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Core Shop
Core center (Cold Box) - Key Features :
  • High speed core sand mixture (capacity 8 TPH) - Ensures uniform mixing of sand
  • High speed fully automatic core making machines (60 shoots per hour) - 2 nos
  • Robotic de-fining of cores - Ensures no parting line on core as well as no damage on core profile
  • Robotics for core handling , assembly & painting
  • Quick core box change over - Setup time to 5 min.
  • On line core box cleaning station - Which helps in cleaning the core boxes at decided frequency without removing core box
Shell core Machines - Key Features :
  • 2 shell core machines to produce auxiliary cores
  • Twin station vertical parted machine -
    Core box size 18" * 24"
  • Horizontal parted machine -
    Core box size 24" * 40"
  • Automatic core box changeover
Continuous core oven - Key Features :
  • Oven length - 23.5 meters with double row
  • Capacity - 60 packages/hr
  • Dual fuel, PLC controlled burner firing - Ensures fuel efficiency
  • Interlocking with painting Robot to ensures core drying at set temperature
  • Automatic temperature control
Core Handling & Transfer - Key Features :
  • Pallet size - 1100 * 900 mm
  • Palletized Core handling - Each pallet will carry full set of cores for one mould
  • No manual handling - To avoid core damages
  • Storage capacity of 3 hrs
  • PLC controlled transfer & feeding to mould line - Ensures FIFO system for cores supply

Mould Shop
Sand Plant - Key Features :
  • Capacity 80 TPH
  • High speed intensive sand mixer - Ensures uniform mixing of green sand
  • Online control of sand compactibility.- Ensures only right quality sand is released to moulding
  • Fluidized Sand Cooler - Controls mixer input sand temperature within Amb+5 deg max
  • Dust collection system to ensure clean environment & absolutely dust free shop
High Pressure Moulding Line - Key Features :
  • Machine model - DFM, Air press
  • Box size : 1000 * 800 * 350/350 mm
  • Suitable for 3/4/6 cylinder block & cylinder head castings
  • Line speed at 90 moulds/hr in two phases
  • Multi piston squeezing - Ensures uniform mould hardness is maintained all over mould surface
  • Hydraulic and pneumatic squeezing facility
  • Automatic sprue cutting & mould venting - Ensures all vents are made at right place and of right size
  • Automatic core setting - Ensures no mould crush and parallel core setting
  • Quick pattern change over (within cycle time) - Ensures quick setup change
Casting Cooling Conveyor :
  • Make - Tata Automations Ltd
  • Length 390 meters with 327 nos hangers
  • Conveying and cooling in single piece ensures no damage to casting
  • Cooling time 3.5 Hrs

Melt Shop
Induction furnace :
  • Model - FS60
  • Melt rate of 6 tons/hr
  • Weighment for charging material and Vibratory chargers for charging in furnace
  • Load cell arrangement for the crucible helps in managing power
  • With Fume extractor and lid - saves energy as well as keeps environment clean
  • Online Spectrometer to check chemistry of each heat
Press Pour - Key Features :
  • Capacity - 5/7.5 MT
  • Press pour with heating arrangement - Ensures constant pouring rate and constant pouring temperature for each box
  • Online inoculation feeding system to control inoculation quantity
  • Fume extractor system for pouring and cooling lines - Keeps environment clean

Fettling
Shot blasting Machine :
  • Make - BMD, Banglore
  • Single piece shot blasting machine with 3 chambers
  • Cycle time 60 sec per casting matched with moulding line speed
  • Equipped with dust collection system

Equipments - Quality
  • Spectroscope - 32 element
  • Image Analyser - For Micro structure
  • Tensile Tester
  • Hardness Tester
  • Carbon apparatus
  • Cutting machine
  • Sand Testing - Moisture, GCS, Compactability
  • Incoming material Inspection facility
  • Simulation - Magma. (Out sourced)
  • White/Blue scanning. (Out Sourced)
  • Radio active material checking facility

Green Initiatives
  • Energy efficient motors - IE-3 for all equipments
  • Energy efficient lighting - LED and Induction
  • Natural lighting - transparent sheets on roof and side cladding
  • Energy management system
  • Use of biogas for ovens
  • Tree Plantation
  • STP plant
  • Dust collection and fume extraction
  • No wooden pallets
  • Asbestos Free
 

  © Menon and Menon Ltd. 2007.Rev.2 - 17/06/2016 All rights reserved.