Indoshell Cast Private Limited

Indo Shell Cast - manufacturing Ductile Iron, Grey Iron, CG Iron (Vermicular graphite Iron), ADI, Ni Resist & Steel Castings using shell moulding, has a history of continuous improvement. A concept that has given it a past that it can be proud of and a future it can look forward to with confidence.

The vision of Promoter and Managing Director that an illustrious organisation should emerge is realised through his hard work and commitment. Today, Indo Shell Cast Private Limited, an ISO/TS 16949-2002 (E) certified company is having 30 years of casting experience in Shell Moulded S.G.Iron Castings, Shell Moulded Grey Iron Castings, High, Low Pressure and Gravity Die Castings and exports to leading International Industrial giants.

As part of the diversifying plans in related areas, Unique Shell Mould India Private Limited – Sister Concern, was founded in 1983 in response to the growing demand for quality aluminium castings with a focus on emerging technologies that meet client requirements.

A diverse and well-structured group that strives to produce quality products that conform to the standards, that would satisfy both domestic and international markets while emphasizing on efficiency in every facet of the operation from manufacturing to marketing.

The Surface finish and dimensional accuracy of the shell-moulded casting is superior to the conventional green sand mould castings.

We have a strong metallurgical base and experience. Our metallurgical quality of our S.G.Iron is very much acclaimed by our domestic & overseas customers.

• A calibration lab has been set up to calibrate and test equipment with latest measuring equipments as CMM, Heightmaster Etc.
• A calibration room has been set up to calibrate and testing equipment with a sophisticated "Trimos" make vertical Micro height measuring equipment.
• A microscope with image analyzing software has been installed for quantitative analysis of microstructure precisely.
• Thermal reclamation for resin coated sand.
• Advanced emmision spectro meter for chemical analysis.
• A special Thermal analysis software to draw cooling curve has been installed at melting stations for online metallurgical analysis.
• Tool room has been equipped with Advanced machining ceters, 3D modeling and latest metal flow and solidification simulation software.

Infrastructural Advantage at Indo Shell:

1. Most of the measuring equipment have been replaced with digital displays.
2. A calibration room has been set up to calibrate and testing equipment with a sophisticated "Trimos" make vertical Micro height measuring equipment.
3. A microscope with image analyzing software has been acquired to quantitatively study the various micro particles, counts, areas, shape factor etc.
4. Manual old dump box shell moulding machines have been replaced by automatic rotary 4-station shell moulding machines.
5. Manual chemical analysis using wet method has been changed over to 25-element spectro analysis machines.
6. A special melt lab with advanced software to draw cooling curve has been installed in melting station to study the metallurgical quality of molten metal before pouring into moulds.
7. An endoscope is in use to check the internal core portions of the castings.
8. We started with a coke fired cupola and modernized with - electric Induction furnaces.
9. We were using coke fired sand drier, which we have now modernized with diesel fired rotary oven.
10. Manual sand sieving has been replaced with vibratory sand sieving.
11. Manual material transports have been replaced with hydraulic, pallet trucks, cranes, monorail, trolley systems etc.
12. Manual core shooting machines have been replaced with automatic core shooters.
13. The shot blasting machines are equipped with dust collectors and stacks.
14. The DG sets have been provided with stacks for exhaust gas and acoustic proof enclosure.
15. Dust collectors are provided for machines, which generate dust.
16. There are two centralized dust collectors of 50 hp each for melting furnace and other areas.
17. The sound level and dust level are measured periodically and controlled.

The products moulded out from Indo Shell Cast are exceptional in quality. Indo Shell Cast is committed to quality - first time, on time, and every time. All the processes are streamlined and strict adherence to international standards of quality is ensured, to offer only the best quality to our customers. Our objective is to deliver the highest quality results to our clients, thus providing good value through competitive systems and processes.

We have been accredited with ISO/TS 16949-2002 (E) certificates.

Accreditations for our Quality Process:

• ISO 9001- 2000 Certification by RWTUV, Germany 2002.
• We have been accredited with ISO 9001:2000 certificate. We have installed ISO / TS 16949-2002-certification.

We are Familiar with and implementing:

• APQP – Advanced Product Quality Planning
• FMEA – Failure Mode Effect and Analysis
• MSA – Measurement System Analysis
• Statistical Process and Quality Control Sampling Technique – Cp & Cpk Study
• Parato analysis for defect analysis.

Here are some achievements and milestones for Indo Shell Cast.

• 1992: Productivity Award from Indian Institute of Foundry men – Coimbatore Chapter
• 1996-1997: Best Performance Award From Hindustan Motors Limited for the Year
• 1999: Self Certification Award from Sundaram Clayton Limited (Deming’s Award winner), Approval from VOLVO Sweden to Produce Safety Critical Parts, Approval from Trelleborg Automotive U.K.
• 2000: Indian National Award for “Best Entrepreneur for the Year
• 2002: Best SSI Unit for the Year 2002 from NIQR (National Institution for Quality and Reliability), Lakshman Kirloskar’s “Foundry of the Year 2002” from Indian Institute of Foundry men, Approved from Cummins – USA, Sauer Danfoss- USA, FMC- USA.
• 2003: Narashiman Award from Indian Institute of foundry men for Best Modernised foundry the Year 2003, Best supplier award from Rane TRW Steering systems Limited, Approval from Iveco – Italy.
• 2004: Sidha steel award "Best Foundry Executive" from M/s Sidha steel (P) Ltd. for the year 2004.

