Nine stages, one roof
From pattern design to a painted, tested and certified part — every stage in-house at Bhagwanpur, Haridwar.
The shop floor
Nine stations under one roof, in the order a part meets them. Pick a station; its sheet opens beside the list.
New product development
In-house design facility and specialised human resource for designing patterns and fixtures using DelCam10 and AutoCAD. From the customer drawing to a first article, submitted for approval before the first production heat.
- 1 Drawing
- 2 Pattern
- 3 First article
- 4 Approval
Melting
An arc furnace carries the bulk melt; two induction furnaces take the smaller and the specialist heats. Four alloys — mild steel, SG iron, grey iron and manganese steel.
Moulding
Three moulding lines, with a PLC-controlled sand plant preparing, cooling and reclaiming the sand behind them.
| Line | Sets | Output | Box size |
|---|---|---|---|
| Disa Arpa | 1 set | 40 moulds/hr | 950 × 1000 × 250 |
| HPML | 1 set | 60 moulds/hr | 950 × 1000 × 250 |
| Lost-foam | 1 set | 10 moulds/hr | 1450 × 1200 × 1200 |
Sand preparation
- PLC-controlled automatic sand plant, 40 MT/hr
- Intensive sand mixer, 2 MT batch, automatic PLC-controlled sand, bentonite, betacoal & water dosing
- 40 MT/hr horizontal fluidised-bed sand cooler
- Dust collector 30 HP
- Polygon screen 40 MT/hr
- Overhead magnetic separator & magnetic pulley 700 mm
- Knockout 1200 × 1200 mm
Pouring
Timed pouring for SG iron, the temperature read at the ladle, metal carried to the line on the monorail.
- Time & hooter for timely SG pouring
- Lip pouring ladle 500 kg & 1,000 kg
- Cordless temperature monitoring
- Hydraulic pusher pouring line
- Monorail for metal pouring
- Overhead crane
Fettling
Pneumatic chippers, welding machines, and swing, bench, pencil and angle grinders.
| Machine | Size | Qty |
|---|---|---|
| Hanger type | 72 in | 1 |
| Table type | 72 in | 1 |
| Tumbler | 48 in | 1 |
Heat treatment
Stress relieving, annealing and quenching cycles for steel, manganese steel and SG iron, held to the mechanical properties the drawing specifies and recorded against time.
- Stress relieving, annealing and quenching for steel, Mn steel and SG iron
- PLC-controlled electric furnace
- Time–temperature recording facility
- Furnace size 1500 × 1500 × 2000 mm
- Furnace capacity 5 MT
- Quenching tank 50,000 L
- Fork crane 6 MT
Machining
Twenty-two CNC machines — vertical and horizontal centres, vertical turret lathes and turning — bringing the company's own components to finished tolerance without leaving the plant.
| Type | Capacity | Qty |
|---|---|---|
| VMC | 1000 × 600 × 500 mm | 1 |
| VMC | 1200 × 650 × 600 mm | 2 |
| VMC | 600 × 450 × 400 mm | 2 |
| VMC | 450 × 450 × 400 mm | 3 |
| HMC | 500 × 500 × 550 mm | 1 |
| VTL | 450 Z, turning dia 800 mm | 4 |
| VTL | 750 Z, turning dia 1100 mm | 3 |
| VTL | 350 Z, turning dia 650 mm | 1 |
| CNC turning | 1200 Z, turning dia 800 mm | 3 |
| CNC turning | 600 Z, turning dia 400 mm | 2 |
Laboratory
Spectrometry, mechanical, chemical, non-destructive, metrology and sand testing. Every heat is verified against the specified grade before dispatch; a component that fails here does not ship.
Microstructure testing
- 1000× magnification microscope
- Auto-analysis software
- Photography arrangement
- Polishing machine
- Comparative charts
Mechanical testing
- Computerised universal testing machine 40 MT
- Digital impact tester with sub-zero testing to −32 °C
- Rockwell hardness tester
- Computerised Brinell hardness tester 3000 kgf
- Portable hardness tester
- Shadowgraph
Chemical testing
- Spectrometer
- Carbon–silicon analyser
- Wet testing for C, Mn, Si, P, Fe-Mn & Fe-Si
Non-destructive testing
- Magnetic particle inspection (MPI)
- Liquid penetrant test
- Ultrasonic testing machine
- Radiography
Metrology
- Coordinate measuring machine (CMM)
- Coordinate measuring gauge (faro gauge)
- Digital height gauge
- Digital bore gauge
- Digital micrometer
- Digital vernier calliper
- Digital pistol calliper
- Scale
- Surface table
Sand testing
- Moisture tester
- Permeability tester
- GCS tester
- Shatter index tester
- Wet tensile
- Compatibility tester
- Sieve shaker
Painting
Spray, brush and dip application in a dust-free room held to temperature and humidity, cured to 300 °C, then checked on DFT, gloss, density and viscosity.
- 1 Prepare
- 2 Apply
- 3 Cure
- 4 Verify
- Dust-free, humidity and temperature controlled paint room
- Spray, brush and dip painting
- Curing oven up to 300 °C
- Professional painters
- DFT meter
- Cross-cut equipment
- Gloss meter
- Density tester
- Viscosity tester