Belgaum Ferrocast India Private Limited

Established in the year 2006, Belgaum Ferrocast, a private limited company is engaged in manufacturing and supplying gray cast iron components like Inertia Ring,  Rubber Damper, Viscus Damper, Damper Hub, Rubber Damper Hub, Damper Inertia Ring,  C.I Pulleys, Drive Pulleys and Damper Housing. Our company is a result of merger between two companies M/s S. N. Engineering, established in 1997 and M/s. Sai Metals, established in 2000. Both the ISO certified companies are engaged in manufacturing and supplying gray cast iron components in machined & semi-machined conditions.

We are situated in Belgaum, Karnataka the manufacturing hub of auto components. Backed by latest machines and professionals we offer wide range of supreme quality gray iron, ductile iron casting & components. Our gray cast iron components are available in finish and semi finished forms which are used in several industries. Our finished inertia rings, hubs and housings are used as torsional vibration dampers while pump body, covers, and manifolds are used in diesel engines.

Further, we tailor made the products with the use of cutting edge technology and state-of-the-art machines installed in our foundry division. To increase our production competence and meet the ever increasing demands of clients, we are in the process of establishing another fully mechanized foundry with ARPA moulding line, sand plant and electric furnace with capacity around 400 Mt /month to meet the growing demands of our global clients.

Since our inception, our company has grown in size and operation and carved a niche in the competitive industry for providing high quality products. We adhere to various regulations which have made our name synonymous to reliable organization. Our business specification includes:

Registrations-

VAT Act 2003 (SEC – 22)	29540726924
PAN No.	AAWF50980K
TAN No.	BLR06218C
Central Excise No.	AACCB 9465 DXM 001
Company Reg. No.	U27320KA2005PTC035442

Statutory and Regulatory Requirements-

• Income Tax Act 1961
• Factories Act 1948
• Local Sales Tax Act 1957
• Central Sales Tax Act 1956
• Rule 11 of Central Excise (No. 2) Rules 2002 & rule of cenvat credit
• Applicable Labour  Laws

We have been in the industry for almost a decade and doing excellent in the competitive industry. Our organization is growing with the clear vision to bring improvements in various segments of manufacturing and continuously achieving economic value by optimizing resources through constant innovation, technological advancements. Our objectives include:

Process	Objective	Responsibility	Target
Prod.	Machine Utilization	Prod. I/c	90 %
	Continual Improvement In Production Process	Works manager	At least 1 project in quarter
QA	Increase In Supplier Quality Rating (Machining Suppliers)	QA I/c	98%
	Increase In Supplier Quality Rating (Casting Suppliers)	QA I/c	85%
	Improve In Quality Rating At Customer End	QA I/c	100%
QC	Reduce In-House Rejection	QC I/c	1000 PPM
	Reduce In-House Rework	QC I/c	500 PPM
Marketing	Schedule Adherence	Works Manager	100%
	Improvement In Customer Satisfaction Index		100%
MR	To Maintain QMS Effectively	MR	Zero NC in Audit
Management	Business Growth	Management	20 Crores

We have a separate wing of research and development which is engaged in improving the product quality by implementing necessary changes in the processes & machinery simultaneously. Their wide experience in the machinery used in various processes such as melting, forging and many more enables them to bring forth required changes. They analyse the casting defects, determine the root cause and helps in implementing the corrective actions. They also analyze the process and procedure issues in foundaries to improve productivity, quality and safety.
 