• For sub zero Application
• For Thermal Applications and to withstand the thermal shock (High Silicon Molybdenum grade)
• Compacted Graphite Iron (Vermicular Graphite Iron)
• Austempered Ductile Iron (ADI) to international Standards
• Customer specific requirements can also be met

Our belief that compliance must be practiced individually before it can be achieved corporately has empowered our personnel to take an active role in establishing and maintaining critical quality compliance programs.

At Indo Shell cast we primarily focus on parts between 300 grams to 50 Kilograms.

• All grades of S.G Iron (ductile Iron) and Grey Iron, Compacted Graphite Iron and steel can be manufactured to international standard or customer specific requirements.
• Specialists in producing High silicon Molybdenum ductile iron, compacted graphite iron, Austempered ductile iron and chilled cast iron and castings suitable for sub-zero applications.
• Malleable iron suitable for cam applications can be made.
• Successfully developed a low silicon ductile iron more suitable for induction hardening applications.
• Dimensional accuracy of ± .3 mm.
• Castings can be supplied in machined, painted condition for customer requirement.
• Special process like nitriding, carburizing is also possible.
• Raw casting surface finish of 6-8 Ra in shell moulding can be achieved.

Capacity

Indo Shell Cast is a community of skilled technicians and professionals dedicated to perfect and diversify their art, Operating round the clock producing 24000 MT per annum

Tonnage	2000 MT/ Month of molten metal
Moulding	375000 moulds / month
Volume	50 -150000* / month per part
* Based on weight of the part.

Indo Shell Cast has equipped itself with advanced technological developments which account for its superior process of casting and moulding for bulk production.

Moulding

Shell Moulding

Semi Automatic 4 station shell moulding (PLC controlled) machines are capable of producing 15000 moulds everyday which finds its application in casting intricate shaped hydraulic and automobile components ranging from 0.05 Kg's to 15.0 Kg's.

Features:

• Casting Dimensional accuracy of ± 0.3mm.
• Indigenously designed Inbuilt Poka – Yoke system for controlling the key process parameters.

No Bake Moulding

Home grown machines developed for producing parts with weight range of 5-50kgs with surface finish comparable to shell molded casting

Features:

• Semi automatic cost-effective low to medium production with dimensional accuracy of ± 1mm.

Core Shooting

Semi automatic PLC controlled core shooters Capabale of producing intricate cores with close dimensional accuracy.

Features:

• Indigenously designed inbuilt poke-yoke system for controlling the key process parameters.

Melting

Medium frequency, one ton capacity induction furnaces to melt nearly 2000 tons of metal every month.

Features:

• Equipped with Spectrometers and thermal analysis soft wares to produce sumptuous molten metal for various applications.
• Nodularization or Spheroidisation is carried out through PLC controlled wire magnesium treatment process.

With the company increasingly focusing on delivering quality products, the performance has been quite significant. We have so far received ‘0’ parts for warranty claim from the field. The PPM level of rejection from the customer has been very encouraging. This has enabled us to accelerate our progress and with customers’ continual support we are sure to grow. Some of our performances have been indicated below.

It should be our objective to fulfil our obligations to society by being good citizens and by protecting the sanctity of life. Indo Shell is involved in several voluntary professional services to assist the government, private sector, non-profit organizations and individuals. They are as follow: -

Non-conventional energy generation is an important step forward to meet the future energy demand. To protect Environmental pollution, we have planned to install wind power and we already installed one plant.

Other Social Welfare activities:

• Periodic Health and Eye camps
• Providing support and facilities to educational institutions imparting free education
• Assisting Temple welfare activities
• Supporting needy people on Education
• Adopting Public parks, Traffic parks and Tree plantation

lndoshell Cast believes in constantly upgrading skills of its employees, driving perfection at work. There are many programs for employees to develop both curricular and non-curricular activities.

We believe that employees are the core asset. We constantly identify individuals / teams with exceptional performance get them to share ideas with the rest. The company ensures through frequent meetings a fair exchange of ideas of development in each of the fields.

Employees are constant updated on technology, market, and the latest developments in the field. All these make the employees get involved in work thereby giving better productivity. Dedication of the Indo Shell Cast team and its unity create a synergic work environment. Indo Shell Cast is running various schemes and adopting various beneficial measures to motivate its workforce. Some are given below:

In addition to the statuary welfare measures like, ESI, Provident fund etc, we are doing the following measures:

1.	Meeting the first month educational expenses of the children of employees every year and liberal assistance for higher education.
2.	Meeting the specialized medical treatment for deserving employees.
3.	Free medical insurance scheme for the employees who are not covered under ESI
4.	Helping the employees to overcome any emergency personal problem.
5.	Blood test and grouping for all employees.
6.	Eye test for all employees and provision of corrective treatment and spectacles.
7.	Arrangement of blood donation for employees and their relatives in case of any emergency.
8.	Arranging for soft loans through co-operative bank to the employees.
9.	Provision of uniforms, shoes etc.

