Seven processes, one roof
From pattern design to painted, tested and certified casting — every stage in-house at Bhagwanpur and Rudrapur.
The route a casting takes
Nothing leaves the site between the first charge and the final coat. Each stage below is the same sequence, in order.
Foundry
Three furnaces, 6.5 tonnes of charge
An arc furnace carries the bulk melt; two induction furnaces take the smaller and the specialist heats. Vessels are drawn to relative scale.
| 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, line and pour
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
Melting facility
| Unit | Capacity |
|---|---|
| Arc furnace | 5,000 kg |
| Induction furnace | 1,000 kg |
| Induction furnace | 500 kg |
Fettling
Riser off, surface to drawing
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
Normalise, anneal, harden
Cycles are held to the mechanical properties the drawing specifies. The curve is schematic — the governing figures live in each part's process sheet.
- 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 machines, established June 2020
Set up as an ancillary for the ZF Rane group, now machining the company's own castings to finished tolerance.
| 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
Six disciplines, 34 instruments
Spectrometry, mechanical, chemical, non-destructive, metrology and sand testing. Every heat is verified against the specified grade before dispatch; a casting 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
Coated in a controlled room, then measured
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.
- 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
New product development
Drawing office to RDSO approval
In-house design facility and specialised human resource for designing patterns and fixtures using DelCam10 and AutoCAD.