Infrastructure

FACTORY UNIT

We have gigantic foundry unit with total of 15,000 sq. yard, including 7500 sq. yard of built up area. Factory unit is located in Village Ravki, Opp. Stone Cousher,Tal. Lodhika, Dist. Rajkot, Gujarat (India).

Factory unit design is ecological and environment friendly, making relatively less use of electricity during day time. Foundry is specially equipped with low noise machinery which produces bare minimum noise to prevent noise pollution.

With production capacity of 1000 MT of CI casting and 350 MT SGI casting in month, today we have achieved production capacity of 600 Mts. Of CI & 70 Mts. Of SGI casting per month. We are producing casting to the tune of 500 Mts. Per month and have installed capacity of producing 1200 Mts. Per month.

HIGH PRESSURE AUTOMATIC MOULDING MACHINE

We are totally committed to understanding and Meeting the quality needs and expectations of all our customers. We have proud reputation for delivering quality casting. We are equipped with high pressure molding line as well as highly lab testing facilities.

SPECIFICATION

  1. Molding Dimension : 610 X 508 X 130-200/130-200
  2. Molding Speed : 30 Sec./Cycle
  3. Core Setting Time : 24 Sec.
  4. Bunch Weight : Max 50 Kg.
  5. Mold Production : 120 Mold/Hr.
  • Sand cooler cum dust extraction system: Drum type cooler with dust extraction system with a capacity of 20 tons per hour.We have installed a green sand plant with a capacity of 20 metric tons per hour sand recycling capacity.
  • The sand plant is totally PLC controlled for the batch mixing and moisture addition, to control the quality and consistency of the sand mixed for molding.
  • We have arrangement to supply sand from the sand plant to all the molding line that we have installed.
  • We have a 100 tons hopper for the storage of return sand overhead which receives the return sieved and demagnetized sand after the Knockout phase.

SAND PLANT

  • We have installed a green sand plant with a capacity of 20 metric tons per hour sand recycling capacity.
  • The sand plant is totally PLC controlled for the batch mixing and moisture addition, to control the quality and consistency of the sand mixed for molding.
  • We have arrangement to supply sand from the sand plant to all the 3 molding lines that we have installed.
  • We have a 100 tons hopper for the storage of return sand overhead which receives the return sieved and demagnetized sand after the Knockout phase.
  • We have conveyor system to support the sand plant by distribution of sand throughout the plant according to the plant capacity. It consists of the underground conveyors for the collection of knockout sand and over head conveyors and bucket elevators to feed the sand back to the hoppers.
  • We have a load cell for hoppers to make fully automatic cycle for hoppers to make fully automatic cycle.
  • We have conveyor system to support the sand plant by distribution of sand throughout the plant according to the plant capacity. It consists of the underground conveyors for the collection of knockout sand and over head conveyors and bucket elevators to feed the sand back to the hoppers.
  • Sand cooler cum dust extraction system: Drum type cooler with dust extraction system with a capacity of 20 tons per hour.

MELTING DEPARTMENT

Cupola furnace is a melting device used in foundries that can be used to melt cast iron, ni-resist iron and some bronzes. We have four cupola furnace each has 1 tonne / hour capacity. On daily basis average C.I. Casting production is ~20 tonne.

INDUCTION FURNACE – PLASMA INDUCTION

We are using one of the leading manufacturer of Induction Heating, Melting Equipment in India, Plasma Induction is a pioneer in offering total induction solutions to its assorted customers across the world.

SPECIFICATION

  1. Dual Track : 350kg & 500kg
  2. Capacity : 550KW

FETTLING

We have fettling shop equipped with the following machines.

  • 350 Kg Batch 4 shot blasting machine
  • 18 inch swing grinder
  • 16 inch table grinder
  • 6 inch pneumatic grinders
  • Pencil grinders
  • Pneumatic chisels

Paint Shop

We have a spray/dip painting facility for the raw castings with red oxide primer for corrosion prevention.

Pattern Storage, Maintainence & Development

  • We have pattern storage and maintenance area with experienced persons capable of match plating and maintaining the equipment.
  • We get all our patterns outsourced from the best pattern makers in our area machine made (VMC) with graded material.
  • Our pattern makers are capable of converting all the 2D drawings to 3D to manufacture a pattern.
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CORE SHOP

We also make Cold Box Casting with 5kg capicity Cold Box Machine.

SAND MOLD

Sand mold is molding structure made out of mixture of foundry sand and binder liquid. It creates the mold cavity, which gets filled up by melted iron. Thus when the iron is cooled down, we get exact replica of what is been molded. We use A-grade quality sand for sand molding, thus producing quality Casting. We have various sizes sand mold boxes ranging from 2kg – 1000kg.

SHOT BLASTING MACHINE

Shot blasting is the process of removing rust, contaminants and roughly policing the material. We have plans to purchase shot blasting machine to increase in house productivity at Vishal Foundry.

Driven By Values, Delivering On A Vision.

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