We can produce most grades of grey iron castings from GG20 to GG30 per DIN EN 1561 and ductile iron castings from GGG40 to GGG60 per DIN 1693 or according to customer specification along with SiMo grade.
Fully Automated DISA Make High Pressure Molding Line Foundry
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Box size: 1000 mm x 700 mm x 325/325 mm
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Inductotherm Heated Press Pour with 5T capacity
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Automatic sand controller with fuly automated DISA sand plant
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Automated core setting of core assemblies of 120 Kg
Mechanized ARPA lines from DISA India with completely automated sand plants (ARPA 900/450/300)
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800 mm x 650 mm – 1
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650 mm x 650 mm – 4
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500 mm x 500 mm – 1
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DISA make fully automated sand plants with 40MT/hour to 24 MT/hour capacity
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Automated mold handling system with auto punch-out (knockout) system
Melting
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Inductotherm make induction furnaces of capacities ranging from 2.0 ton to 0.5 ton crucibles
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Magnetic lifting and vibratory charging for large furnaces
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Total connected capacity of around 13 MW with 13 furnaces – IGBT technology adopted
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Ductile Iron treatment done by sandwich method with timely pouring
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Pouring done via press pour or EOT cranes
Core making
26 cold box core shooters - 100 Kg to 5 kg core capacities along with shell core shooter up to 800 mm length
Pneumatic sand transporter and PLC controlled binder dosing units
Core sand drying plants from 5MT/hr to 3 MT/hr
Core painting and baking ovens with 100% trolley storage
Shot blasting and Fettling/painting
Spinner hanger type shot blasting machines for good shot coverage
In-house fettling and painting facilities with mechanized conveyor type paint booth
Environmental and Safety
Environmental consciousness via use of dust collectors, cyclones, scrubbers and other pollution control equipment
STPs, ETPs and rain water harvesting employed to save water
Provision of PPE for all workmen to ensure personnel safety
Returnable packaging employed where permissible
Horizontal Machining Centers – 51, Pallet size 800x600 mm to 450x450 mm (Mazak 6800, Makino A51 etc.)
Vertical Machining Centers – 40, Pallet size 1020x550 mm to 600x400 mm and Nikken 4th axis indexers (Makino S33, BFW, etc.)
Vertical CNC Turning Centers – 20
Horizontal CNC Turning Centers – 2
Special Purpose Machines – ~104
Haimer shrinkfit and Zoller tool presetter
Material handling (conveyors, cranes, pallet trucks etc.) for ease of handling
Storage systems (bins, separators, etc.) for minimizing damage during processing
High pressure washing machines to clean components before dispatch
QA in Foundry:
GOM Bluetooth Scanning for casting layout and tooling inspection
ESI ProCAST simulation for flow analysis during design stage
Spectro-lab make spectrometers (4 nos)
Hardness testing machine, Universal Tensile testing machine and electronic tensobar testing machine
Dog bone core shooter/tester and hot strength tester for green sand
Optical Microscopes with automatic image analyzer
Chemical testing (wet analysis) lab facility – SST testing, electronic DFT meter,
Radiation trace element testing equipment
Access to labs for radiography, Dye-penetrant, ultrasound and other tests
QA in Machine shops
3-D CNC controlled CMM (6 nos) with pallet size upto 800x2000x900mm (Mitutoyo, Brown & Sharpe) and 1-D electronic height gauges- make Trimos and Tesa
Air gauges for critical parameters
Optical profile projector, Surface testers, various bore dial gauges, plug gauges deployed on lines
Air and water leakage testing equipment
Mistake proofing deployed to prevent defects from flowing forward in the system
Critical characteristics (process and product) monitored by run charts/ SPC
Quality Assured
Dedicated team of design engineers work to support new product development
Capable team with relevant experience to develop new products in a wide array of product families
3D modelling and simulation techniques in foundry ensure first time right casting (CREO and ESI Pro CAST)
3D concepts of fixtures and tooling ensure First Time Right tooling (CREO and Auto CAD)
Detailed documentation and customer interaction to ensure robust developments
Use of APQP and project management ensures customer satisfaction