FACILITIES
A Fully Integrated Casting Facility.
From pattern shop to final inspection, every critical process is performed in-house under one quality system.
OUR INFRASTRUCTURE
Built for Complete Process Control.
01 Pattern Shop
- In-house pattern making in wood, aluminium and thermocol (EPS)
- Pattern repair, modification and storage facility
- Library of 6,000+ patterns maintained and catalogued for repeat orders
- 3D design and reverse engineering support for new pattern development
02 Moulding Section — Sodium Silicate CO₂ Process
- Sand mixers / muller units for sodium silicate bonded sand preparation
- CO₂ gassing stations for rapid mould and core hardening
- Mould boxes in a full range of sizes supporting castings from 2 kg to 2,500 kg single piece
- Core making section with core boxes, core driers and core assembly area
- Green sand moulding line for smaller and repetitive castings
- Dedicated mould painting / coating area (zircon and graphite based refractory coatings)
03 Melting Section
- Medium frequency induction melting furnaces with a combined capacity supporting 8 MT/day output
- Charge make-up area with segregated raw material bays (scrap, ferroalloys, returns)
- Ladle preheating and treatment stations
- Spectrometer-linked bath analysis for chemistry correction before every pour
04 Heat Treatment
- Electrically controlled / fuel-fired heat treatment furnaces with calibrated temperature recorders
- Full heat treatment capability: annealing, normalising, hardening, quenching (water / oil), tempering, and solution annealing / water toughening for manganese and stainless grades
- Quenching tanks sized for the largest castings in our range
05 Fettling & Finishing
- Shot blasting machine for surface cleaning
- Swing frame and pedestal grinders, pneumatic chipping tools
- Gas cutting and arc-air gouging for riser removal
- Welding stations for approved-procedure repair welding
06 Digital Infrastructure
- Casting simulation software for methoding and defect prediction before the first pour
- 3D CAD design and 3D scanning for reverse engineering
- ERP-driven order tracking, traceability and despatch documentation
- Every casting traceable to its heat number, chemistry and test certificate
07 Material Handling & Utilities
- EOT cranes and hoists covering moulding, pouring and fettling bays
- Weighbridge-verified despatch
- Power backup and power factor correction systems for uninterrupted melting
TESTING & QUALITY
Precision Checked at Every Stage.
Chemical Analysis
- Optical Emission Spectrometer for full chemistry analysis of every heat (C, Si, Mn, P, S, Cr, Ni, Mo, Cu and trace elements)
- Wet analysis facility for verification and referee testing
Mechanical Testing
- Universal Testing Machine (UTM) for tensile, yield and elongation testing
- Brinell / Rockwell hardness testers (bench and portable)
- Impact testing (Charpy) arrangement for grades requiring toughness verification
Sand Testing Laboratory
- Green compression strength tester
- Permeability meter
- Sieve analysis / AFS grain fineness set-up
- Moisture tester and mould hardness tester
- Compactability and shatter index testing
Non-Destructive Testing (NDT)
- Dye Penetrant Testing (DPT) for surface defect detection
- Magnetic Particle Inspection (MPI) arrangement for ferromagnetic grades
- Ultrasonic Testing (UT) through approved agencies for critical castings
- Radiography (RT) through approved third-party facilities where specified
Dimensional Inspection
- Surface plates, height gauges, vernier and micrometer sets
- Templates and gauges for repeat production items
- 3D scanning support for complex geometry verification