Sl. No.
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Activity
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Technology Need
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Cost (Rs in lakh)
|
Advantages
|
1.
|
Melting Section.
|
Divided blast cupola.
|
3-5
|
15 per cent coke saving, Better melt quality, Higher tapping temperature, Lower emissions, Reduced air pollution.
|
Gas fired cupola.
|
12-15
|
Eco friendly, Higher tapping temperature, Better melt quality.
|
Gas fired Pit furnace.
|
0.75-1.50
|
Eco friendly, Higher tapping temperature, Better melt quality.
|
Oil fired rotary furnace.
|
37 (imported),
3 (indigenous)
|
Pollution control, Better quality product, cost effective.
|
Induction Furnace with cooling tower & water treatment plant.
|
10 - 25
|
Flexibility to produce ferrous castings of all grades, Flexibility for charge mix selection, Best melt quality, Eco friendly.
|
Induction ladle refining furnace.
|
30-40
|
Value added casting, eco friendly.
|
D.C. Arc Furnace.
|
30-40
|
Special grade castings, eco friendly.
|
Oil fired rotary furnace.
|
37.40 (imported).
30 indigenous.
|
It is proven technology, reduced air. pollution, better quality product, cost effective .
|
Metal Refining Converter.
|
40
|
Value added castings, eco friendly.
|
Skip charger for cupola.
|
Up o 1.50
|
Ease of charging, reduced labour cost, better control.
|
Pouring/treatment ladles as per Indian standard 4475, 4476.
|
Up to 1
|
Quality assurance, increased safety for workmen.
|
2.
|
Utility Section
|
Gas based Generating set.
|
Up to 30
|
Reduced air pollution, energy saving.
|
3.
|
Quality Control Lab.
|
Metallurgical Testing:
Metallurgical Microscope with image analyzer, photographic attachment, sample preparation machines.
|
1.50-10
|
Quality assurance, Defect analysis, Diversification e.g. SG Iron Production equipment essential to meet process control requirements.
|
Laboratory Testing / Quality Control equipment.
Stroholien Apparatus, Muffle furnace, Hot Plate, Glass ware etc.
U.T.S.
Spectrometer / Mass Spectrometer.
Hardness tester.
e) Izod & Charpy Impact testing machine.
Ultrasonic testing machine.
g) Magnaflux testing machine.
|
1
Up to 3
15-25
Up to 1
Up to 0.75
Up to 3
Up to 1.50
|
Quality control, defect investigation, Quality assurance, Consistency in quality, Reduced defective casting, Cost control.
|
Sand Testing equipment Moisture Teller, Universal Sand Strength testing machine, Sieve shaking device, Compactability scale, Rapid Moisture Teller, Permeability Meter, Mold Hardness Tester, Muffle furnace, Wash bottles, stirrer/Shaker, Hotplate, Vortex shaker, Centrifuge etc., Shatter index machine, Scratch Hardness Tester, Stick point, hot tensile, peel back
|
2 to 8
|
Reduced defective casting, consistency in quality, Reduction in additives cost, Better as cast surface finish.
|
Dimensional Inspection instruments:
Surface plate for marking, Height gauge, Micrometer, Vernier, Profile projector with Digital Reading system, Dial & Micro snap gauges, Floating careage dia measuring machine, 3-Co-ordinate measuring machines.
|
Up to 10
|
Quality assurance, Defect analysis.
|
Process Control Equipment:
a) Carbon equivalent meter.
b) Pyrometer (dip type immersion).
|
0.75-1.75
0.20
|
Consistency in quality, Reduced defective casting, Cost saving.
|
4.
|
Design & Development
|
Computers & CAD Software's, simulation software with Printers/Plotter.
|
1.50 - 15
|
Computerisation of design & development to gain efficient & fast working.
|
5.
|
Molding/Core.
|
Intensive mixers.
|
2.50 - 5
|
Reduced defective casting, Better as cast surface finish, Reduction in additive cost, Reduced air pollution.
|
Simultaneous Jolt/Squeeze moulding machine.
|
3-10
|
Higher productivity, dimensional accuracy, less skill requirement.
|
Shell Moulding Machine.
|
3-5
|
Higher productivity, dimensional accuracy, less skill requirement.
|
Centrifugal casting machine.
|
1.50-3.50
|
Liner castings exclusive process, eco-friendly.
|
Spun pipe casting machine.
|
up to 40
|
Export potential, higher productivity, eco friendly.
|
6
|
Investment Casting
|
Wax Injection Machines.
|
up to 10
|
Requirement for modern investment casting process.
|
Sand Raining Machine.
|
up to 4
|
Requirement for modern investment casting process.
|
Slurry Mixtures.
|
Up to 2
|
Requirement for modern investment casting process.
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Dewaxing Oven.
|
Up to 2
|
Requirement for modern investment casting process.
|
Burt out furnace.
|
Up to 2
|
Requirement for modern investment casting process.
|
Belt Polishless.
|
Up to 1
|
Requirement for modern investment casting process.
|
Sand reclamation system.
|
Up to 20
|
Cost saving, pollution control, reduced binders composition.
|
Continuous mixer for no bake sand.
|
Up to 15
|
Reduced additive cost, Quality improvement, Pollution control, Improved quality.
|
Shot blasting machine.
|
Up to 8
|
Better surface finish & Quality improvement
|
CO 2 Gassing machine.
|
Up to 0.50
|
Cost saving, pollution control, Quality improvement.
|
Moulding boxes as per Indian Standard 1280 & 10518.
|
Up to 3
|
Better dimensional accuracy, higher productivity
|
Core shooter-shell or no bake sand.
|
2 - 5
|
Higher Productivity, Consistency in quality, Narrower as cast dimensions, Excellent finish.
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7.
|
Heat Treatment Section.
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Induction Hardening Equipment
100 KW, 500Hz to 3KHz.
Removable Hearth type chamber F/C upto 1200 C moving with computer compatible temp. controller.
Handling equipment-overhead crane- 2 ton capacity.
Quenching.
Water quenching tank-with Heat exchanger unit.
ii. Oil Quenching tank-fitted with oil heating & heat exchanger to obtain desired & cooling rates for hardening.
iii. Air quenching fans.
|
10 - 15
3 – 5
1-3
0.75
1.50
0.30
|
Higher Productivity, Consistency in quality, eco friendly.
Cost saving, Consistency in quality, Better productivity.
Reduced labour cost, Higher Productivity, Consistency in quality.
Process requirement to achieve quality.
Process requirement to achieve quality.
Process requirement to achieve quality.
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8.
|
Machine Shop.
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CNC Milling machine.
CNC Lathe Machine.
Capstan lathe/Turret lathe.
Radial Drill.
Planner.
Shaper.
Jig Boring Machine.
Hydraulic Hooning machine.
|
25-30
10-15
up to 3
up to 5
up to 3
up to 3
up to 5
up to 3
|
Higher productivity, dimensional accuracy, less skill requirement, Consistency in quality.
|
9.
|
Pattern Shop.
|
CNC Milling.
Pentograph.
Drilling.
Disc and bobino sand grinder.
|
30-50
Up to 2
Up to 1.00
Up to 3
|
Higher Productivity, Consistency in quality, Narrower as cast dimensions, Excellent finish, Better productivity.
|
10.
|
Fettling Section.
|
Shot Blasing Machine.
Pedestal Grinder.
Swing Frame Grinder.
Painting Booth.
|
up to 5
up to 0.50
up to 0.25
up to 0.50
|
Higher Productivity, Process requirement to achieve quality.
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