By Heneage Mitchell
Dickinson Fowler (DF) is an Indian manufacturer of high quality, good value tobacco processing equipment whose products can be found in primary and green leaf processing plants throughout Asia and beyond. Formed in 1965 as John Fowler India Ltd., the company was originally focused on manufacturing tobacco and tea machinery and road construction equipment. Latterly it concentrated on tea and tobacco machinery only.
In 1998, the company entered into a 50/50 joint venture agreement with Dickinson Legg of UK which is presently a subsidiary of Garbuio S.p.a. Italy. The group commands over 50% market share of the global PMD (primary manufacturing department) segment. Dickinson Fowler is a direct descendant of Legg, which was founded in 1886, and claims to be the oldest surviving company in the tobacco industry (together with Tobacco Asia’s sister publication Tobacco International which was also founded in 1886...Ed)
DF now manufactures a complete range of PMD and GLT equipment that is found in factories globally. Business is brisk, not only with leading international tobacco companies but also with smaller enterprises seeking a competitive edge by purchasing high quality equipment at reasonable prices.
"Dickinson Fowler manufactures equipment for large multi-nationals as well as smaller, independent tobacco processors," said Sanjoy Dutta, general manager (marketing). "Presently the company is booked with a lot of orders in the GLT and PMD sectors globally and expecting a few very sizable orders from the Asian and African regions."
The equipment is manufactured at the company’s state-of-the art factory in Bangalore, India, in its modern and efficient sheet metal and assembly shops, and is finished in what may be India’s most sophisticated painting room.
But, there is always room for expansion, and with an eye on the future, the group, comprising DF and sister company John Fowler, which manufactures air and automobile filters in the factory next door, has already purchased an additional seven acres adjacent to the plants for future expansion plans
The company attracts the most experienced and professional staff and retains them through various benefits and training and incentive schemes on offer.
"We have an excellent engineering team of over 15 people who design all the equipment from concept through detailed engineering layout and final engineering of all the equipment produced," explained Sanjoy. "The company also has a complete control panel division with dedicated software engineers for plant and process controls. It also has a highly skilled project management team who have installed and commissioned projects globally with the highest level of customer satisfaction."
Equipment is designed to individual customer’s specifications. The largest facility installed to date is 8.5 tons/hr, while the smallest was a pilot plant capable of processing 150 kg /hr. More commonly, production solutions in the range of from 4-8 tons per hour are supplied.
Sophisticated software solutions can link each item of equipment in the processing line, providing further layers of consistency and continuity in production.
"Software controls are developed and customised to the customer’s needs," said Sanjoy. "If a client has more than one facility, software solutions can link these and provide consistency and continuity in production. The software is designed around individual customer’s language and processing philosophy. All operator training is provided by DF, either in situ and in our DF factory."
Compatibility and linkageNot every customer needs a complete line, and the company is geared up to supply different solutions for different scenarios.
"In some cases, only parts of the production line are required, In these instances, the engineers ensure complete compatibility and linkage with the existing machinery set-up to ensure smooth, hassle-free operation," Sanjoy explained. "Every effort is made to ensure complete standardization of parts throughout the lines to simplify maintenance tasks and spares management Operational manuals are supplied providing standard maintenance tasks and schedules, including the spares categorization, consumables, critical and normal, with minimum and maximum recommended stock quantities. The manual is designed in an easy to understand format that clearly lists items that are standard across the plant ensuring that maintenance tasks are carried out in the most economical and efficient way."
This ensures that every client’s needs are carefully assessed and explained prior to a contract being signed: there are no surprises when it comes to spare parts inventories required.
"Spares lists are supplied at the time of the initial order and sufficient stocks of spare parts, which are guaranteed for 12 months, are supplied at turn-over of the plant," Sanjoy said. "Stocks are then replenished as they are used to ensure the plant always has adequate supplies.
DF also accepts plant audits for upgrading and modernization. Based on the findings of the audit, DF can suggest the best solutions to meet the budget and expectations of the client including refurbishment of existing lines or replacement kits.
Corporate ethicsDF recognizes the importance of keeping its staff happy and fulfilled. It is proud of its retention statistics, which are way above the average in a country that commonly sees professional employees moving on from one job to another in efforts to improve their prospects. It has achieved this success by ensuring that employees’ aspirations and abilities are fully catered to and developed.
"All shop floor technicians and supervisors are trained in-house in a dedicated training facility and also in external programs," Sanjoy commented. "Some are also sent to training in similar industries in exchange programs where appropriate, as well as engaging in small group activities that engender team spirit and encourage thinking out of the box. Employees are encouraged to excel and achieve advancement and promotion within the company. The company’s skill retention is outstanding. Employees dine in a subsidised canteen on site, and enjoy above average health benefits as well."
On the social outreach side, there are blood donor programs in place, and AIDS awareness and check up programs across the board. The company also endorses a voluntary eye donation program that employees are encouraged to support.
EnvironmentThe factory floor is as airy, bright, clean and clutter-free as it is possible to be. What is particularly inspiring is the effort that has been put into the surrounding environment. Instead of the usual concrete and cement hat make up most factories’ exteriors, the DF facility is surrounded by lavishly landscaped gardens that flourish around the 4.8 acre facility, so employees have always got views of natural greenery wherever they may be working.
Added to this is the environmental concern shown in the maintenance of these gardens.
"The factory is a completely rain-harvested estate," Sanjoy said proudly. "All rain water is trapped and stored in eight rain storage and recharge pits. The factory is EHS (environment, health and safety) compliant: a team conducts regular internal audits to monitor and improve compliance where appropriate. The factory is also equipped with the most modern air and effluent treatment devices. It recycles all the sewage produced and this ends up watering the gardens. The factory has not purchased water from outside to hydrate the gardens since investing in this system."
It is factors such as this, together with the quality and functionality of the equipment, that are part of the reason DF has developed into a preferred supplier to a number of multi-national tobacco companies worldwide, and why the future looks bright for India’s leading PMD and GLT equipment manufacturer.
