All heats are checked for chemical composition using fully computerized Direct Reading Vacuum Emission Spectrometer before casting the billets. The Billets in Medium and High Strength Alloys required to be extruded for Engineering, Auto Sector, Defence and for other stringent applications are checked with Ultrasonic Flaw Detector to ensure that there are no internal flaws. The Billets in Medium and High Strength Alloys are turned to minimize surface defects and rear-end defects in the extrusions.
Our testing facility is equipped with Electrical Conductivity measuring equipment for Bus Bars – both flat & tubular.
The leakage and pressure testing facility for Irrigation Tubes enables us to supply these tubes as per BIS:7092 Part-II.
Our testing facilities have also been approved by CQA (Metals) vide their letter No. CDN-747/TC dated 27.11.01 for supply of Defence Stores.
We also have the facility to carry out ‘product-specific tests' such as flattening tests for the ferrule sections, dumbed test for the Detonator Shell stock, machinability tests for the supplies to the engineering industry, examination of macro-structure in case of supplies to Defence, detection of internal flaws in case of profiles subjected to high pressure applications (e.g. Gear Pump Casings) etc. besides the conventional tests like determining the U.T.S., Yield Strength, percentage Elongation and Hardness.
Our Quality Assurance
We have excellent Quality Assurance Systems. Our Plant is accredited with ISO-9001:2000 certification for its quality systems. We are in the process of upgrading to ISO : 9001 : 2008.
We usually supply extrusions as per the tolerances laid down by the Bureau of Indian Standards in accordance with BIS: 6477-1983 and BIS – 2673 – 1979. Our processes are capable of meeting the dimensional, mechanical, electrical and composition requirements of international standards such as ASTM, BS, DIN, JIS and others and also as per consumers’ requirements by mutual agreement.
Management
CEL represents a prudent combination of hands-on Promoter-Directors and empowered professionals. The company is headed by Mr. M P Jhunjhunwala, a true visionary, the Chairman-cum-Managing Director, ably assisted by a team of professionals.
Staff & Workmen Strength
CEL employs 150 staff members and 200 permanent workmen.
Manufacturing Facility
Remelt Shop
The Company has 3 (three) oil-fired, fixed-hearth, reverberatory Melting-cum-Holding Furnaces of bath capacities 3 MT, 6 MT and 8 MT.
The D C Casting unit is flexible to cast 6”, 7” & 9” dia billets in alloys ranging from 1xxx to 7xxx series.
Molten metal treatment is carried out by an Automatic Flux Feeder in conjunction with “eco-friendly” nitrogen degassing. The presence of hydrogen gas in the molten metal is detected using a Gas detector. Further degassing is carried out, if required, prior to casting.
Composition is determined using Direct Reading Vacuum Emission Spectrometer.
The ‘on-line' modification (wherever required) / grain refining are carried out using Al-Sr and AlTiB / AlTiC respectively imported from world renowned – M/s. KBM Affilips Bv, The Netherlands and M/s. Asturiana DE Aleaciones S.A, Spain. These ensure fine grains and thus, uniform strength along the length of each profile.
The Electrical Homogenizing Furnace is suitable to homogenize billets in various alloys with a temperature control of ± 5°C, a pre-requisite for good homogenizing. Homogenizing of the billets ensures uniform mechanical properties – hardness, UTS, Yield Strength, percentage Elongation etc. besides offering excellent surface for finishing operations such as anodizing, powder coating, electro-colouring, etc.
Extrusion Shop
With the 3 Extrusion Press lines – 2700 MT & 1620 MT (UBE, Japan) and 1250 MT (indigenous) – all PLC controlled, the Company is able to cater to the requirements ranging from miniature profiles up to large-sized Bars in Soft, Medium and High Strength Alloys. The arrangement for taper quenching / taper heating of billets ensures ‘ near-isothermal ' extrusions for achieving uniform property along the length of the extruded profiles / sections / bars.
Strength requirement of Rods / Bars and sections / profiles in Medium and High Strength Alloys for the engineering industry, auto sector and the Defence Sector, is very stringent and calls for separate solutionizing prior to age-hardening. We have the necessary solutionising furnace with drop quench facility for this purpose.
Detonator Shell Stock, Forging Stock, Rivet Stock and Welding Filler Stock in Medium and High Strength Alloys are to be supplied in annealed condition. We have the necessary furnace for this purpose.
With the facility available for coiling and wire drawing, we are able to supply Armour Rods, Rivet and Welding Filler Stock in various sizes.
With the Draw Bench and associated auxiliary equipment available to cold-draw Bars – round, square & hexagonal, we are able to cater to the exacting requirements of the automats which is the need of the hour to enhance plant productivity, a ‘ must ' in this era of globalization.
Tool Room
The Dies required to extrude profiles from the simplest to the most intricate in Soft, Medium and High Strength Alloys are designed ‘in-house' using 'mastercam'. Use of ‘mastercam' also assists in assessing the type of fit and the clearances required for the assembly of complementary profiles. The dies are machined on CNC Vertical Machining Centres.
The ‘in-house' heat treatment facility ensures good resilience in the Dies (manufactured out of one of the best available Hot Die Steels in the world) during ‘real-time' extrusion thus ensuring consistency in shape and size of the profiles.
Production Facilities
The Company has 3 (three) extrusion presses of 1250 MT, 1620 MT & 2700 MT capacities.
The Company has complete in-house facilities for Die Manufacturing, Melting and Casting of Billets and a very well equipped Quality Assurance Department besides the Extrusion Shop. The land area on which the plant is located is approx. 7.5 acres.
The main equipment viz. the Extrusion Presses - 1620 MT Press & 2700 MT Press have been manufactured by M/s. UBE Industries, Japan and the 1250 MT Press by M/s. Siddharth Industries, India.
Our production capacity is 15000 MT of aluminium extruded products per annum.
Once an order for a new profile is received, and accepted, it is executed as per the following procedure:
Order Execution:
Receipt of Profile Drawings / Samples from the customer.
Preparation of counter drawings by the Tool Room, which are then forwarded to the customer for approval. If there are any corrections / changes, the counter drawings are revised and again sent to the customer for his approval.
Receipt of approved counter drawings from the customer.
Manufacture of Dies.
Samples are sent to the customer for his approval, if specifically required.
Production of material
Shipment
For a new profile, our normal cycle of order execution is as follows:
Die Design: 3 to 4 working days after receipt of our counter drawings duly approved by the customer.
Manufacturing of Die after customer's approval: Within 4 to 6 weeks after the final clearance from marketing.
Submission of samples: One week after the Die is manufactured.
Production of first lot: 2 weeks from the date of acceptance of the samples and receipt of techno-commercially clear order from the customer.
Processing...
