From a single-tool trial that led to a plant-wide shift, Kolhapur-based Technocube India Pvt. Ltd., transformed its machining performance by adopting REGO-FIX High Performance powRgrip toolholding solutions. Integrating REGO-FIX powRgrip solutions across their operations helped the company boost machining performance, achieving 25-60% longer tool life, 30% faster speeds, and major gains in accuracy and efficiency.
In high-precision machining, where every micron matters, even the tiniest detail could make a big difference. As tolerances get tighter and components get more intricate, solely relying on the best machines or cutting tools cannot guarantee success. Sometimes, it comes down to overlooked elements, like the toolholder, that can tip the scales between a perfect finish and a costly mistake. This insight proved crucial for Technocube India Pvt. Ltd., a rapidly expanding precision parts supplier based in Kolhapur, Maharashtra.
After investing in a high-end turn mill centre and even being equipped with competent cutting tools and CAM software, when inconsistent tool life, lengthy changeovers, and irregular accuracy in crucial tasks continued to impact Technocube India’s operations, they realised it was time for a tooling system upgrade. After incorporating REGO-FIX’s advanced toolholding technology, Technocube India observed that their machines and cutting tools were performing at optimal capacity, tool life was enhanced, the setup time decreased, and the microns were mastered with ease.
Technocube India’s Humble Beginnings
United by a shared ambition and a desire to carve their own path, three engineers, Imtiyaz Mujawar, Chetan Pawar, and Pradeep Patil, brought together their skills, determination and entrepreneurial spirit to establish Technocube India Pvt. Ltd.
“Technocube India Pvt. Ltd. began in 2009 as a modest machining setup in Kolhapur. With a small team, we catered to local production needs with a rented CNC machine, relying on manual setups and limited resources. Back then, our annual turnover was a mere ₹60,000 per month. 2016 was our turning point. We made our first major investment by purchasing an advanced turn mill centre of a reputed brand from Japan; we also witnessed growth in our customer base. Our new customers wanted us to produce critical components,” Mujawar recalls.
Technocube India was growing from a small local machine shop into a high-precision manufacturing company. This growth opened up new opportunities to work with industries like oil and gas, aerospace, and gearbox manufacturing where accuracy and consistent quality are extremely important.
The Challenges: Getting to the Root of Tooling Trouble
By 2024, Technocube India had established itself as a trusted name in high-precision component manufacturing. With over 20 machines, a team of more than 100 people, and an annual turnover of ₹27 crores, the company had come a long way. But the journey was far from easy.
As the company grew, so did the pressure to maintain precision, improve tool life, and reduce the cost per part.
“We had invested in VMCs from a well-known brand. While these machines helped improve cycle time and processes, we still couldn’t save much on tooling costs,” says Mujawar. “We were expected to deliver high-quality parts at competitive prices. Achieving this was difficult, as our tool life was not good.”
When they compared their Indian machines with international ones, they noticed clear differences, particularly in cutting performance and programming ease. But the bigger issue was tooling. “We struggled to get consistent tool life, and that was a problem, especially because many of our operators are semi-skilled, due to the shortage of skilled manpower in Kolhapur,” he adds.
Despite improving their machining strategies, refining programming, and using top-quality cutting tools and toolholders from reputed brands, the company still faced the same issue. Everything seemed right, the machines, the tooling, the processes, but the results remained inconsistent. The tool life failed to improve as they expected.
The Turning Point: From Trial to Transformation
While looking for an ideal solution, Mujawar encountered REGO-FIX’s robust mechanical clamping technologypowRgrip at IMTEX in 2023. After a brief interaction to understand Mujawar’s concerns, REGO-FIX presented him with a chart comparing REGO-FIX’s technology versus the other toolholders he was using.
“The findings of the comparison seemed unreal, but we were keen to try it out. After using just one REGO-FIX toolholder, we noticed a 45% improvement in tool life compared to the other toolholders we have been using over the years,” he says, adding, “With such great results during the three-month trial period, we immediately placed a purchase order.”
