Infrastructure

Foundry

To brief, the foundry has 2 different lines, in one line we manufacture high volume parts in a new technology Tower furnace which gives uninterrupted metal continuously & consistently 24×7,365 days a year. The GDC platform on the Tower furnace has 22 machines (static & Tilt pour) & GDC dies running to full capacity manufacturing 4MT a day (100 MT per month). Here we manufacture parts weighing 110 grams to 500 grams & volumes of 10,000 nos to 100,000 nos per month

The other line comprises of 30 machines (static & tilt pour) to make castings in batch sizes of 50 to 5000 nos per month manufacturing 100 MT per month. Here we manufacture parts weighing from 1 kg to 30 kg & length of 1000 mm & all cored castings with shell cores which are hollow to reduce weight & improve the quality & cost.

Foundry Infrastructure at a glance

Line no 1	Nos	Line no 02	Nos
Tower Furnace	1	Melting Furnace	04
Belt polishing	08	Holding Furnacce	08
Gate cutting	05	GDC Static	22
GDC Static	14	GDC Tilt Pour	08
GDC Tilt pour	08	Gate Cutting & SPM	04
Heat Treatment(T5&T6)	02	Belt Polishing	06
(100 Kg Capacity)	01	HT(1000kg)(T5 & T6)	02
(500 kg capacity)	01	Thermal Decoring (500 kg)	01
Shot Blasting	02	Millipore	01

Machine Shop

The machine shop is also built with a LEAN layout by doing value stream mapping & maintain a sequential flow for better productivity & consistency. The machine shop comprises of 10 CNC Machines & 17 VMC machines which are well equipped with 4^th axis & rotary & linear pallet changers as per the part requirement. This is clubbed up with the latest IMPREGNATION plant with pressure vessel & rotary wash for better sealing & cleaning purpose. There are 9 leak testing machines to check for any leak in casting with pressure bar at 140 PSI. Similarly dedicated casting cleaning machines are provided after machining & before packaging to send cleaner & dust free parts to customer. All cored parts are tested with Millipore before shipments.