Moldinglines

Our foundry shops have engineered molding lines, including mechanized sand system, conveyors for handling molds, knockouts for separating castings from molds. Green sand molding is done on pneumatically operated high-pressure pin lift and turnover molding machines. Plant for washing sand before molding is in place to ensure premium quality. Apart from green sand molding; CO₂ resin sand is also used for moulding of complicated castings.

Coremaking
shops

We manufacture a range of complex castings and produce cores using diverse methods as per specific molding requirements. Core shooter and specially designed pneumatic fixtures are used to construct and place variety of cores into their respective molds. Different materials like silicate, fusion resin and molasses are utilized in our core making shops.

Melting

There is a range of both Induction and Cupola furnaces installed at the foundries. The capacity of induction furnaces is 1,500 kg, 700 kg, 500 kg and 250 kg per hour. Extreme care is taken during this key process of casting so that a precise blend of ingredients are used to match the required grade of Cast Iron, Ductile Iron and other alloys.

Excel Engineering and Hussain Engineering have an installed casting capacity of 20,000 tons &15,000 tons per annum respectively.

Fettling

After shake out, castings freed from sand are brought into fettling shops. Our fettling shops, have a number of shot blasting machines (both hangar and rotary) that assist in preparing parts for the next stage. For some auto parts, cores are removed using pneumatically operated chisel and grinding machines. After cleaning, paintwork is carried out as per OEM requirement, using baked paint or oxide spray paint.

Machining

Almost all the castings produced by the foundry shop are machined in-house as per the specifications / drawings provided by the OEMs clients. Independent Machining lines have been established for mass production of individual parts. Our Machining lines include conventional machines, NC and CNC machines along with SPMs to ensure high level of precision in the components manufactured. Internationally approved quality machine tools are being used to ensure that components are manufactured according to the specified standards.

sheetMetal,
forging,
Fabrication
and
heat
Treatment

Apart from machined castings we also produce sheet metal, forged and fabricated parts. This engineering facility includes pneumatic and mechanical presses, hammers, shearing machines, induction-heating, temperature controlled furnaces, normalizing and salt bath units, Co₂ welding, Flash and Butt welding.

Development

Development of new parts in this ever-changing engineering environment is our key area of strength. Our experienced and well qualified team of engineers are ever ready and eager to undertake all the challenges they may face in this process. Technical data sheets and drawings are thoroughly studied by our designers before creating the in-house illustration for producing patterns, molds, machine fixtures, and quality control gauges. Additionally SPM are also being developed during the process. While developing a part complete S.O.Ps are developed to ensure no area including casting, machining, inspection and quality assurance is left out.

Qualitycontrol

We believe in Engineering Excellence and that is only possible with stringent quality control throughout the production process. Our quality control department works independently certifying the quality at each stage. From procurement of raw materials, to casting process including molding, melting etc. Our team of trained inspectors is present to make sure the quality of the sand used for molding is accurate, the sand permeability is impeccable and mold hardness is of the required standard at our SAND TEST LABORATORY.
At the stage of melting, quality is ensured using CARBON EQUIVALENT METER, CHEMICAL LABORATORY and SPECTRO METER.
Pouring Temperature is gauged through THERMOCOUPLES. Samples from each heat are also taken for testing on UTS machines to record the tensile strength. Another sample is taken from metallographic structure to be checked on our MICROSCOPES.

Similar quality checks are carried out at each stage of machining and also before the final delivery to our customer. Apart from specially designed inspection gauges and fixtures, digital universal gauges and CMM is also used to guarantee the precision of machining sizes.

We always operate in a 5S environment and maintain ISO operations/ management and quality standards at all stages.