Die Casting - Suvarna Alloys Pvt. Ltd.

Report
SUVARNA ALLOYS PVT LTD
Aluminium High Pressure Die Casting
BACK - GROUND
 New High Pressure Die Casting Aluminium foundry.
Location – Kagal Five Star Industrial Area, Kolhapur.
 Established in 2013.
 New venture of Esmo group.
 Esmo group is in the following business sectors,
 Mining.
 Logistics & Warehousing.
 Information Technology.
 High Pressure Die casting
SAPL - Company Briefing
INFRASTRUCTURE
State of the Art Infrastructure –
 Melting – Crucible less gas fired furnace. (500kgs/hr)
Fuel – Bio-Gas.
 Melt Treatment - Nitrogen Degassing Machine.
 Die Casting - Buhler Ecoline – Multi step HPDC.
(Locking force - 340T and 660T)
 Holding Furnace – Crucible Less, low energy
consuming top heating electric furnace. (500kgs/hr)
 Compressor – Atlas Copco GE series screw type. (200
cfm)
SAPL – Machinery & Capacity
INFRASTRUCTURE
Cooling Tower – Inductokool IK-10 & IK-40. Seperate
cooling circuits for die and machine.
Material Handling – EOT Crane 10T & 2T double girder,
Trolley mounted Transfer Ladle.
Quality Assurance –
Alloy testing – Spectrometer with 32 element detection.
Melt testing – Density Index Tester.
Component testing – Gauges, Tools and CMM.
SAPL – Machinery & Capacity
INFRASTRUCTURE
 Fettling – At HPDC cell fettling and manual inspection
with go-no go guages.
 Shot Blasting – Shot Blasting machine for surface
finish requirement.
 Machining-
Ace Micromatic VMCs and CNCs with
tooling capability.
SAPL – Machinery & Capacity
INFRASTRUCTURE
BBUHLER ECOLINE
Features of Buhler machines:1. Proven 3 Platen toggle system.
2. High shot speed up to 8.5 m/s filling velocity with metal.
3. Shot profiles set manually or by multistep remote control
4. Multistep Technology for more flexibility
5. Auto Ladle, auto sprayer and auto extractor.
SAPL – Fully Automatic Cell
Quality Lab Equipment
Density Index Tester
Density Index Unit is
also a part of SAPL
Facility. This is very
important Test which
provide Gas content
into molten metal.
Spectrometer
The metal analyser is used
for material testing in
foundries. It determines all
of the elements in the metal,
trace analysis of carbon,
phosphorous,
sulfur
&
nitrogen.
Degasing Unit
Foundry
degasing
unit is installed for
molten
metal
treatment.
By
purging inert gas we
improve metal and
casting quality.
SAPL – Quality Assurance
DIFFERENTIATOR
 Buhler Die Casting Cells. – Fully Automatic.
 Maximum automation, minimum man power requirement.
 Auto Ladle, Auto Sprayer, Auto Extractor.
 Components ranging from 150 Tons to 800 Tons locking force.
 Raw Material Quality control through Spectrometer.
 Molten metal treatment through Nitrogen Degassing.
 Molten metal quality control through Density Index Testing.
 Environment friendly initiative with Bio Fuel for melting
furnace with zero emissions. (95% Methane.)
SAPL – What makes us different ?
DIFFERENTIATOR
 In house casting, machining, finishing and sub assembling.
 Energy efficient set up. Maximum use of alternative clean fuels.
Energy cost constant for several years.
 Product development and Engineering Support from –
 Buhler AG
 Ace Micromatics.
 Separate Melting shop – Die Casting Shop and Machine Shop.
 Dedicate Tool Maintenance Area.
 Future Ability to ramp up and expand. With Electrical, Plumbing,
Pneumatic and civil infrastructure laid out for further 3 HPDC cells
each of 840 T.
 Industry renowned and highly experienced & qualified Technical
advisors.
SAPL – What makes us different ?
PLANT LAYOUT
Melt Shop– 3,000 sq ft.
Melting
Shop
RM Store
Die
Maint.
Die Casting – 10,000 sq ft.
Die Cast
Shop
Machine Shop– 7,000 sq ft.
Quality Lab
Machine Shop
Dispatch Gate
Total Land Area – 1,40,000 sq ft. Total Plant Area – 20,000 sq ft.
SAPL – Efficient Movement!
Plant in Picture
Suvarna Alloys Pvt Ltd. Plant-1
Double girder EOT crane is
installed of Size 10T x 2T. Crane
is suitable to take care all die
maintenance as well other
operations in the plant. 200 TR
capacity cooling tower. Layout of
Plant is planned as suitable for
process.
Suvarna Alloys Pvt Ltd. Plant-1
Total Area constructed 20,000 Sq
ft. It covers Melting shop, Raw
Material store, Compressor Room,
Die casting Shop for 5 Machines,
Die Maintenance, Quality Lab,
Machine Shop, Shot Blasting
Area, Finished good Store and
Dispatch.
Future at SAPL
 Land, Electricity, Manpower available to set up another 2 plants
of this size at this location.
 Energy price is locked for 5 years for bio gas, hence making sure
cost control is possible.
 Non Destructive Testing will be set up in next 12 months.
 Image Analyzer
 X- Ray.
 Ability to ramp up in short time and expand. With Electrical,
Plumbing, Pneumatic and civil infrastructure laid out for further
3 HPDC cells each of 840 T.
 Looking for Joint Venture in setting up entirely dedicated plant
for single customers long term requirement or dedicated new
product development facility.
SAPL – Future offerings.
POLICIES THAT GOVERN US
Operating Policy:
 Most efficient operating practices should be employed.
 Standardization of operations and practices.
 Documentation of operations.
 Maximize waste reduction.
 Simplification of tasks and micro – processes.
Infrastructure Policy:
 Best possible equipment in terms of technology and quality has no
alternative.
 Focusing on consistent quality output, even if it means low ROI.
 Equipments and technologies to enable future advancements and
developments.
 Infrastructure that has global acceptance in terms of best in class
standards and technologies.
SAPL – Beliefs
POLICIES THAT GOVERN US
Man Power Policy:
 Worlds best machines and pure raw material will only lie idle
without able hands to direct it in the right manner  Organizations most important resource is HR.
 Get the best possible human resource only then world class
infrastructure can operate to its potential.
 HR is partner in growth and success of the organization.
Accordingly they share the stakes of performance just like owners and
management.
 Multi level empowerment of employees. Through delegation of
work comes responsibility and sense of owning.
 Continuous & comprehensive training and technical foundation of
work force. To know HOW, one needs to understand what, where,
when and why first!
SAPL – Beliefs
Contact
Office Address:
Rahul Suvarna
Director – Operations
255/1, Highway Park,
Old PB Road, Tararani Chowk,
Kolhapur – 416003
Plant Address:
Sameer Potdar
Plant Head
Plot C-8, Kagal Five Star MIDC,
Kolhapur.
Correspondence:
Office: +91-231-2662167
Fax: +91-231-2662170
www.suvarnaalloys.com
Thank you – Please Visit us!

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