Advanced Foundry Facilities with 100% Shell Moulding, Dual Track Induction Melting, Integrated Casting Simulation, Automated Material Handling Systems, and 4,000 Tonnes Per Month Production Capacity
Our foundry operations begin with casting simulation using MAGMA software to validate gating design and thermal behavior before production. We operate 100% shell mould and shell core processes using precision core shooters, enabling superior dimensional accuracy and surface finish. Advanced shell moulding technology supports complex geometries and consistent core positioning, forming the foundation of high-quality cylinder head castings.
Melting operations are supported by dual track Inductotherm induction furnaces rated at 550 kg capacity, ensuring uninterrupted production and controlled metal chemistry. Automated monorail systems and PLC-based conveyors manage safe and timely material transfer from knockout to downstream processes. Robotic air vent drilling improves casting quality by eliminating air entrapment and reducing defects during pouring.
Our in-house sand reclamation plant enables sustainable foundry operations by recovering and reconditioning used sand. Metallurgical inspection, sand testing, and mechanical property validation ensure every casting meets required material composition and performance standards before moving to machining.
Total molten metal pouring rate across dual furnace system.
Inductotherm dual track induction furnaces used for melting.
SUSHA make shell moulding and core shooter machines.
Achieved through in-house sand reclamation plant.
Our foundry operations combine 100% shell moulding, casting simulation, and dual-track induction melting systems. Integrated material handling, robotic processes, and metallurgical control ensure consistent casting quality and process stability.
Each major plant operates dual-track Inductotherm induction furnaces rated at 550 kg capacity, enabling continuous melting, chemistry control, and stable casting operations.
Automated monorail systems and PLC-based conveyors transfer castings from knockout to downstream processes, improving operator safety and ensuring consistent process flow.
An in-house sand reclamation facility recovers and reconditions used mould and core sand, reducing fresh sand consumption while supporting sustainable foundry operations.
Automated shot blasting removes sand residue, scale, and surface contaminants from castings, ensuring clean surfaces and revealing defects before machining operations.
Fettling removes parting line flash and surface irregularities, while decoring clears burnt sand from internal cavities to achieve cleanliness required for machining.
Internal cavities are cleaned using targeted blasting, while spray painting applies coatings per customer specifications with masking of critical ports and surfaces.
The shell moulding process uses precision equipment to produce moulds with high dimensional accuracy, smooth surfaces, and capability for complex casting geometries.
Shell core shooters produce precision cores that undergo dimensional checks and inspection before mould assembly, ensuring consistent core positioning and stability.
KUKA robotic drilling creates precise air vents in moulds, allowing gases to escape during pouring and preventing porosity or gas-related casting defects.
Controlled heating and cooling cycles relieve internal stresses in castings, improving dimensional stability and preventing distortion during machining operations.
Online spectrometer testing verifies molten metal chemistry, while microstructure analysis confirms graphite morphology and material consistency.
Universal testing machines and hardness testers validate tensile strength, elongation, and hardness to confirm mechanical reliability of cast components.
The sand laboratory monitors resin content, grain fineness, stick point, tensile strength, and moisture to maintain consistent mould and core quality.
The water curtain paint booth captures overspray and maintains controlled painting conditions while ensuring operator safety and consistent coating quality.
Our manufacturing campus brings together advanced foundry and machining infrastructure designed for efficient, high-volume production. From shell moulding foundry operations to automated machining lines, every facility is organized to ensure smooth process flow, safety, and consistent manufacturing quality.
Integrated material handling systems, modern equipment, and controlled production environments support reliable cylinder head manufacturing while maintaining precision, productivity, and operational stability across all stages of production.
