Our Foundry

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Our Foundry

A greenfield foundry project utilising a high level of automation and advanced technologies designed by industry experts and operated by people who take pride in the products they deliver to customers.

From casting simulation to finished products, every critical process parameter has been considered and recorded for thorough traceability.

Process & Equipment

Capability

Design capacity of 12,000 tonnes per annum
Casting capacility up to 15 tonnes finished weight
Dedicated semi-automated moulding lines
Capacity of manufacturing castings in manganese, high chrome and martensitic steel

Sand Reclamation System

A remarkable recycle rate of 98.5%;
A unique sand reclamation system without generating dust and waste water

IT & Digital Technology

Integrated Desk Cloud IT & computer system
Advanced CAD and solid modelling softwares
Casting simulation software
Production integrated ERP

Pattern Workshop

CNC pattern cutters
Automated pattern storage and retrieval system under construction

Moulding

Ceramic sand with sodium silicate bonding
12 tonnes per hour moulding line for apron feeder pans and shredder hammers
25 tonnes per hour moulding line for regular cone and jaw liners
40 tonnes per hour moulding station with vibrating deck for large castings
Recirculating refractory liquid coating system

Melting

High energy efficient induction melting furnaces
Automated scrap and raw material feeders
Combined melting capacity of 21 tonnes for casting up to 15 tonnes finished weight
Fume extraction and filtration greatly reduces harmful air emissions
ERP melting management system that allows for efficient operation and fine tolerance chemistry adjustment

Pouring

Bottom discharge ladles
4 meter deep pouring pit for large gyratory mantles
A movable gantry type fume extraction system

Heat Treatment and Quenching

Automated casting loading
Computer controlled gas ovens with a combined capacity of 40 tonnes
Rapid automated transfer from oven to quenching tanks
Forceful agitators to maintain rapid flow and even temperature distribution
Cooling towers and extra ice storage system to maintain quench water temperature below 200C at all times

Fettling & Cleaning

Fetting cells with high efficiency extraction systems
Shot blasting
Oil hydraulic press of 1000 tonnes capacity

Machining

CNC vertical borers for cone liners up to 3500mm in diameter
Horizontal milling machines
Dedicated CNC machining equipment for feeder pans and chute liners

Testing and Inspection

PMT electro spectrometers (ARL3460)
Hardness, impact, tensile and elongation tester
Portable microscope for microstructural analysis
3D scanner for final demensional inspection, wear profile and reverse engineering
Patented wearing test equipment