“Forward-looking Indian manufacturers are already adopting these globally proven practices and have shown strong results in improving throughput, accuracy and cost efficiency, particularly in high-precision machining segments,” says Makarand Dande, Managing Director, REGO-FIX India Pvt Ltd in an conversation with Neha Basudkar Ghate.
What emerging trends do you currently see shaping the precision toolholding market in Western India?
In Western India, particularly in manufacturing hubs such as Maharashtra and Gujarat, the precision toolholding landscape is undergoing significant transformation. The region is seeing a clear move towards smarter, faster and more connected machining practices. MSMEs and OEMs in the region are actively investing in toolholding solutions that support digital integration, operational flexibility and future-ready performance, which are key to staying competitive in an increasingly globalised market.
One of the leading trends driving this evolution is the adoption of quick change and modular systems. These are designed to minimise setup time and maximise spindle uptime, making them essential in high-mix, low-volume operations, where agility is critical. Another important trend is smart toolholding with digital monitoring. There’s a growing adoption of holders equipped with sensor technology to track vibration, thereby enabling predictive maintenance and greater process stability.
Additionally, ultra-low runout and precision collets are gaining traction, especially as industries like die and mould, aerospace and medical demand higher repeatability and tighter tolerances. These systems are vital for consistent, high-quality output. There is also a rising need for high-speed and five-axis compatibility. Today’s toolholders must offer excellent dynamic balance and rigidity to meet the demands of high RPM operations and complex tool paths.
Besides these, manufacturers are looking for hybrid and legacy-compatible solutions. These systems help bridge the gap between older machines and modern CNC setups, allowing gradual upgrades without disrupting production. Micro machining and tight tolerance capability are also becoming crucial. With increasing demand for fine-feature machining, there is a noticeable shift toward ultra-concentric, low-vibration solutions tailored for sub-millimetre tools.
Cumulatively, these trends emphasise a maturing manufacturing ecosystem that values precision, scalability and technological resilience at every step.
With advances in toolholding technology offering features such as ultra-low runout and vibration damping, how do you see these developments impacting productivity and part quality in high-speed machining environments?
Toolholding advancements have significantly transformed high-speed machining outcomes. Ultra-low runout and vibration-dampening designs directly contribute to several critical improvements on the shop floor. One major benefit is extended tool life. Manufacturers have reported tool wear reductions of up to 30-40%, lowered tooling costs and increased uptime. Another clear advantage is achieving a superior surface finish. Even at high spindle speeds, smoother finishes and tighter tolerances are consistently maintained, leading to reduced cycle times.
Additionally, manufacturers have experienced better chip control and reduced chatter that allow for more aggressive cutting parameters while ensuring high part quality. There’s also improved dimensional accuracy achieved through mechanical clamping systems, which deliver repeatable performance across batches. This is especially important in precision part manufacturing. These innovations have unlocked the full potential of high-speed spindles and micro tools, especially where precision and reliability are non-negotiable. As a result, manufacturers have gained not only productivity and quality improvements but also greater confidence in process stability.
How do innovations in internal cooling solutions and quick-change systems help manufacturers optimise tool life and minimise cycle times, especially in demanding production settings?
Internal coolant-through systems are essential for thermal stability and efficient chip evacuation, especially in deep-hole drilling and high-hardness materials. By maintaining ideal cutting temperatures, these systems help maximise tool life and improve surface finish.
Quick-change toolholding platforms are equally vital in setups where frequent changeovers occur. They drastically reduce non-productive time, allowing shops to maintain high throughput even in high-mix environments. Together, these innovations contribute to better OEE (Overall Equipment Effectiveness) and more agile manufacturing operations.
What challenges and opportunities are presented when manufacturers strive to integrate next-generation toolholding systems with legacy machinery and processes?
One of the primary challenges in integrating next-generation toolholding systems with legacy machinery is compatibility, particularly with older spindle interfaces such as ISO or SK. Some of the newer mechanical clamping systems offer an extremely high gripping force with minimal runout, even at high RPMs, without relying on heat or hydraulics. These systems are known for their repeatability, ease of use and long-term stability, which make them an ideal upgrade for legacy machines where precision and consistency are critical.
Additionally, custom adapters, modular extensions and hybrid toolholding solutions enable users to modernise specific parts of their tooling setup without requiring complete machine replacement. This makes it possible to achieve incremental productivity gains, especially for small-to-mid-sized shops looking to bridge traditional setups with emerging production standards. In essence, the right integration strategy allows manufacturers to extend the usable life of existing machinery while still adopting the benefits of high-performance toolholding technology.
What feedback have you encountered from industries investing in toolholders and clamping solutions with enhanced safety features, such as anti-pullout mechanisms and precision collets?
The feedback from the die and mould industry has been particularly strong. Manufacturers in this sector deal with high-value components, tight tolerances and complex geometries, where tool pullout or slippage can lead to costly rework or scrap. Enhanced safety features such as anti-pullout mechanisms and precision-ground collets have become a priority for shops working in deep-cavity roughing and high-torque milling.
Manufacturers report that 360° uniform clamping improves both toolholding security and process stability, particularly in aggressive operations. Anti-pullout solutions help eliminate tool movement under load, which is vital for maintaining dimensional accuracy during long cycle times and in hardened materials. Many die and mould users also appreciate the repeatability and ease of setup offered by high-precision collet systems. These systems reduce manual error, enhance consistency across batches and minimise tool change downtime, leading to better overall productivity and quality control.