 

Owing to our premium quality iron casting, customized product and timely delivery we are able to increase our client base. Some of our esteemed clients include the following:

• Hodek Vibration Technologies Pvt. Ltd., Pune
• Craft & Technik Industries Pvt Ltd., Pune
• Arni Mech Products, Kolhapur
• Manish Engineering Works, Pune
• Coupling Engineering services, Pune
• Prasad Industries, Pune
• Qualitech (exporters of valve bodies)
• Geared Hydropower Pvt. Ltd. (manufacturers of gear pumps)
• Ace Manufacturing Systems (manufacturers of CNC and VMC machines)
• Premium Energy Transmission ltd.(gearbox manufacturers)
• Indo Woosung Pumps Pvt. Ltd (vacuum pumps exporters)
• CMC Commutators Pvt. Ltd. (commutators manufacturers)
• Bell Tools (hydraulic manifolds manufacturers)
• Flow Mech Precision (hydraulic manifold manufacturers)
• Polyhydron Pvt. Ltd. (manufacturer of hydraulic valves and manifolds)

We are an ISO certified company which has acquired the accreditation from ICS (JAS-ANZ) and TUV South Asia. Our entire endeavor is channeled towards offering qualitative gray iron castings that are in compliance with the ISO 9001: 2000 standard. Moreover, we have successfully undergone annual control audit and triennial registration audit from the time of inception to learn and improve our processes.

We adhere to several quality norms from the very beginning of our production. We choose and procure premium grade of raw material from reputed manufacturers. Our vigilant inspection, tests and appropriate manufacturing processes ensures the castings get the appropriate exactness and dimensional accuracy.

We obtain the feedback from customers before the start of production that enables us in configuring the casting equipment. The efficiency of our ‘quality system’ is regularly tested through audits held by our clients. This improves our processes & intervention methods & ultimately meets the client satisfaction.

Further, the quality of our products is enhanced by the final inspection of the product range. In addition to this, other processes are rigorously controlled with minimized risk of defects. We conduct specialize testing such as such as ultrasonic, X-Ray, wet-phase magnetic particles inspection, and many more. We use various methods and instruments for testing & measuring our range of casting equipment. Some of them include the following:

• Trimos (V300 ) 0-300mm
• Trimos Vectra Touch, Application Range: 0 – 872mm /  0 – 34”
• Pressure air gauge (baker)
• Profile Projector 10 X magnification by 400 dia screen.
• Bore dial gauge set from range of 0 to 400 mm
• Roughness tester
• Digital depth micrometer from range of 0 to 150 mm
• Digital height gauge of 300 mm
• Micrometer digital range of 0 – 50 mm
• Micrometer set from range of 0 – 500 mm
• Vernier calipers
• Dial Vernier calipers
• Plunger dials
• Hardness tester
• Carbon, Silicon Apparatus
• Metallographic Set Up-Digital Analyzer For Microstructure Testing
• Universal Testing Machine
• Brinell Hardness Testing Machine
• Poldi Hardness Tester
• Mould Hardness Tester
• Sand Siever
• Sand Rammer
• Permeability Tester
• Green Compression Strength Tester
• Clay Washer
• Muffle Furnace
• Combustion Furnace
• Polish Machine
• Scratch Hardness Tester

Pollution Control Measures:

• Scrubber to control smoke
• Exhaust fans to control dust
• Future we are going for ISO 14000 to become totally pollution free foundry.

We have a professional team segregated in to engineers, technicians, quality control analysts, marketing & sales staffs, and administrative staffs. They have profound knowledge in their respective fields. They work diligently and collectively towards achieving growth oriented results for the company. 

The engineers and technicians have in-depth knowledge about the machinery and testing equipment used in the manufacturing unit. Their expertise in the operations of
moulding, forging, casting and other processes enables us to manufacture iron casting & components that are at par with ISO standard.

Our group of sales & marketing personnel has broad market knowledge which supplements us in finding prospective clients for our range of iron castings & components.

