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Our production process are as follows:

 

SELECTION OF RAW MATERIAL AND TESTING (For all material)

Pig iron, Hard Coke, Limestone and other raw material is purchased with reputed companies and Govt. Organisations. The Chemical report is attached with the Invoices All the inputs are again tested in the highly sophisticated foundry Lab

MELTING

All the raw materials are inserted into Coupla Furnace with a perfect combination of airflow, and the temperature of the furnace. There is a constant check in temperature of the molten material with a temperature meter and the ratio of Carbon ,Silicon is constantly monitored by Carbon Silicon Analyser.

MOULDING (For all material)

All the dry mould is made up of sand and its mixtures: Sand is the key factor for any foundry. Quality of the sand depends for the surface finish of the castings. The Sand is mixed here in the high Capacity 1000 Kg fully automatic Sand Mixer Plant.

SAND MIXING (GREEN SAND) COMPOSITION

White Sand : 40%
Floor Sand : 50%
Coal Dust : 6- 8%
Bentonite : 2 – 3%

CORE SAND (COMPOSITION)

White Sand : 94%
Linseed Oil : 02%
Bentonite : 03%
Molasses : 01%

  1. All the moulding are done by the skilled workers under the supervision of experienced supervisors.

  2. After the moulding all the moulds are dried by blow Lamps to remove excess moisture from the mould.

  3. Before pouring when the moulds are ready this is re-inspected by the floor in charge to inspect the workmanship of the moulders.

  4. Temperature is checked in the Spout and in the ladle before pouring of molten material into the moulds.

  5. Material is kept into the moulds for at least 5 Hrs for gradual reduction of temperature.

FETTLING (For all material)

The material which is taken out of moulds are sent to proper chipping yard. Here the following process is followed :-

  1. Separation of rejected material.

  2. Through brushing is done through hand for removal of sand.

  3. Chipping is done to remove runners and risers with materials.

  4. Grinding is done with the grinding machine to remove sparks and finse.

  5. Buffing is done whole over the surface of the casting after grinded.

  6. Through inspection is done at last and the material is sent for machining.

MACHINING

After Fettling the castings are sent to machining section. The foundry is equipped with in house machine shop. The machining of the grey Iron Castings are done with the extreme accuracy. Drilling and Tapping is also done in the machine shop.

PAINTING (For all material)

Before painting the material is once again inspected and then sent to the painting area. Here the painting is done by the process of Dipping and brushing. Painting is done so that minimum 4-micron thickness is achieved. After this painted material is left for at least one day to dry up completely.

PACKING & DESPATCH (For all material)

Here the material is packed in the wooden crated or the Mild Steel crates as per requirements of the buyer.