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 the respective molds. Different material like silicate, fusion resin molasses vare utilized in our core making shops.
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 molding of complicated casting.
After shake out, castings freed from sand are brought into fettling shops. Our fettling shops have a number of shot blasting machines (both hanger and rotatory) that assist in the preparing parts for the next stage. For some auto parts cores are removed using pneumatically operated chisel and grinding machines. After cleaning paint work is carried out as per OEM requirement, using baked paint or oxide spray paint.
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 install casting capacity of 20,000 tons and 15,000 tons per annum respectively.
Almost all the casting produced by the factory foundry shop are machined in house as per the specification 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 machines tools are being used to ensure that components are manufactured according to the specified standards. Our machining lines includes the CNC vertical lathes CNC horizontal lathes, CNC machining centers, CNC drilling and tapping centers, Imported and self deployed special purpose machines, milling machines, radial drills and variety of other conventional machines. Jigs and fixtures at each stage are developed with extreme care guaranteeing that each part produced comply with the OEMs required level of machining precision.
Development of new parts in this ever changing engineering environment is our key are 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, mold, 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 endure no area including casting, machining, inspection and quality assurance is left out.
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 the molding is accurate, the sand permeability is impeccable and mold hardness is of the required standards at our SAND TEST LABORTARY. At the stage of melting, quality is ensured using CARBON EQUIVALENT METER, CHEMICAL LABORTARY and SPECTRO METER.
131/4 Quaid-e-Azam Industrial Estate Kot Lakhpat, Lahore, Pakistan,
Interested in working with us?
exports@excelengg.com
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