Facilities

A) Melting shop

Suitable materials are used to melt different grades of cast iron in the medium frequency core-less induction furnace. The chemistry of the molten metal is checked before pouring the castings. Pouring temperature and pouring speed of individual items are monitored to ensure consistently high quality of castings.

Induction furnace

550 kW, Dual Track 500 Kg capacity, medium frequency core-less
induction furnace - Inductotherm make

Ladles

250 kg capacity pouring ladles (5 nos)

500 kg capacity pouring ladles (2 nos)

1000 kg capacity ladles (2 nos)

EOT crane

5 ton capacity (1 no)

Carbon equivalent meter for checking composition of molten metal before pouring

Monorail system for mould pouring

B)Moulding shop

The moulds are made of silica sand of high purity.

The grain size and size distribution of this critical raw material is monitored during all supplies.

Other moulding sand additives like bentonite and coal dust are also tested before use.

The mixed sand that is supplied for making moulds is tested at regular intervals.

The quality of moulds made is also routinely checked before they are closed and sent for pouring.

Hand moulding to make up to1000 kg single piece castings.

Electric hoists to handle moulding boxes before after moulding and also moulding bed during maintenance.

Mould cars, track lines, pneumatic pushers.

Green sand system in machine moulding.

Green sand and CO2 silicate processes in hand moulding.

CO2 silicate and no bake processes for cores

Moulding machines

Intensive High Speed Mixers

500 kg capacity (2no) 200 kg capacity (2nos)

Sand plant

Including sand storage hoppers of capacity 120 tons, belt conveyors, bucket elevators, polygonal sieve, magnetic separators etc.

EOT cranes

5 ton capacity (1no) 2 ton capacity (2nos)

C)Core-shop

Cores are made manually and by a core - shooter. Core-making is done by
sodium silicate - CO2, amine and no - bake oil processes.

The mixed sand used for making cores is tested regularly.

Cores are inspected visually and for all critical dimensions before use. A sand drier is used to dry incoming wet sand during monsoon.

Sand drier

Sand mixer

100 kg capacity (2 nos)

Core-shooter

Cores manufactured by amine process (4 no)

D)Pattern shop

All patterns and core - boxes are inspected and corrected if required, before being released for production of moulds and cores. New patterns and core - boxes are checked for dimensions and methoding. Repairing facilities for wooden, aluminium, gun - metal and cast iron patterns and core - boxes are available in - house.

Continuous improvement in the areas of casting yield and cost reduction are carried out regularly.

Facilities for inspection, repair and mounting of patterns on match plates.

Marking table for dimensional inspection of patterns, core boxes and castings.

Methoding, mounting patterns and fixing gating risering on match plates.

E) Shot-blasting & fettling shop

The castings produced are cleaned of sand sticking. The running and risering systems are removed from the castings. They are then ground, finished, painted, packed (wherever necessary) and made ready for shipping.

Shot-blasting machine

Pedestal grinders

Portable electric and pneumatic grinding machines

Portable cut-off machines

F) Machining Facilities

Milling machines

Radial drilling machine’s

Lathes

Multi Spindle drilling and tapping machine

Hydraulic pressure testing rig

G) Engineering services

Preventive maintenance of all equipments directly or indirectly involved in production is carried out. On the rare occasion of a machine breakdown, repairs are carried out. Spare - parts of critical machines are kept. The aim is to achieve zero breakdown in the long-term.

Department-wise energy consumption is also monitored and analysed.
Suggestions for energy savings are implemented.

Power transformer

22 kV / 575 V 850 kVA transformer for furnace

22 kV / 440 V 400 kVA transformer for auxiliary equipments

Compressors

Air-compressor screw-type : 8 kg/cm 2 pressure

Air-compressor screw-type : 8 kg/cm 2 pressure

Air-compressor (2no)

Diesel Generators

Furnace accessories

heat-exchangers, cooling water pumps, hydraulic power pack etc

Pollution control

Wet scrubbers, bag - type dust collectors, cyclone filters

Rain-water harvesting

H) Quality control & laboratory

Spectrometer with provision to measure 22 elements to test Chemistry of incoming raw materials and molten metal before pouring castings.

Sand testing equipments (permeability, compactability, moisture,

green compression strength, green shear strength, AFS number,

Active clay, Dead clay, Total clay, Ash, Loss on ignition, Volatile

matter for testing incoming, moulding and core sands.

Universal Testing Machine of 40 T capacity to test mechanical

properties of various grades of metal being poured.

Brinell and Poldi hardness testers to check hardness of castings, and critical bought-out items like moulding pins, closing pins, bushes etc

Metallurgical microscope for microstructure analysis of metal poured in various heats.

Impact testing machine (Charpy and Izod tests) to check impact toughness of metal poured.

Wet analysis testing facilities.

Facilities for dimensional inspection of castings, patterns and core boxes.

Spectrometer

3460 model Spark emission spectrometer ARL - make

Carbon-equivalent meter

Rapid carbon and silicon testing in molten metal

Universal testing machine

40 ton capacity

Impact testing machine

Brinell hardness tester

750 / 3000 kg loading capacity

Sand-testing equipments

Sieve shaker : Permeability meter : Mould-hardness tester : Total clay, active clay and dead clay tests : Fixed carbon, volatile matter and percentage ash tests : Green compression and shear strength tester : Moisture tester