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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 |
750 kW, 1.5 ton 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)
2000 kg capacity ladle (1 no) |
| EOT crane |
5 ton capacity (1 no) |
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- Carbon equivalent meter for checking composition of molten metal before pouring
- Monorail system for mould pouring
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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 to 750 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
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| Moulding machines |
moulding machines |
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moulding box size (mm) |
ARPHA 300 |
(1 pair) |
520 × 400 × 160 ht |
ARPHA 450 |
(1 pair) |
850 × 600 × 200 ht |
BQ 5 |
(1 pair) |
1100 × 700 × 250 ht |
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| Sand mixers |
500 kg capacity (2 no)
200 kg capacity (2 nos) |
| Sand plant |
Including sand storage hoppers of capacity 120 tons, belt conveyors, bucket elevators, polygonal sieve, magnetic separators etc |
| EOT cranes |
5 ton capacity (1 no)
2 ton capacity (2 nos) |
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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 |
1 ton / hr capacity (1 no) |
| Sand mixer |
100 kg capacity (2 nos) |
| Core-shooter |
Cores manufactured by amine process (1 no) |
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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.
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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
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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 |
| Diesel Generators |
300 kVA capacity (1 no)
62.5 kVA capacity (1 no) |
| Furnace accessories |
heat-exchangers, cooling water pumps, hydraulic power pack etc |
| Pollution control |
Wet scrubbers, bag-type dust collectors, cyclone filters |
| Rain-water harvesting |
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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.
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| 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 |
Izod test - 330 J capacity
Charpy test - 600 J capacity |
| 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 |
098430 19800
