Plant and equipment
Five shops on one site at GIDC Savli, arranged around a single material route and served by EOT cranes throughout the casting bays.
18,500 square metres, 9,400 of it covered.
Material moves from the melting deck through moulding, knockout, heat treatment, fettling and machining without leaving the site. That is what makes a delivery commitment worth something.
Processes and machinery are selected with environmental impact in mind: recuperative burners on both heat treatment furnaces, mechanical sand reclamation, closed-loop cooling and 820 kWp of rooftop solar.
Main casting bayShop by shop.
Melting shop
Three medium-frequency induction furnaces, 4,600 KW installed, with a maximum single heat of 10 tonnes. Chemistry is checked on the spectrometer before every tap.
Induction furnaces
- 350 KW — Power Cone Engineers, Ahmedabad — 500 kg and 1,000 kg crucibles
- 750 KW — Inductotherm (India) Pvt. Ltd. — 2,000 kg and 2,500 kg crucibles
- 3,500 KW — Power Cone Engineers, Ahmedabad — 10,000 kg crucible
Pouring ladles
- Bottom-pour — 15 MT, 10 MT and 5 MT
- Tilting — 2 MT, 500 kg and 300 kg
Moulding shop
Two-part no-bake finotech resin sand with PLC-controlled mixing. Mould hardness is tested on every box, and reclaimed sand covers most of the line's demand.
- Automatic resin sand mixer with PLC control
- Vibrating table — 3.5 m × 2.5 m
- Sand muller 500 kg, sand mixer 250 kg
- Moulding boxes across a full range of sizes
- Pneumatic ramming machine
- Mould hardness tester
- Mechanical sand reclamation unit
Heat treatment shop
Solution annealing is the step that makes manganese steel work. Both furnaces are paired with a fork-lift crane sized to lift the full charge out and into the quench tank inside 45 seconds.
Furnace 1
- 5 MT batch, ceramic wool lining, four oil-fired burners with recuperative exhaust
- Three-point temperature recorder and control
- 5 MT fork-lift crane to the water quench
Furnace 2
- 15 MT batch, ceramic wool lining, four oil-fired burners with recuperative exhaust
- Six-point temperature recorder and control
- 15 MT fork-lift crane to the water quench
Fettling shop
Risers and gates come off, surfaces are dressed and every casting is shot blasted before inspection. Manganese steel does not machine easily, so this shop carries load that a machine shop would take elsewhere.
- Swing frame grinders
- Flexible shaft grinder
- Shot blasting machine — 1.5 m table
- 600 A rectifier welding machine
- Air screw compressor — 185 cfm, ELGI
- Pneumatic chipping machine and pencil grinder
- Dust extraction on every grinding station
Machine shop
Finish machining in-house means castings ship ready to fit. It removes a handling step, a supplier and a source of dimensional argument from your chain.
- Vertical boring machine — 1200 mm spindle diameter
- Vertical boring machine — 100 mm spindle diameter
- Vertical boring machine — 75 mm spindle diameter
- Milling machine
- Planing machine
- Shaping machine
- Radial drilling machine
How a casting moves through the plant.
Pattern and methoding
Your drawing becomes a methoding plan — parting line, gating, feeding, machining allowance — before any pattern work starts.
Moulding and core making
Two-part no-bake moulds on PLC-controlled sand, compacted on the vibrating table and checked with a hardness tester.
Melting and pouring
Charge melted on the induction deck. Chemistry verified before tapping, then poured through a bottom-pour or tilting ladle to suit the casting.
Knockout and fettling
Shake-out, riser and gate removal, surface dressing on swing frame and flexible shaft grinders, then shot blasting.
Heat treatment
Solution annealing against a recorded profile, followed by a water quench completed within 45 seconds of the charge leaving the furnace.
Machining and final inspection
Finish machining where specified, then dimensional layout, hardness, mechanical, micro-structure and NDT checks before despatch clearance.
What keeps it running.
3,000 KVA
Sanctioned demand on a dedicated HT feeder with capacitor bank correction.
820 kWp solar
Rooftop installation covering a growing share of daytime plant load.
5 to 20 MT cranes
EOT cranes across the casting, heat treatment and machining bays.
Zero discharge
Closed-loop cooling with rainwater recharge. No process water leaves the site.
Utility figures are indicative placeholders. Confirm current ratings with the works before publishing.
See it for yourself.
We welcome customer audits of melting, moulding, heat treatment and inspection. Get in touch and we will set up a plant visit.