In general, the shift towards safer, more reliable toolholding has not only reduced tool breakage and part rejection rates but also increased operator confidence during critical machining processes.
The Western region of India is home to many MSMEs and high-tech manufacturers. What are some unique market needs and opportunities you have observed in this region?
In Western India, there is a clear demand for high-performance yet practical tooling solutions that can be integrated without major changes to the existing infrastructure. Many manufacturers are seeking plug-and-play systems that offer excellent accuracy, repeatability and tool life without the complexity of heat-based or hydraulic setups.
MSMEs in this region, especially those involved in high-precision and intricate machining, value low-maintenance systems, long service life and ease of operation. This allows them to maintain global quality standards while working within tighter budgets and resource constraints. There is also a strong preference for modular and upgradeable tooling platforms and systems that offer flexibility to adapt to new machining demands without requiring full replacements. Customers increasingly prioritise on-site application support, quick access to local inventory and training services to ensure smooth implementation and faster return on investment.
Additionally, decision-makers in this region often appreciate multi-functional holders that minimise setup changes and reduce the number of toolholders required for different operations. Trial-based evaluations are becoming more common, as buyers seek measurable performance improvements before committing to long-term investments. Overall, the market reflects a strong blend of cost-consciousness and quality focus, creating opportunities for tooling solutions that combine reliability, precision and adaptability.
What are some of the challenges that manufacturers in the Western region of India face when adopting new toolholding technologies? How could they overcome them?
Tool and gauge manufacturers, particularly those serving the die and mould sector, face several recurring challenges when adopting new toolholding technologies. One of the most common concerns is the high initial investment. The upfront cost of premium toolholding systems often creates hesitation. However, justifying the cost becomes easier when factors such as longer tool life, reduced scrap and improved machining accuracy are taken into account.
Another key challenge is operator training and adaptation. Many shops operate with lean teams. Introducing new technology often requires skill upgrades. Without proper training, operators may resist change or underutilise the system’s potential. Downtime during the transition is also a major concern. Integrating new holders into ongoing production can lead to setup delays or temporary dips in productivity. Manufacturers often worry about how quickly they can make the switch without disrupting delivery timelines.
Additionally, machine and tooling compatibility pose challenges. There are often doubts about whether newer systems will fit legacy machines or existing tool paths, especially in shops using older CNC setups, which are common in the die and mould segment. Overcoming these barriers typically requires a hands-on approach. This includes live demos, technical training sessions and cost-benefit analyses to build confidence and ensure a smooth, risk-free transition. When supported correctly, users often find that the long-term performance benefits far outweigh the initial concerns.
With sustainability goals becoming more prominent, how should tool and gauge makers rethink their processes to minimise environmental impact, particularly in areas such as coolant usage, tool recycling and energy consumption?
In the die and mould industry, where high-precision machining is often coupled with long cycle times and heavy-duty tooling, sustainability is becoming a key area of focus. Tool and gauge makers can take several steps to reduce environmental impact while maintaining performance. Some of these steps could be:
- Adopt cold or mechanical clamping systems that eliminate the need for electrical heating or induction units, resulting in lower energy consumption during tool changes and setup.
- Use Minimum Quantity Lubrication (MQL) or dry machining, wherever feasible, particularly in roughing and semi-finishing operations, to significantly reduce coolant usage and disposal needs.
- To extend tool life and reduce waste, invest in toolholding systems known for long service intervals, repeatable clamping and reusability. This minimises the frequency of replacements and lowers material consumption over time.
- Recover valuable material and reduce landfill waste by integrating regrinding and recycling programs for worn tools and inserts. Many shops are integrating such programs as part of their standard maintenance cycles.
- As die and mould manufacturers increasingly align their operations with both customer expectations and global environmental goals, they could probably explore tooling and accessory solutions that meet green certification standards.
Looking at global benchmarks, are there best practices from international tool and gauge manufacturing that can be realistically adapted for the Indian context?
Absolutely. Several global best practices in tool and gauge manufacturing are highly adaptable and beneficial for the Indian market, especially for shops aiming to improve efficiency, consistency and overall competitiveness.
One such practice is the standardisation of toolholding systems in line with DIN or ISO specifications. This helps ensure interchangeability, reduces variability and streamlines procurement across machines and operations. Another important approach is centralised tool presetting and tool management. When enabled by holders designed for precision repeatability, this allows for accurate, offline tool preparation. The result is reduced machine downtime and improved process control.
Quick-change tooling systems and modular adapters are also widely adopted in international setups to support high-mix, low-volume production. These practices drastically reduce changeover time and enhance spindle utilisation, especially in short-batch or prototype machining. Routine reconditioning and consistent preventive maintenance using durable, high-precision accessories extend the lifespan of toolholders and minimise unplanned costs. This approach aligns with the goal of reducing the total cost of ownership.
Automation of quality inspection through in-line metrology is another effective practice. It ensures faster feedback loops and reduces reliance on offline checks, contributing to tighter process control. Lastly, collaborative development between machine users and toolholding suppliers is a growing trend globally. Involving end-users in the selection and customisation of toolholding systems results in more effective, application-specific solutions.
Forward-looking Indian manufacturers are already adopting these globally proven practices and have shown strong results in improving throughput, accuracy and cost efficiency, particularly in high-precision machining segments.
This interview was published in TAGMA Times
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