IPD Manufacturing Excellence

Interior and Plastics Division

TACO Interiors & Plastics Division excels in manufacturing high-quality plastic components for automotive and industrial sectors. With advanced infrastructure, lightweighting solutions, and rapid product development, we serve global OEMs as a trusted, full-service supplier focused on innovation, efficiency, and evolving industry needs.

Manufacturing Excellence

Interior and Plastics Division

Established in January 1998, Tata AutoComp Systems’ Interior and Plastics Division is a Full-Service Supplier (FSS) and a leading plastic component manufacturer, specializing in engineering and manufacturing high-quality interior and exterior plastic components and aggregates for the automotive and industrial sectors. We serve major OEMs in the passenger and commercial vehicle segments, meeting both domestic and global requirements.

Our advanced infrastructure includes moulding machines ranging from 60T to 3200T in capacity, along with a robotic paint shop to ensure superior paint finish. Our commitment to innovation, quality, and customer-centricity allows us to deliver quick turnaround times for new products, making us a trusted partner for our customers. We are at the forefront of lightweighting initiatives, replacing large sheet metal parts with polymers. Our adoption of advanced technologies, such as the moulding process, enhances vehicle interior components by using a chemical foaming agent to produce stronger, lighter parts—up to 30% lighter than conventional alternatives. Our injection moulding machines are equipped with articulated robots for pick-and-place operations and automated deflashing. Additionally, we are developing innovative solutions like battery protection parts for electric vehicles, reinforcing our dedication to evolving automotive industry needs.

Hot Press Lamination

Tata AutoComp Interiors and Plastics Division utilizes Hot Press Lamination (HPL) technology across its facilities to deliver superior surface finishes for automotive interiors. This process laminates soft-touch fabric, pre-stitched fabric, or vinyl, ensuring enhanced aesthetics and durability. The inclusion of gluing activation within the tooling setup, facilitated by a hot water circulator, ensures optimal adhesive properties and a flawless bonding process.

Key Features:

  • Advanced HPL technology for seamless lamination.
  • Compatibility with soft-touch fabric, pre-stitched fabric, and vinyl.
  • Integrated gluing activation for superior adhesion.
  • Hot water circulator in press tooling for enhanced adhesive efficiency.
  • High-quality and durable interior finishes.

Injection Moulding Machine (IMM)

Our advanced Injection Moulding Machine (IMM) facility is equipped with state-of-the-art technology to handle large-scale manufacturing with precision:

Injection Moulding Machine Capacity: Ranges from 60 Ton to 3200 Ton

Key Features:

  • Pick and drop robotic system
  • Quick mould change system
  • Gas injection for optimal performance

Vibration Welding

It uses high frequency vibration and pressure to weld two plastic parts where one part remains stationary, and the other part moves in a linear back-and-forth motion. This process is particularly suited for high-productivity assembly lines.

  • Vibration Welding Technology: Advanced level technology to optimize productivity
  • Key Features:
    • Camera-based vision inspection
    • Barcode printer for quality traceability
    • Display for cycle time and welding quality monitoring

Heat Staking Welding

Heat staking welding allows for material joining without vibration, ensuring there is no cosmetic damage to Class ‘A’ surfaces. This method utilizes the base material to form the stud without requiring design changes or the addition of extra components like screws.

  • Multiple Heat Staking Machines: Equipped with a cassette-type changeover fixture.
  • Key Features:
    • Barcode for traceability
    • Display for cycle time and welding quality monitoring

In-Mould Graining (IMG)

At Tata AutoComp Interiors and Plastics Division, we implement In-Mould Graining (IMG), an advanced process designed to create textured grains on TPO skin during deep drawing or vacuum laminating. This technique involves the direct suction of warmed, ungrained foil into a contoured, grained shell during the forming or laminating process. In addition, the IMG-L process facilitates seamless integration by vacuum-adsorbing customized skin to the composite of moulded plastic parts in a single step.

Key Features:

  • Advanced IMG technology for creating textured grains on TPO skin.
  • Efficient deep drawing and vacuum laminating process.
  • IMG-L process for seamless integration of customized skin and moulded plastic parts.
  • Known for high efficiency, delivering superior texture and precision.
  • Enhances product quality while ensuring precision and durability.

Laser Scoring

Tata AutoComp Interiors and Plastics Division utilizes advanced laser scoring technology for precise instrument panel (IP) weakening, ensuring reliable and seamless airbag deployment. This patented process employs a laser source to create a series of blind holes on the ‘B’ surface of the IP, forming a hidden weakening line along the contour of the airbag flap. This integrated breaking line is invisible to passengers under normal conditions but allows for controlled material rupture when the airbag is triggered, ensuring passenger safety.

Key Features:

  • Patented laser scouring technology for precise IP weakening.
  • Creates a concealed weakening line along the airbag flap’s contour.
  • Invisible to passengers but facilitates airbag deployment when needed.
  • Enhances passenger safety while maintaining interior aesthetics.
  • Ensures controlled material rupture for effective airbag activation.

