Our foundry division located in Arasur is spread over a sprawling built-up area for various sections as specified below:
|Main shop floor bay||10472 Sq Mt|
|Product development center||1530 Sq Mt|
|Pattern storage||1000 Sq Mt|
|Fettling||1100 Sq Mt|
|Incoming material stores||688 Sq.Mt.|
|Sand plant||688 Sq Mt|
|Core shop (shooting)||320 Sq Mt|
|Resin storage||400 Sq Mt|
|Others||1160 Sq Mt|
Built-up area isspread over to 16300 Sq. Metres in total.Fast Loop Line:
Flaskless moulding line, with maximum cake size not exceeding 1500 mm X 900 mm X 450 mm (cope) / 450 mm (drag). Ideal single piece weights ranging from 100 kgs to 300 kgs shall be made in this line. IMF continuous mixer (25 MTs/hour capacity) is available for mixing silica sand with binder system. Automatic roll over machine removes the pattern and leaving the mould for further processing. Mould handlers are available for better maneuverability in final closing operation of cope and drag. Heating ovens are available prior to and after coating to ensure moisture free moulds.
Heavy Moulding Section:
Heavy castings are cast with metallic moulding boxes, with maximum cake size not exceeding 3000 mm X 3000 mm X 850 mm (cope) / 850 mm (drag). Ideal single piece weights ranging from 0.5 MT to 7 MT shall be made in this line.
Continuous mixers (6 MT capacity 2 nos. and 2 MT capacity 1 no) with cold box core machine (3 litres capacity, 2 nos.), Shell core machine (14” X 16” –1 no & 18” X 24” – 1 no.), Nobake core shooting machine (with capacity of 50 kgs), shell moulding facilities are available.
2.5 MTs capacity, 3 nos, medium frequency induction furnaces form the main melting bay. In addition 2 nos. of 3 MTs capacity, dual track furnaces are also planned to augment the capacity of pouring.
Hanger type shot blasting machines (1 Mt, 2 MT & 6 MT capacities) are available for handling medium to heavy weight castings.
Heat treatment furnaces (2 nos., each with capacity of 10 MTs) are in operation for stress relieving functions. New furnace (of 10 MT) capacity will be added to the present infrastructure to handle enhanced capacity requirments.
Castings staked for heat treatment
Overhead trailer type (1 MT capacity) booth and wet type booth (2 MT capacity & 4 MT capacity) are available for handling all Painting applications for sealer primer and also for finish painting.
10 dust collectors (with capacity ranging from 4000 CFM to 60000 CFM) are available in strategic locations to take care of the pollution risk in the foundry.
Thermal reclamation (3 MT/ hour) and mechanical reclamation (15 MT / hour) plants handle the full cycling requirement for the sand.
Reverse Osmosis Plant (1 Lakh Litres / day) is in operation within the premises to take care of recycling of water.
Lighting /Safety and Security:
Inside the foundry, sufficient lighting arrangements, provision of fire extinguishers, sand pots in critical locations, water jet points are placed sufficiently to ensure proper safety of employees during any emergency.
Pattern Shop & Product Development:
Pattern making in various materials such as seasoned teak wood, Aluminium, epoxy resin, cast iron and expandable polysterene shall be made by using following softwares.
Kodimould Vertical CNC machining center (table size 1200 mm X 600 mm X 800 mm) is available for pattern making.
ZAYER 2000 moving column vertical CNC Machining Center (Table Size 4150 mm X 1140 mm X 920 mm) is available for pattern machining.
3D layout and marking unit with a surface plate (3 m X 1.5 m X 1.2 m with accuracy of 100 microns) is used 5 Axis versatile wood working milling machine is used for wood pattern machining.BWR (Boiling water resistant) marine plywood is used for match plate applications.
Following machines are available in machine shop, in a built-up area of 4500 Sq.Mt.
Machine shop is under constant upgradation to meet the demanding value addtion requirments.
Sand plant is equipped with testing facilities to analyse sieve size, clay percentage, ADV, permeability, compression strength, mould hardness, specific gravity of coatings, shell sand hot tensile strength etc. This is a vital department controling the inprocess quality.
Laboratory is equipped with BAIRD Vacuum emission spectrometer (18 elements), tensile strength tester (UTM) Impact tester, facilities for testing hardness, microstructure, Dye penetrant inspection, Ultrasonic inspection, paint film thickness (DFT) etc.,