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.

▪ 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

    ▪ 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.

SUSTAINABILITY 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.