Testing Equipment & Facilities

Tata AutoComp’s Interior and Plastics Division ensures the highest quality standards by employing advanced testing equipment and facilities. These are used to validate raw materials and product performance.

  • Raw Material & Product Performance Validations
  • Coordinate Measuring Machine (CMM)
  • Linear & Profile Measurements
  • Universal Testing Machine
  • Spectrometer for Colour & Gloss Testing
  • Conditioning & Climatic Chambers
  • Leak Testing System
  • Aging Oven & Muffler Furnace
  • Performance Testing for Painted Parts
  • Gap & Flush Analysis

Vision Based End of the Line Inspection Facility

Tata AutoComp also has a specialized facility for the inspection of door trims, bumpers, and consoles, which includes the following capabilities:

  • Barcode traceability
  • Child part detection and monitoring
  • Colour detection

 

Manufacturing Capabilities

Manufacturing Footprint

A combined manufacturing area exceeding 187,300 sqm, supporting large-scale production and seamless operations.

Injection Moulding Capabilities

100+ injection moulding systems ranging from 60T to 3200T, including vertical moulding machines and 2K moulding machines, enabling versatile and high-precision production.

Robotic Paint Technology

Advanced robotic paint facilities with high-volume handling capacity, ensuring flawless finishes and uniformity.

Assembly Expertise

Just-In-Sequence (JIS) cockpit assembly lines for streamlined and efficient component integration.

Manufacturing USPs 

State-of-the-Art Infrastructure: Cutting-edge technology and systems ensuring superior manufacturing outcomes.
High Production Efficiency: Capable of meeting large-scale demands with precision and reliability.
Integrated Operations: Comprehensive solutions incorporating moulding, painting, and assembly under one roof.
Customer-Centric Solutions: Custom-engineered components tailored to meet stringent OEM standards.

Locations 

Hinjewadi

The Hinjewadi facility of Tata AutoComp Interiors & Plastics Division, inaugurated in 1998, serves Tata Motors, VW, and FIAT. Spanning 32,700 sqm, this facility features a robotic paint shop with a capacity to handle 4,000 bumpers and is equipped with nine injection moulding machines ranging from 850T to 3,200T. Certified with IATF, ISO 14001:2015, and ISO 45001:2018, the Hinjewadi facility upholds excellence in quality, safety, and environmental management.

Chinchwad1&2

The Chinchwad facility of Tata AutoComp Interiors & Plastics Division, inaugurated in January 2007, serves Tata Motors’ PVBU. Spanning 32,500 sqm (Plants 1 and 2), the facility is equipped with JIS cockpit assembly lines; moulding machines ranging from 1300T to 2300T; and technology processes such as Laser Scoring, IMG, press lamination, and vibration welding. Certified to IATF, ISO 14001:2015, and ISO 45001:2018 standards, the Chinchwad facility adheres to the highest benchmarks of quality, safety, and environmental management.

Chakan

The Chakan facility of Tata AutoComp Interiors & Plastics Division, inaugurated in July 2016, serves Tata Motors, VinFast, Stellantis, and Volvo. Spanning 45,300 sqm, the facility is equipped with two moulding bays and 41 injection moulding machines ranging from 60T to 2700T. Certified to IATF, ISO 14001:2015, and ISO 45001:2018 standards, the Chakan facility ensures the highest levels of quality, safety, and environmental management.

Sanand

The Sanand facility of Tata AutoComp Interiors & Plastics Division caters to Tata Motors Plants 1 and 2. Spanning 84,000 sqm (Plants 1, 2, and 3), this state-of-the-art facility is equipped with a 48 JPH robotic paint shop, along with two moulding bays and 20 injection moulding machines ranging from 850T to 2700T. The facility boasts a manufacturing capacity of up to 850 car sets per day. Certified to IATF, ISO 14001:2015, and ISO 45001:2018 standards, the Sanand plant upholds the highest standards of quality, safety, and environmental management.

Jamshedpur

The Jamshedpur facility of Tata AutoComp Interiors & Plastics Division, inaugurated in 2014, spans 7,500 sqm (Plant 1+2). Serving Tata Motors CVBU, it features one moulding bay with three injection moulding machines (2000T to 2750T) and an integrated paint shop. Certified with IATF, ISO 14001:2015, and ISO 45001:2018, the facility upholds excellence in quality, safety, and environmental standards.

Bangalore

The Bangalore facility of Tata AutoComp Interiors & Plastics Division, inaugurated in 2006, spans 28,300 sqm. It supports customers like Toyota, Ashok Leyland, and OLA. Equipped with 20 injection moulding machines ranging from 1300T to 2300T, the facility ensures high-quality manufacturing. Certified with IATF, ISO 14001:2015, and ISO 45001:2018, it exemplifies excellence in safety, environmental, and quality management standards.

Ranjangaon

Assembly plant, customers include Fiat – Jeep Compass, Nexon and Altroz.