INFRASTUCTURE
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INFRASTRUCTURE
Group’s Foundry facilities are spread over in 06 different plants with 04 locations across India. All plants are well equipped with the latest Moulding Technologies like DISA make High-Pressure Lines with Flask & without Flask, High Productive, Robotic Venting Systems, etc. Molding lines are supported by DISA make Auto Controlled Sand Plants with effective Sand cooling, Handling systems & High-Speed Intensive Mixers with different capacities. Sand Mix Controls (SMCs) are ensuring the delivery of good quality Sand with Auto Process Control & Testing Facilities.
MELTING FACILITY
Group is having a capacity of melting 20 tons of metal per hour from its technologically upgraded Melting sections. Melting sections are equipped with Inductotherm to make Dual, Tri & Quadra Track Medium Frequency Furnaces with different pot capacities, Auto Raw material charging & alloy addition systems with the help of high-speed magnetic lifter & Vibro-charger, etc.
INDUSTRY 4.0 (IT)
Great innovations by our in-house IT Team, i-Melt & Energy Management system (EMS) are helping us to track real-time data of KW, KWH, Time for every heat and significantly controlling Unit Consumption and Heat Time.
AUTO POURING SYSTEM
Pouring Sections are also adding great value by pouring required metal well in time with help of Kunkel Wagener Fully Auto Lift Pouring System which operates with a press of a single button, Inductotherm makes Auto Pour & ABP make Press pour systems. Steam inoculation & Quick ladle change system enables us to maintain good casting quality with high productivity.
MOUDING FACILITY
DISA makes modern box & casting handling system, Knock Out, Casting Cooling conveyor, Slat conveyors are capable to prevent Castings from handling damages for weight range from 1 Kgs. up to 400 Kgs.
ROBOTIC FETLLING
Fettling shops equipped with DISA make Shot Blasting machines, sophisticated MAUS Robotic Grinding machines, Grind-master make Robotic Machines, and Trimming & Snag Grinding Machines helped us to remove Foundry bottlenecks by maintaining expected Quality & productive.
Melting Centre
SHRIRAM FOUNDRY PVT. LTD. - KOLHAPUR (1984)
Inductotherm MF Furnaces.
750 Kgs./ 750 KW - Dual track,750 Kgs./750 KW - Dual track
500 Kgs./500 Kw - Mono Track, Melting - 2000 Tons/mont
Real time Production and Unit consumption data monitoring through i-Melt & EMS
ASHTA LINERS PVT. LTD. - ASHTA (HPML) (1989)
Inductotherm MF Furnaces.
3 Pots of 1500 Kgs. each with 2250 KW - Tri track
Melting – 1800 Tons/month
Real time Production and Unit consumption data monitoring through i-Melt & EMS
S. J. IRON & STEELS PVT. LTD. - KOLHAPUR (2005)
Inductotherm MF Furnaces.
1000 Kgs. 1000 KW - Dual track , Melting - 800 Tons/month
Real time Production and Unit consumption data monitoring through i-Melt & EMS
KASTURI FOUNDRY PVT. LTD. - ASHTA (2007)
Inductotherm MF Furnaces.
3 Pots of 1000 Kgs. each with 2250 KW - Tri track
Melting - 1800 Tons/month
Real time Production and Unit consumption data monitoring through i-Melt & EMS
SHRIRAM FOUNDRY PVT. LTD. - PANTNAGAR (HPML) (2008)
Inductotherm MF Furnaces.
3 Pots of 1500 Kgs. each with 2250 KW - Tri track
Melting – 2200 Tons/month
Real time Production and Unit consumption data monitoring through i-Melt & EMS
KASTURI FOUNDRY PVT. LTD. - KAGAL (HPML) (2018)
Inductotherm MF Furnaces.
Inductotherm MF Furnaces.
