Core Centre – Loramendi – Spain

Core center (Cold Box) – Key Features

• High speed core sand mixer (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 oncore as well as no damage on core profile
• Robotics for core handling , assembly & painting
• Quick core box change over – Setup time 5 minutes
• On line core box cleaning station – Which helps in cleaning the core boxes at decided frequency without removing core box

Shell Cores – Susha and SPAN , India

• 3 shell core machines to produce auxillary cores
• Twin station vertical parted machine – Core box size 18” X24”
• Horizontal parted machine – Core box size 24” X 40” -2 Nos
• Automatic core box changeover

Core Oven – Sharp Thermal , India

• Oven length – 30 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 System – Tata Automations Ltd , India

• Pallet size – 1100 x 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

Sand Plant – Kunkel Wagner , India

• 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.

Moulding Line – Kunkel Wagner – Germany

• Machine model- DFM , Air press
• Box size : 1000 x 800 x 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

Melting Furnaces – ABP , India

• Induction furnaces
• 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 – ABP, India

• Capacity – 5/7.5 MT
• Press pour with heating arrangement – Ensures constant pouring rate and constant pouring temperature for each box
• Online innoculation feeding system to control innoculation quantity
• Fume extractor system for pouring and cooling lines – Keeps environment clean

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.

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.
• 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.

FOUNDRY – KOLHAPUR DIVISION

Capacity – 2400 mt / month

Core Shop

Cold Box Machine

Shell Core shooter

• Common sand feeding facility for all cold box machines.
• Single directional flow for head core assemblies
• Gas fired (Dual fuel – LPG/Bio Gas) Core ovens. We have both continuous and batch ovens
• Core Storage and handling system.

Melting Furnaces

• Lifting Magnet for raw Material handling for all three lines with load cells.
• Charging system with load cells
• Fume extraction system.
• Spectrometer and Spectraview to check and display online chemistry.

Fettling

In-house fettling facility

Machine shop

Total Plant Capacity

• Cylinder block machining capacity
  760 nos./ day
• Cylinder head machining capacity
  500 nos./day
• Total machining capacity
  1260 nos./day

Dedicated lines

• Mahindra Block Line. Capacity :- 300 nos./ day
• TML Block Line. Capacity:- 200 nos./ Day
• Ashok Leyland block line :- 100 nos. /day
• TML 5L / 3L block line :- 50 nos. / day
• TML Head Line Capacity :- 400 nos./ Day
• Flexible head line :- 100 nos. / day

Flexible Lines

Cylinder head Line. Capacity :- 100 nos./ day

Cylinder Block Line. Capacity :- 100 nos./ day

Robotic Drilling machine

Robotic Washing applications

Other Capabilities

• Design & manufacturing of Jig fixtures :- 2D 3D software Capability of pipe less fixture designing WMW jig boring facility Cylindrical and surface grinding facility.
• Standard Room:- Our standard room is NABL accredited. The dedicated staff in the standard room calibrate the gauges and instruments inhouse.