Unique Shell Mould India Private Limited

Unique Shell Mould India Private Limited was founded in 1983 in response to the growing demand for quality castings with a focus on emerging technologies that meet client requirements. Today, we are one of the leading manufacturers of Non-Ferrous Castings - Aluminium alloy castings by Pressure die, Low-pressure die and Gravity die casting process.

Unique Shell Mould India Private Limited is lead by experienced technocrats with more than 30 years of sound understanding and exposure. Our expertise and professionalism earned us the assistance and support from Tamil Nadu Small Industries Development Corporation and State Bank of India.

The development through CAD CAM Route of Tool and Pattern making shorten the prototype development period and first time acceptance is assured.

We have a strong metallurgical base and experience. The metallurgical quality of our aluminium has been very much acclaimed by our over seas customers.

PRODUCT MIX:

Non-ferrous Castings – Aluminium Alloy Castings

• Pressure die-casting - wheel Hubs, Brake Shoes, Adaptor Disc Brake and Housing Rollers for two wheelers
• Drive End Brackets for four wheelers

Gravity die-castings

Manifolds, Handle Holders, Upper Brackets, Master cylinders and Body calipers (Disc Brake), Cylinder heads for two wheelers.

- Inter coolers and center coolers for compressors.

- Housing and cover for fuel pump in four wheelers.

Shell Mould Casting

Gun metal Bushes for Connecting Rods of compressors. Gun metal Body and Brass spindle mixed Shut off Valve assemblies and Non-Return Valve assemblies Phosphor Bronze bearing Bushes.

Indoshell Cast has a dedicated Machine shop unit for machining the components produced in the foundry. Machine shop not only focuses on value addition to the product but also helps in maintaining very low rejection PPM at the customer end. More than 80% of our machine shop turnover comes from machining components for export.

Our machine shop is equipped with New generation turning centers, vertical milling centers with 4th axis and horizontal milling centers machining facilities. We are also equipped with other ancillary machines like honing, lapping and cleaning machines. Our primary focus is machining complicated hydraulic castings. This requires a very low contamination levels in the complicated core areas. We have installed an ultra-sonic cleaning machine which can achieve cleanliness to the level of about 2 milligrams.

Necessary softwares are installed in all the key areas of manufacturing and measurements to ensure productivity, accuracy, repeatability and reliability. Machine shop is equipped with state of the art of metrology lab with the latest measuring equipments for linear, angular dimension and surface finish measurements to compete and satisfy stringent quality measurement requirements of the customer.

Since we understand our castings better, we design tools suitable for machining to achieve the required dimensional accuracy.

Our services ensure a long-term customer relationship; our list of satisfied clientele proves our quality service.

• Bajaj Auto
• Volvo
• Maruti
• Ashok Leyland
• Hindustan Transmissions
• Godrej
• Tempo

and many more.....

Indoshell cast has a R&D facility with latest testing and measuring instruments for making advanced researches in metallurgical aspects such as Gating system design, failure analysis and foundry process with the involvement of rich knowledgeable professionals.

With the aid of R&D activities, Indoshell Cast has developed and fine-tuned the following process.

• Magnesium treatment for nodularizaion with cored-wire for ductile iron production
• Producing impeccable compacted graphite iron economically
• Developed ADI treatment methods to achieve desired properties without adding any expensive alloying elements
• Effective gating system has been developed to produce safety critical parts
• Developed various core making techniques suitable for hydraulic parts
• Developed new method for automatic inoculation
• Designed & developed indigenous mould making machines suitable for parts up to 50 kgs
• Develop various customer specific grades like Ductile Iron 900-5 etc
• Exploring various avenues in various cost saving projects with enhanced quality of the products in various manufacturing process such as thermal reclamation of resin coated sand, hot coating process, application of producer gas etc.

At Indo- Shell Cast, quality starts right from the selection of the resources. Aided by stringent quality checks and controls in every stage of the process, the Process drastically reduces the risk of final inspection, enabling mitigation of the quality costs.

Some interesting highlights of our Quality Control Process:

• Spectrometers( 26 element analyzer), thermal analysis software, image analyzer to Ensure metallurgical superiority of the castings.
• UTM’s and various hardness testers ensure conformity of mechanical properties of the casting.
• Cmm, Height master, Profile Projector and other conventional measuring instruments ensure dimensional accuracy of the castings.
• Similarly Millipore checks enable cleanliness of the casting.
• Soundness of the castings is ensured by Ultrasonic Flow detectors, Gamma ray, X- ray and magnetic particle testing.

At Indo Shell Cast, Superior Products, Sound Quality Control Process matches with Excellent Delivery Systems.

Packaging is custom designed to suit the specific requirements of the domestic and international supplies.

Many crucial factors like Seaworthiness, Shelf life, Rust Prevention, Pest Control, Termite Control, Size of the package, Handling systems at customer end are considered to ensure proper delivery.