4 Pots of 1500 Kgs. each with 4000 KW - Quard track Melting,
Melting - 800 Tons/month - 6 Tons/Hr. & 4000 Tons/month, High-speed magnet lifter with Vibro charger, Non-contact lesser temperature pyrometers
Real time Production and Unit consumption data monitoring through i-Melt & EMS
Molding Line
SHRIRAM FOUNDRY PVT. LTD. - KOLHAPUR (1984)
DISA Flask less HPML line – 700 X 600 X 300 mm
Mold Production – 120 /Hr
ARPA 900, Horizontal Parting : 800 x 700 x 350 mm
No Bake Molding – 2000 x 1200 x 300 mm
ASHTA LINERS PVT. LTD. - ASHTA (HPML) (1989)
DISA Flask less HPML line – 700 X 600 X 250 mm
Mold Production – 100 /Hr
ARPA 900, Horizontal Parting : 800 x 700 x 350 mm
No Bake Molding – 2000 x 1200 x 300 mm
S. J. IRON & STEELS PVT. LTD. - KOLHAPUR (2005)
ARPA 900, Horizontal Parting : 750 x 650 x 350 mm
ARPA 450, Horizontal Parting : 700 X 500 X 200 mm
Shell Molding
KASTURI FOUNDRY PVT. LTD. - ASHTA (2007)
ARPA 1300, Horizontal Parting : 1100 x 900 x 350 mm
ARPA 900, Horizontal Parting : 800 x 700 x 350 mm
SHRIRAM FOUNDRY PVT. LTD. - PANTNAGAR (HPML) (2008)
DISA HPML Flex70 – 900 X 700 X 325 mm
Mold Production – 80 Molds /Hr
ARPA 450, Horizontal Parting : 750 x 650 x 250 mm
KASTURI FOUNDRY PVT. LTD. - KAGAL (HPML) (2018)
DISA HPML Flex70 – 1000 X 700 X 350 mm
Mold Production – 100 Molds /Hr
Robotic venting system
Auto core Assembly Transfer Fixture
Sand Plant
SHRIRAM FOUNDRY PVT. LTD. - KOLHAPUR (1984)
DISA TM 160 High Speed Intensive Mixer
Automated Sand Plant
Sand Cooling System
Auto Sand Mix Control (SMC)
ASHTA LINERS PVT. LTD. - ASHTA (HPML) (1989)
DISA TM 190 High Speed Intensive Mixer
Automated Sand Plant
Sand Cooling System
Auto Sand Mix Control (SMC/GSC)
S. J. IRON & STEELS PVT. LTD. - KOLHAPUR (2005)
Automated Sand Plant
DISA High Speed Intensive Mixer TM-160
Sand Cooling System, Wesman
KASTURI FOUNDRY PVT. LTD. - ASHTA (2007)
DISA TM 190 High Speed Intensive Mixer-2 Nos
Automated Sand Plant
Sand Cooling System
SHRIRAM FOUNDRY PVT. LTD. - PANTNAGAR (HPML) (2008)
DISA TM 240 /160 High Speed Intensive Mixer
Automated Sand Plant
Sand Cooling System
Auto Sand Mix Control (SMC)
KASTURI FOUNDRY PVT. LTD. - KAGAL (HPML) (2018)
DISA TM 285 High Speed Intensive Mixer
3.2 Tons batch, 100 Tons/Hr
Automated Sand Plant with Cooling System
Auto Sand Mix Control (SMC)
400 Tons sand storage capacity
Surface Coating
Modern Surface coating facilities are adding more value in Zanvar Group Ferrous casting Business. Group is having a separate division with advanced Cathode Electro Deposition (CED) Coating, Liquid Nitriding & Powder coating plants. CED & Powder coatings give protection life of 500-1000 Hrs. for salt spray & Humidity. Nitriding is improves surface hardness up to 450 HV & enhancing wear resistance. Apart from this dedicated facility all Foundries are supported by Conveyorised paint shops with Paint baking Oven facilities.
LIQUID PAINTING
Electrostatic Spray Painting two stations
100 Mtrs. Conveyor system
Auto control Paint Baking Oven
ETP
CED COATING
Uniform coating
Better corrosion protection up to 500 Hrs
Better humidity protection up to 500 Hrs.
NITRIDING & POWDER COATING
Improves surface hardness to 450 HV
Enhance wear resistance
Corrosion protection up to 500 Hrs.
Improves aesthetics
Machining Division
Modern & advance machining division to provide a World Class finished good castings to our customers.
HORIZONTAL MACHINING CENTERS
QTY. :- 350
SPECIAL PURPOSE MACHINES
QTY. :- 450
TURNING CENTERS
QTY. :- 175
VERTICAL MACHINING CENTERS
QTY. :- 275
CNC/CMM
QTY. :- 11
Technology Up-gradation
Group Foundry infrastructure is supported by technically advanced inspection & test facilities like, Bosello make Online X-Ray Testing for checking internal soundness of castings, GOM Germany make Casting Scanning machine for easy & fast Dimensional Inspection, ‘Any Cast’ Casting simulation for first time right development, modern Magnetic Particle Inspection facilities etc. Additionally all foundries are backed with well-equipped Metallurgical Testing Labs, Spectrometers, Universal Testing Machines, Micro-structure with image analysers, Harness testing etc.
BOSELLO ITALY MAKE
Online casting X-ray testing
CASTING SIMULATION
Casting simulation software to improve yield
of casting
GOM GERMANY MAKE
Casting inspection scanner
SPECTROMETER
Metallurgical inspection at all foundries
3 COORDINATE MEASURING MACHINE
Available at all machining locations