From Uncertainty to Accuracy: How REGO-FIX Redefined Performance
Armed with REGO-FIX’s powRgrip toolholding solutions, the company reduced their bottom line, as the tool life had increased. This was a huge cost-saving for the company. “Apart from the enhancement in the tool life, we also realised that the same toolholder is compatible with drills, reamers, end mills, and U-drills, eliminating the need for external clamping devices for each operation,” explains Mujawar.
Another area of improvement the company observed is the reduction in setup time. “Typically, in a day, we make 18-20 tool setups, which take up to 4-5 hours. Now, with REGO-FIX toolholders, we can accomplish this in 30 minutes. Also, we don’t need skilled manpower or experts for the task, as the setup is extremely user-friendly, even a layman can do it,” Mujawar elaborates.
Seeing the impressive results after using REGO-FIX powRgrip toolholders, the company also invested in accessories like ER collets and clamping nuts and saw a 15% performance boost, with accessories lasting over 3 years. This contrasted annual replacements required with previous setups. The results extended across materials and applications, from high-carbon steels to superalloys, delivering consistent improvements in cycle time, which improved by 30%. While some applications showed an improvement of 20% in terms of tool life, others showed a remarkable 60%.
Using REGO-FIX’s toolholding solutions, Technocube India has been able to achieve unthinkable precision levels. “Going below 20 microns was considered impossible. But thanks to REGO-FIX’s toolholding solutions, we achieved position tolerances of up to 10 microns over a 300-mm length by minimising micro-vibrations through superior clamping stability. The accuracy level was consistent across 400 components,” highlights Mujawar. This was a game-changer for Technocube India.
Case In Point: The REGO-FIX Impact
Technocube India leveraged the ability of REGO-FIX’s toolholding solutions for producing a component for Kirloskar Engines’ project called ‘Camp on Wheel’. Previously, with other toolholders, they were able to generate 100 parts per tool. This number increased to 130 parts per tool when they used REGO-FIX’s technology. With a production volume of 2000 parts per month, the ROI on REGO-FIX solutions was recovered within 46 days.
Looking Ahead: Technocube India’s Journey to Future-Ready Manufacturing
In precision manufacturing, success depends on the choices made at every level, especially when it comes to tooling. Technocube India’s decision to partner with REGO-FIX wasn’t just about selecting a product, it was about embracing a mindset focused on quality, reliability, and long-term growth.
Today, REGO-FIX has become an important part of Technocube India’s machining process. What began as a trial with just one toolholder quickly proved its value. Earlier, the company needed around 80 toolholders to manage the same set of operations. But after switching to REGO-FIX, they were able to bring that number down to just 36, without losing any performance or flexibility. In fact, they could do even more with fewer holders. “We gradually upgraded our tooling setup with REGO-FIX solutions across all operations. In a few months, all our toolholders will be from REGO-FIX,” Mujawar shares.
By investing in the right tooling solutions, the company was not only able to take on more demanding jobs and deliver consistently high-quality results on time, it has also built a business that’s scalable, future-ready, and trusted by customers. “I have seen many people consider cutting tools and toolholders as consumables, but with REGO-FIX powRgrip, I feel it’s an asset for me. REGO-FIX has proved that investing in the right technology delivers consistent, high-quality performance,” Mujawar concludes.
Key Outcomes:
- Improved tool life: Across various applications, tool life has increased by 20% to 60%, leading to fewer tool changes, lower costs, and more consistent output.
- Multi-purpose compatibility: The same holder accommodates drills, reamers, end mills, and U-drills, making it easier to standardise tooling across machines.
- Zero runout concerns: Every tool now maintains under 6-7 4-5 microns of runout, enabling consistent accuracy even with unskilled operators.
- Setup time savings: Earlier, changing 18-20 tools took up to 4-5 hours a day. Now, it’s accomplished in 30 minutes.
- No external clamping devices needed: This has simplified the process for floor operators.
- Elimination of skilled manpower: Even a layman can now clamp tools and start machining with confidence.
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