is confident of this proposal.
o 71 Fully assembled SS301 carbodies for Mozambique CG Coaches
o 40 DETC Locoshells to PLW Unit - 3
o 33 Shells of varying design i.e. RIV, CC, TRC, ORC, OHE IC, to SAN Engg (on-going)
o 40 Work Room Shells for Rail Grinding Cars to BEML
o 79+71 AC-3TE coach furnishings at RCF
o 10 AC-3TE coach furnishing at MCF, after 2 AC-3T coach furnishing at MCF for World Class Coach interiors.
o 13+101 AC-3TE Coach furnishing at ICF.
o 6 Rakes MEMU Coach furnishing at MCF
o 7 Sets of AC 2nd Class Chair Car at MCF
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 Capacity for Legacy Business and New Generation Shells
and for Furnishing Business for Coaches, Metros, Locos with fully integrated facilities in 4 Plants…
Product Category Components Customers Legacy Business New Generation Business
Underframe Assembly
Shell Kit assemblies o
o Sidewall Assembly; Lavatory Sidewall
With additional 1,00,000 SqFt new shop
Assy Indian Railways PUs o Fully Backward floor area capacity
o Roof Assembly integrated facility
BEML (Metro)
Roof

o End wall Assembly o Loco Shell: 100 p.a. (2/Week)

Sidewall

o Front Part & End Part Assembly

o Partition Frames Alstom SW Skin o 600 coach sets p.a.
Underframe
o VB Shell: 600 p.a. (2/Day)
o
o
Body Side Entrance Door;
SS Outer Door; Cut out Assembly (RRTS) o Valued ₹300Cr p.a.
Sleeping Berths Air / Water / Fuel Tank Door End-wall
o Nose Cone (Shell Painting also possible, if required)
Cantrail
CRF Kit assemblies o
o Middle duct frames
o Keystone plates
o Carline
o Cover door
o Upper cover o CRF for Loco-Shells and Metros can be
o Trough floor developed and manufactured in-House.
o Solebar / Longitudinal beam o 750 coach sets p.a.
o Rain gutter
Sidesills
Metro RS OEMs o Bogies for Loco and VB WAG9 can be
o
o Valued at ₹100Cr p.a.
o Outside sill fabricated and machined on 5-axis
o Upper panel
o Roof cantrail M/c. Capex on M/c made 90%.
o Roof panels, Roof Flange
o Corrugated panel
o Sidewall cantrail

Flooring
Coach interior furnishing o
o Sidewall & Ceiling panels
o Partition frame Indian Railways PUs o Aluminium Honeycomb panels with
o Seats & Berth (HL 3 compliant) Tenders in Pipeline: Honeycomb Core manufacturing
o Window, Doors & Steps o MCF: 325 LACCNE Coaches
o Roller Blinds
o MCF: 250 LACCN Coaches o 900 Coaches p.a. installed along with composite panels
o FRP Modular Lavatory
o Luminaires & Lighting, Switches and BRL o RCF: 121 LACCNE Coaches making facility in-House. Inter-alia can
o Passenger Amenity: Mobile Holder, Water o ICF: 130 LACCNE Coaches o @75Sets/ monthly be provided.
Bottle Holder, Snack Table
o AC Ducting Order-in-Hand: o Valued at ₹400Cr p.a. o Floating floor, Aluminium Ceiling and
o Chair Pillar with Ladders
o PAPIS & CCTV
o MCF: 24 MEMU Coaches side interior panels in Alu HC sandwich
o Aluminium Extrusion Profiles o RCF: 121 LACCNE Coaches
o Stainless Steel parts for skirting o ICF: 101 LACCNE Coaches panel.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 73

 DTL’s Complete Rolling Stock @Unit-4 Plan: 4 Acres

Existing
Proposed

Testing Track Length Available: 254 Mtr,

Total length available is 1016 Mtr track,
as was required by CRRC.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 74

 Advantages by partnering with DTL
 Strategically located to serve all PUs & RS OEMs.
 Better connectivity between Pune and PU/OEMs vide Rail & Road.
 One Company to Contact for Shell as well as Furnishing
 Single point for Contractual dealings.
 Better Productivity as Design and Manufacturing are in Sync.
 Costs are Cut.
 Greater Quality.
 Lesser Inventory.
 Utilizing DTL’s “all-under-one-roof” competency.
 DTL’s networking will greatly come to influence by indigenized
procurement, meeting “Make-in-India” mandate.
 DTL’s foreign collaboration in technological improvements for
modernized “future-ready” can be leveraged.
 Leverage the expertise in shell modification and interiors, as
already done in the export coaches, indigenously developed
GLOCAL Product for CFM Mozambique.
 Therefore rolling out coaches from DTL is beneficial for all.

[Link] © 2024 DTL Ancillaries Ltd. All rights reserved. 75

 Our Vision & Mission

Mission @ DTL Railway Manufacturing

o To enhance competitiveness
o by investing in required resources
o including specialized technology like CRF (Cold Roll Forming), Surface Coating & Painting
o to become a reliable partner to customers
o by providing excellence in railway coach manufacturing, furnishing and commissioning
for turnkey projects.

…in short, Roll-Out Coaches from DTL.

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 From MD‘s Desk: Develop what will be important tomorrow.
The world never stands still.
And new challenges arise every day.
With a passion for questioning things, for
supplying ideas, and intelligently driving
things forward we are helping society move
towards a smarter tomorrow.
Be it with technologies, innovation, up-
gradation, collaboration, knowledge transfer,
learning appetite, etc.
This is how we are able, to tackle the most
important projects and push them forward
together.
Help us shape the future.
We have been very clear from the beginning
that we exist to serve our Customers.
And so, being focused on meeting or
exceeding our customer’s wishes is DTL’s
culture.
We are Future Ready.
Mr. V. M. Jain – MD, DTL Group

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 Thank You for giving us Opportunity to serve YOU.

Since 2005 Since 2010 Since 2015 Since 2018 Since 2009 Since 2008 Since 2015 Since 2018 Since 2010

POWER
Since 2006

TRANSPORT

Looking forward for a

Successful Business
Partnership with
Trust.
Reach us at: sadananda@[Link] / 9823 575 284 | jsv@[Link] / 9823 129 393 | md@[Link] / 9823 069 893
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