The late R.A. Padmanathan (RAP) and his two sons Srinivas (SRI) and Mr. P. Sriram (SRI) founded RAPSRI in the year 1971. Rapsri has since then emerged to become one of the largest copper alloy foundries in India serving niche business segments with high quality products.
The company has been run by three generations of entrepreneurs and an enthusiastic team of professionals. Sustained focus on technology, research and development has resulted in its reputation for being a niche player in the global arena. Combine this with its strong process and systems orientation, it provides customers worldwide with a value proposition that results in satisfaction.
Rapsri is now poised to become a globally dominant player in this niche space with remarkable success in USA, UK and Europe. Rapsri has a track record of exporting its products to global OEMs since 1980 and currently approx. 40% of its total production is exported.
We produce a large variety of machined castings using a wide range of casting processes and a comprehensive list of alloys.
Rapsri enters product segments and market segments that place a premium on technology, engineering and quality- where entry barriers are high.
History
1971
Rapsri was established as a foundry and machine shop to make bronze bushings for Automotive OEMs.
Developed shell moulding process when the rest of the industry was using green sand moulding process.
Focus on value addition by machining castings way back in the 1970s.
1980
Rapsri identified growing demand for high conductivity copper in electrical power distribution industry for diversification.
Technical collaboration with French foundry for development of high conductivity copper castings
Developed gravity die casting process and continuous casting process for production of bushings.
Commitment to new technology as the means to offset competition.
1990
Rapsri was one of the first foundries in India to be certified ISO 9002 in 1994.
Certification changed in 1996 to ISO 9001 based on extensive capability in design and development.
Developed centrifugal casting process for copper alloys.
Modernized the foundry and machine shop for expansion and technical capabilities.
Commitment to systems conformance to improve product and process reliability and quality.
2000
Rapsri was QS 9000 certified to the stringent needs of the global auto OEM standards in 2000.
Sales, warehousing and distribution partnerships in USA, UK and Europe to service the global needs of customers- “comforts of local sourcing and the advantages of global sourcing.”
Developed gravity die casting (permanent mould castings) to produce near net shape castings in high conductivity copper and short freezing range of copper alloys.
Certification upgraded to TS 16949 systems standard.
Commitment to structuring the company by alignment of product-process-market to support customer response and build domain knowledge.
Alloys
Rapsri manufactures castings in a wide range of copper and copper alloy specifications. While Rapsri has a comprehensive proprietary range of alloys that are equivalent to various international standards’ specifications, one of the key capabilities of Rapsri is to custom manufacture alloys in specifications that the customer desires. A wide range of alloys in the following broad categories is possible. Please contact us with your specific needs.
Aluminum Bronzes: Magnetic, Non Magnetic, Corrosion Resistant grades
Gun Metals: Leaded gun metals and corrosion resistant grades
Leaded Bronzes: Commercial Grades and High Leaded grades (Aero Space)
Lead Free Bronzes: Attractive substitutes for lead with good machining properties
Gear Bronze
Silicon Brass/Bronze
Manganese Brass/Bronze
High Conductivity Copper
Copper Chromium/Zirconium
Copper Beryllium
Zinc Aluminum ( Substituting Bronzes)
This section will be updated shortly with a comprehensive list of alloys that Rapsri currently manufactures.
Foundry Process
Rapsri is one of the most diverse copper alloy foundries in the world. Multiple moulding processes and different types of furnaces and melting technology give Rapsri anedge in meeting the various needs of the copper casting buyer under one roof.
Bronze Bushings:
Continuous Casting Process
Rapsri casts bars and hollow tubes upto 75 mm diameter by horizontal continuous casting process on a Wertli machine.
Rapsri is commissioning two Rautomead furnaces and will have the capability to cast upto 150 diameter by continuous casting process from September 2008.
Gravity Die Casting Process/ Permanent Mould Process Shell Moudling Process
Centrifugal Casting Process/ Spun Cast Process
Induction melting and channel melting
Pure Copper Castings:
Permanent Moulding Process/ Gravity Die Casting Process(Manual and Machine Moulding)
Shell Moulding Process
CO2/Sodium Silicate Hand Moulding Process
Shot blasting and sand blasting
Induction melting and resistance melting
Brass/Bronze Shaped Castings:
Shell Moulding Process
CO2/Sodium Silicate Hand Moulding Process
Shot Blasting and sand blasting.
