Foundry Facilities

Utilities

The Plant is equipped with 2 sets of Kirloskar Cummins make Diesel Generator sets of capacity 1000 KVA and 1375 KVA as power backup for running entire plant during power failure.

It also has 8 nos. Air Compressors having total Free Air Delivery capacity 2252 cfm meeting specific operations of the entire plant.

The Plant is also having 2 nos 5 MT, 1 no 6 MT and 1 no. 10 MT capacity overhead cranes and Air Hoists cover lifting equipments of the plant.



Maintenance

Cresmac is having separate well equipped maintenance department. Experienced maintenance engineers and highly trained technicians are there for installation and up-keep of Plant & Machinery and electrical maintenance.



Pattern Shop

A well equipped pattern shop is run in house for making patterns with precise accuracy to ensure castings are made with close dimensional tolerance. ure.



Molding Shop

This shop is having 4 Continuous Mixers, 3 Shell Core machines and 2 Sand Muller for CO2 cured Sodium Silicate sand binder systems. Moulds and cores are made with Pepset system through continuous mixer and also with CO2 cured Sodium Silicate system. Both Mechanical and Thermal Reclaimed sand systems are used for making molds and cores. After moulds / cores are made refractory paint is applied by brush and flow coating application. Molds and cores are properly dried with gas burners and in ovens as per mold size before closing. Gauges are used during closing. Closed molds are given overnight curing and then transported in Forklifts to pouring station.



Melting & Pouring Section

This section is having 550 KW Power Pack Monotrack Induction Furnace with 4 crucibles, a couple of them having capacities of 1100 Pounds, 1 no having capacity 2400 Pounds and 1 no having 3300 Pounds capacity. Graded scrap is used for making specific grades of product cast. After processing a heat and getting chemical composition bath result through Spectrometer, liquid metal is tapped from Induction Furnace in a gas fired well preheated ladles. After Slag off from ladles, temperature is recorded using Immersion Pyrometer. Liquid metal is transferred to pouring bay with the help of overhead crane and poured into molds.



QA / Laboratory

Scrap and major incoming raw materials are tested in laboratory using specific testing procedures. Spectrometer is used for bath and final sample analysis for all grades of metal cast.



Knock-out

After pouring and sufficient cooling of poured molds, demolding is done manually.



Short Blasting

2 Shot Blasting machines are utilized for proper cleaning of castings.



Heat Treatment

7 gas fired heat treatment furnaces are used for heat treatment of castings adopting specific heat treatment cycle for specific grades of metal cast. Air Quench by Industrial fans and Quenching Tank for Water Quenching are available in heat treatment shop. Heat Treatment facility is available for casting having maximum size 8ft x 6ft x 3ft height. Propane : We use LPG cylinders for heat treatment furnaces, Laddel heating and Thermal Reclaimer.



Finishing Grinding

Runners and Risers are removed as per norms. Grinding and other related finishing operations are done in this section before and after heat treatment. Interim visual inspection and Non Destructive Test is done on case to case basis.



Inspection

Rough castings ready for shipment are once more inspected before painting and shipment. Here proper gauges are used to meet dimensional requirement.



Machine shop

This section is having 18 Conventional Lathes (40 inches max Swing), 9 CNC Lathes (36 inches max Swing), a VMC (Table Size 3 ft x 1 ft), 1 HMC (Table size 20 inch sq), 6 VTL (Chuck Diameter 4.5 ft maximum ) and half a dozen Drill Machines.

Machining is done for all grades of castings having maximum hardness 700 BHN produced in Foundry. Pressure testing facility is also available for Valve Bodies