Welcome To Malnad Alloy Castings Private Limited. Est : 1983 Alloy Steel, Stainless Steel, Nickel Base Castings Manufacturer

Transcription

1 Welcome To Malnad Alloy Castings Private Limited Est : 1983 Alloy Steel, Stainless Steel, Nickel Base Castings Manufacturer

2 MALNAD GROUP COMPANIES Malnad Alloy Castings Pvt Ltd since 1985 :Scope: Manufacture & Supply of Raw, Machined and Hydro tested Castings in Ferrous, Nickel and Cobalt based alloys Shimoga Precision Castings Pvt Ltd since 1996 :Scope: Manufacture and Supply of Alloy Steel, Stainless Steel, Nickel Alloy Steel, Cast Iron and Cobalt Alloy Steel Castings By Investment and Sand Casting Process Malnad Prime Machining Technologies since 2010 :Scope: Manufacture of Precision Machined Components Malnad Alloy Castings Pvt Ltd (Laboratory Division) since 2017 NABL Accredited Mechanical and Chemical Testing Lab

3 We are located in

4 Management Contacts Y. V. Madhukar Jois, Managing Director Prateek M Jois, Executive Director pj@malnad.co.in Land Lines - (08182) 46141,246142,

5 Organisation Chart

6 Photo Name Department Mail ID Cell phone Issues Handled Vynatheyan Manager Marketing Enquiry; PO; OA Mahesh C.N Subhanna. N Manager Production cnmprd@malnad.co.in Manager Quality Assurance nsqa@malnad.co.in Delivery dates; Planning Dates Test certificates (chemical & Mechanical) Swamy M.S. Manager Quality Control swamyqc@malnad.co.in NDT Related Manjunath M L Manager Pattern Shop manjupatn@malnad.co.in Pattern development Subramanya Hegde Manager Dispatch and Logistic sharath@malnad.co.in dispatch dates; Logistics Details Mahaveer Jain Process Engineer mjain@malnad.co.in Customer complaints

7 Vision & Mission The Vision of our company is to Become global leader for the supply of finished cast components in wide range of materials with highly committed and socially responsible employees Our Mission is to *To meet the casting requirements of the country using latest state of the art-technology in wide range of materials at competitive cost. *Provide stable employment and develop highly skilled technical manpower and develop wide vendor base. *Adopt environmentally sound and safe technology and create awareness on energy conservation. *Serve the community around through welfare schemes.

8 Our Progress 1985 Started with 175 KW furnace & 30 MT/Month capacity Addition of 250KW furnace & Capacity Enhanced to 100 T/Month Well known foundry status from IBR Implemented QMS & Certified for ISO Implemented integrated ERP system Certified by AD 2000 MarkBlatt Enhanced Furnace capacity from 250 to 350 KW & 150T/Month capacity Qualified for PED Certificate Direct Export Business Started Enhanced Furnace Capacity from 350 to 450 KW increasing production to 275T/Month Added Machine shop Started LEAN activities Approval by BV Marine Division Added testing facilities like PMI, Height Master & Surface tester Separated processing of stainless steel and carbon steel in different areas Added 750KW Furnace increasing production to 625T/month

9 Our Progress 2013 MAGMA Simulation Software installed 2014 Lloyds Foundry Approval Certified ISO 14001:2004 & OHSAS 18001: Highest sales DNV Foundry Approval New building sq foot for processing of above 500kg castings 2015 CETP of capacity liters installed 2015 Mould Carousel 8 Station semi automatic system 2016 Fork Lift for Pattern Movement 2016 NORSOK Certification for 4A, 5A and 6A Grades 2016 Upgraded ISO to 2015 Version 2016 Solar Roof Top Cells 100 KW Capacity Installed MT Shake Out Machine With Material Handing EOT Crane 25 /10 MT 2016 Mechanized HT Quenching System to facilitate quenching within 50 sec IBR Well Known Foundry status & certified for Carbon & Alloy Steel up to 2400 Kg single piece Installed 3MT Capacity Table type Shot Blasting Machine ISO upgraded to 2015 Version.

10 State of Art Omega Semi Automatic Mold Carousal for consistent mold quality for small & medium casting production with 120 molds/shift capacity. Mechanised Quenching system for Heat treatment Process. 10 WPS-PQR Certified Operators for various grades witnessed by TUV, Lloyds & DNV. 10 Qualified Welders for handling the welding activities of various grades More than 15,000 Patterns with 6000 patterns live!. Traceability through ERP maintained location system and Product code. Our Strength Exclusive storage arrangement for preservation of patterns. 50 to 60 New Products being developed every month. More than 750 fully machined cast components exported / month.