Induction Melting
Machining Process
Rapsri machines the castings produced in its foundry either in the comprehensive inhouse machine shop or at one of the certified vendors approved to Rapsri’s international quality standards.
In the machine shop Rapsri has state of the art CNC turning and milling centers, Vertical Machining Centers, SPMs for Oil Grooving, Single Spindle Automats, Broaching Machines, Drill-Mill Centers.
Bronze Bushings:
Turning/Fine Boring/ Centerless Grinding on state of the art CNC machines and conventional super finishing machines.
Face Milling and Body Drilling on drill-mill centers
Oil grooving in various patterns on specially designed Special Purpose Machines.
Broaching
Pure Copper Castings:
Turning on CNC turning centers.
Milling, Drilling and Tapping in state of the art Twin Pallet Vertical Machining Centers and CNC milling centers.
Brass/Bronze Shaped Castings:
Turning on CNC turning centers.
Milling and Drilling on conventional machines, CNC machines, Vertical Machining Centers and Horizontal Machining Centers.
Management Team
The performance of the operating management in Rapsri is overseen by a Board of Directors. The board of Rapsri delegates authority of the day to day running of the business according to an approved rolling business plan to the executive directors.
Executive Director and Company Secretary (Executive)
Sridharan Rajagopalan
52
B.Com, (Hons) ACA, ACS
Professional Director
Director (Non Executive)
Sarosh Ghandy
71
B.Sc (Met), Carnegie Institute of Tech, USA
Independent Outside Director - formerly CMD Telcon
Director (Non Executive)
Capt. S. Prabala Indian Navy (Retd)
75
B.E. Electrical Engg., Madras University
Independent Outside Director - formerly CMD BEL, Bangalore and Director BPL, Bangalore
Director (Non Executive)
Dr. L. R. Vaidhyanathan
84
B.Sc (Met), BHU University, PhD in Industrial Metallurgy, Birmingham University, UK
Independent Outside Director - formerly CEO of ICDC
Invitee to Board Meetings
Pranabh Mody
44
MBA – Oakland University, USA B.Ph - Bombay University Executive Education Program, Howard University
President, JB Chemicals & Pharmaceuticals Ltd.
Quality Policy
Rapsri is committed to continuously upgrade its systems and processes which are calibrated to international standards and certified by certification audit agencies of international repute. Rapsri believes that product quality is ensured by reliable processes which conform to stringent systems audits. After having been certified ISO 9002, ISO 9001 and QS 9000, Rapsri is now certified to TS 16949 standards for automotive customers and ISO 9001:2000 for non automotive customers.
Rapsri’s stated quality policy is follows:
QUALITY POLICY
We will satisfy customers by providing value in all our product and service offerings consciously adding value by engineering, systemic and technological suggestions for improvement to mutual benefit.
We will provide an environment for business partners which inspires innovation, change, and self development towards creating wealth.
Excellence will be synonymous with any Rapsri endeavour.
QUALITY OBJECTIVES
Improve systems and practices continuously towards product and process superiority.
Develop engineering and technological skills towards enhancing the value proposition.
Select and apply the appropriate techniques towards dominating the global market.
Consistent with Rapsri’s commitment to continuously upgrade its systems, Rapsri is planning to go in for ISO 14000 for environmental standards and for AS 9100 for aero space certification.
Quality Control
Lab and Foundry
Rapsri has a comprehensive quality assurance and quality control facilities in the foundry with a wet laboratory for checking chemistry as a back up. Rapsri measures process capability of chemistry within specification to higher than a CpK of 1.66.
Vacuum Emission Spectrometer- ERP integrated for online melt control
Microstructure Microscope
Universal Tensile Testing Machine/Tensometer
Hardness Testing on BHN, VPN and RB Scales
Conductivity Meter- temperature control built in
Hot Tensile Tester (Sand Strength)
Metrology and Machining
Rapsri measures dimensions for quality control and assures quality by process and machine capability studies. Strong systems in Statistical Quality Control as well as Measurement Systems Analysis for Gauge R&R ensure consistency in outgoing quality.
Coordinate Measurement Machine (CMM)
Roundness Tester
Monochromatic (Optical) Checklite for Flatness Testing
Profilograph Computer Integrated
Digital Height Gauge
Surface Finish Testers Digital
Gauges of various types
Machines
Coordinate Measurement Machine (CMM)
Roundness Tester
Monochromatic (Optical) Checklite for Flatness Testing
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