Available in different finish and semi finished forms, our wide gamut of casting iron and cast iron components like Automobile Castings, Integrated Rubber Damper Hub, Poly V Groove Inertia Ring, Poly V Groove Damper Hub, Rubber Damper Hub, Rubber Damper Inertia Ring, Viscus Damper Housing and Viscus Damper Inertia Rings finds applications in various industries such as:

• Engineering
• Petrochemicals
• Mechanical
• Automobiles
• Chemicals   

We offer cast iron in three different types such as gray iron, ductile iron and Ni-hard iron. Our range of iron casting and components comprises of Automobile Castings, Integrated Rubber Damper Hub, Poly V Groove Inertia Ring, Poly V Groove Damper Hub, Rubber Damper Hub, Rubber Damper Inertia Ring, Viscus Damper Housing and Viscus Damper Inertia Rings. Some of the inherent features of our cast iron include the following:

• It requires low temperature to be poured than those of steel
• Liquid iron casting contains more fluid than steel allowing it to acquire  complex & varied shapes
• Less prone to casting defects than steel

The types of cast iron we manufacture are as following: 

 

Foreign Standards	IS Grades
	F.G-150	FG-200	FG-260	FG-300	FG-350	FG-400
Japan JIS G 5501	FC-15	FD-20	FC-25	FC-30	FC-35	-
Germany DIN 1691	GG-15	GG-20	GG-25	GG-30	GG-35	GG-40
U.S.A ASTM A-48	25B	30B	40B	45B	50B	60B
France NF-A32-101	Ft15D	Ft20D	Ft25D	Ft30D	Ft35D	Ft40D
U.K BS-1452	Grade 10	Grade 14	Grade 17	Grade 20	Grade 23	Grade 26
U.S.S.R GOST-1412-54	Sch 15-30	Sch 21-40	Sch 28-48	Sch 32-52	Sch 35-56	Sch 38-60
ISO R-185	GRADE 15	GRADE 20	GRADE25	GRADE 30	GRADE 35	GRADE 40

 

Under the able guidance and leadership of our mentor, Mr. Sachin Sabnis, we are growing in a steady pace and meeting the varied requirements of esteemed clients. He is a technocrat with expertise in foundry technology. His knowledge & innovative approach towards technological changes in the manufacturing processes has enabled BFPL to achieve remarkable position in foundry technology.

The executive chairman of the company Mr. Niranjan Sant is also a technocrat with experience in engineering & manufacturing field. He has been influential in maintaining cordial relationship with customers while inspiring the manufacturing team to manufacture premium quality castings.

Owing to meticulous efforts of our mentor, we are able to increase the annual turnover of our company manifold from 3.50 Cr in 2002-03 to 16.50 Cr in the 2006-07 within a gap of mere five years. 

We employ several processes for manufacturing supreme quality Cast Iron and Cast Iron Components like Inertia Ring,  Rubber Damper, Viscus Damper, Damper Hub, Rubber Damper Hub, Damper Inertia Ring,  C.I Pulleys, Drive Pulleys and Damper Housing. With the help of cutting edge technology, we are able to effectively undertake the casting procedures and meet the requirements of clients. Some of the processes we utilize are as following:

• Pattern making: We have in-house pattern shop where minor repairs & modifications of molds are done. The patterns we use are made of wood or composite material or aluminum and are used for preparation of sand mold.

• Pouring: At this stage the mold is filled using network of runner troughs. The runner troughs are designed to achieve the requirements of each casting. We maintain the temperature to ensure proper pouring process.

• Moulding: We use jolt squeeze machines to carry out floor moulding, and loose moulding processes. Moulds are generally made of green sand, or of self-hardening, air-setting moulding sand, silicate, no bake and also shell. The moulding is done in fix boxes as well as in loose flask type.
  

• Melting: For melting we use cupola machines with varying capacities which are fitted with scrubbers for environment friendly operations.

• Shakeout/cleaning:  The casting is lifted out of its molds after the solidification & cooling process is over. This is followed by another molding cycle where the casting is freed from its risers, shot blasted and cleaned for shipping.

• After the cleaning the casting is ready to undergo other operations such as thermal treatment, machining or painting whenever necessary. Thermal treatment is essential for stress relieving and changing the mechanical properties of the casting. Painting of the castings is essential for the surface protection of the castings.