11 Our Sales!! Sales in Cr. INR Sales in Cr. INR Highlights : Highest sales for financial year M USD. Business with Export 5.8 M USD

12 Certificates & Awards ISO 9001:2015 ISO 14001:2015 OHSAS 18001:2007 Well Known Foundry Status IBR Since 1983 PED AD MERKBLATT Lloyds, Bureau Veritas & DNV Foundry Approval NORSOK Process Approval for 4A, 5A & 6A Export Excellence Award By Govt. Of Karnataka Export Excellence Award By IIF

13 Product Mix Valve components Pump components Hydraulic Components General Engineering Turbine component Defence Components Ball Valve 2 to 30 Globe Valve 0.5 to 12 Gate Valve 0.5 to 12 Check Valve Control Valve 0.5 to to 16 Class 150 to 1500 Class 150 to 900 Class 150 to 900 Class 150 to 900 Class 150 to % 5% 5% 5% 5% 70% Butterfly Valve Diaphragm Valve Piston Valve Double disc 2 to 40 2 to 12 2 to 8 2 to 24 Class 150 to 1500 Class 150 to 300 Class 150 to 300 class 150 to 300 Check Valve 2 " to 12 " class 150 to 300

14 Foundry Capacity Total Capacity MT/Month. Utilized Capacity MT/Month (in view of recession in market). Maximum Single Piece Weight We Can Produce is 2400 Kgs.

15 10/11/ Kg Butterfly Valve 2700 Kg Casting Exported from Malnad 15

16 Typical Lead Time SECTION Pattern Development Sample Castings (Including Radiography Test) Sample Machining Production Castings Production Machining TIME REQUIRED 3 weeks 45 Working Days (From the date of receipt Pattern ready for molding) 3-4 Weeks (From Receipt Of Castings) 45 Working Days 75 Working Days All the above lead time depends on the size & complexity of the castings.

17 Carbon Steel Material Of Construction ASTM Grades WCB,WCC,WC6,LCB,LCC,WC9 Alloy Steel C5,C12,C12A Stainless Steel CF8, CF-8C, CF8M,CA-15,CD4MCU,CD4MCUN, Grade 4A, 5A, & 6A, CN7M,CF-3,CF-3M, CG8m,CA6NM, SS420. CA40, SS410, SS430, 17.4PH Nickel Base Alloys CW12MW, CW2M,CW6M,CW6MC,CU5MCuC,N7M,N-12MV. All the above grades corresponding to DIN and Indian Standards.

18 Pattern Methoding And Mounting Magma Simulation Pattern Mounting

19 Manufacturing - Molding NO BAKE System Continuous Mixer 12 MT/Hour 1 Number Continuous Mixer 6 MT/Hour 2 Numbers Continuous Mixer 1.5MT/Hour 2 Numbers Batch Mixer 150 Kgs 2 Numbers Sand Reclamation Plant 4 MT/Hour 1 Number

20 Manufacturing - Molding Core Making Mold Coating.

21 Manufacturing - Melting Medium Frequency Induction Furnaces 750 KW 3000 Kg & 2000 Kg Crucible 450 KW 1500 Kg & 1000 Kg Crucible 175 KW 300 Kg & 150 Kg Crucible One Crucible is standby in all the above cases.

22 Manufacturing Post Pouring Shot Blasting Machine 1MT hook type - 1 No 5MT hook type - 1 No Shot blasting machine Table type 1 MT - 2 Nos. Table type 3 MT - 1 No Aluminum grit blasting Machine 750 Kg - 2 Nos. Room Blast - 2 Nos. Pedestal grinding Machine 3HP - 1 No Swing frame Grinding Hp - 4 Nos. Flexible shaft with variable Speed 2.5 HP - 25 Nos. Subcontracting Facilities: 3 Groups within the campus with capacity 20 & 80 MT/Month. 6 Subcontractors outside with total capacity 350 MT/Month

23 Manufacturing Heat Treatment 3 & 5 Ton Furnaces Mechanised Quenching System One each of Electric PLC Controlled, 0.75, 1.5, 2.0 & 3.0 MT Furnaces & one each of 3 and 5 MT furnace with Mechanized quenching system to facilitate water quenching within 50 Sec. Quenching Water tanks of & Liter Capacity with Cooling System.

24 Quality/Testing Facilities Spectro Analyzer with Three Base Metal - Iron, Nickel and Cobalt with 25 elements including Nitrogen And Oxygen.

25 Quality/Testing Facilities PMI Vickers Hardness. Impact testing Machine up to -196 C 20 MT Capacity UTM PMI with BHN attachment. BHN Testing Machine

26 Quality/Testing Facilities Magnetic Particle Inspection Ultrasonic Test Die Penetrate Test, RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters. 5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard.

27 Quality/Testing Facilities LIST OF N.D.T QUALIFIED INSPECTORS AND OPERATORS - M.A.C.P.L. SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY 1 Mr.M.S.SIDDALIGESWARA SWAMY 2 Mr.C.U.KESHAVAMURTHY 3 Mr.A.VIGHNESHWARA MANJA 4 Mr.N.SURESH RAO 5 Mr.DOULATH PASHA 6 Mr.GAJENDRA 7 Mr.K.MANJUNATHA 8 Mr.KRISHNA 9 Mr.NANJAPPA.N EN-3197CERT/NDT R.T 23-Sep-2021 P2MG03905 L.P.T. M2MG03905 M.P.T. 5-May-2019 R2MG01905 R.T BNDT/134/UT/II/10 U.T. 22-Oct-2019 BNDT/114/PT/II/10 L.P.T. BNDT/115/MT/II/10 M.P.T. BNDT/116/RT/II/10 R.T BNDT/117/UT/II/10 U.T. BNDT/124/PT/II/08 L.P.T. BNDT/125/MT/II/08 M.P.T. BNDT/129/RT/I/10 R.T BNDT/130/UT/I/10 U.T. HYD/B/266 L.P.T. HYD/B/266 M.P.T. HYD/B/263 L.P.T. HYD/B/263 M.P.T. BNDT/123/PT/I/08 L.P.T. BNDT/122/MT/I/08 M.P.T. BNDT/117/PT/I/08 L.P.T. BNDT/116/MT/I/08 M.P.T. BNDT/118/PT/I/08 L.P.T. BNDT/119/MT/I/08 M.P.T. HYD/B/268 L.P.T. HYD/B/268 M.P.T. 22-Oct May Apr Apr Apr Apr Apr Apr-2019

28 Quality/Testing Facilities 0.50 Flow Bore Casting

29 Quality/Testing Facilities Other Testing Instruments :- Ultrasonic Thickness Gauge Digital Poldie Hardness Tester Ferrito Scope Radio Active Contamination Detector Digital ph Meter Digital Lux meter; Sound meter; Tachometer Casting Comparator From Steel International France Infrared Temperature measuring instruments 500 C & 1600 C

30 Manufacturing Machine Shop In House Machine Shop equipments & Facilities Vertical Machining Centre. CNC Turning Centre. Conventional Lathes Radial Drilling Machine Conventional Milling Hydro Testing Machine for 150/300/600 & 900/1500/2500 CLASS Malnad hydro procedure in line with ASNT and EN standards

31 Customer Base China

32 Major Customers

33 Web Access To Customers Website address: Customers will be given with unique login id & Password Data Available: Order Status, Test Certificates (3months) Dimension Ins Report, NDT Reports & Pattern List 33

34 On Going Projects-2017 Thermal Reclamation plant- 1.5 M.T per hour to improve Sand quality & to reduce environmental issues. NABL Accreditation for chemical & mechanical lab. Planned Projects Energy Management System Rain water harvesting 34

35 EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500lts/hour capacity has been installed 100 KW Roof top static solar cell installed in hall number 7 RO plant 1500lts/hour capacity 50+ Plants planted Across The Company Compound

36 10/11/2017 SHIMOGA PRECISION CASTINGS PVT LTD 36

37 10/11/2017 Our Progress 1996 Start up of Production Started ERP 2002 ISO 9001 Certification Added new building for shell activity 2009 Started Wax formulation in house 2010 Started Manufacturing of Ceramic cores Crore sales(inr) Crore sales (INR) 2016 ISO 9001 upgraded to Latest version EMS & OHSAS Certifications under progress SHIMOGA PRECISION CASTINGS PVT LTD 37

38 Facility Details 10/11/2017 Total Installed Capacity - 40MT per Month. Utilized Capacity 25 MT per Month. Single piece we can pour up to :40 Kgs Experts in-steam Trap, Control Valve components Special grades: Stellite-6,Stellite-21,NNRD2,Monel- M35, Ultimate Alloy, Duplex steel apart from standard Austenitic, Martensitic Steels SHIMOGA PRECISION CASTINGS PVT LTD 38

39 10/11/2017 Various Stages Of Investment Casting SHIMOGA PRECISION CASTINGS PVT LTD 39

40 Customer Base SHIMOGA PRECISION CASTINGS PVT LTD

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43 10/11/2017 Manufacturing Experience Ball Valve 15MM TO 25 MM Class 150 to 300 Globe Valve 0.5 to 2 Class 150 to 900 Gate Valve 0.5 to 2 Class 150 to 900 Check Valve 0.5 to 2 Class 150 to 900 Control Valve 0.5 to 3 Class 150 to 2500 Butterfly Valve 2 to 4 Class 150 to 1500 Diaphragm Valve Upto 2 Class 150 to 300 Piston Valve Upto 2 Class 150 to 300 Double disc 2 to 4 Class 150 to 2500 Check Valve SHIMOGA PRECISION CASTINGS PVT LTD 43

44 10/11/2017 MALNAD PRIME MACHINING TECHNOLOGY 44

45 M A C H I N I N G F A C I L I T Y Malnad Prime Machining Technology Private Limited, a Sister concern of Malnad Alloy Casting, is well equipped to machineup 10 size Valves. We have following CNC machines with the table size details. We can supply the castings in completely machined & Hydro tested condition. Machines Specification Size X Y Z VMC VTL HAAS VF MAX TURNING DIA MAX TURNING LENGTH 700 VCS 430A MAX TURNING DIA MAX TURNING LENGTH 750 HMC HORIZONTAL CENTER NEXUS CNC - Turning MAZAK E160C Conventional Lathes 9C Lathes 9C Lathes Radial Drilling Machine MALNAD PRIME MACHINING TECHNOLOGY

46 10/11/2017 Thank You 46