The Company was founded in the year 1977 and is one of the oldest manufacturer of Grey Iron Castings in India. Since then the Company has been the unchallenged leader in the Industry. It is on the outskirts of the Metropolitan City of Kolkata. The company’s sprawling 8 acore factory houses a State of the art manufacturing unit and employs more than 300 Workers.
Since the inception we have been moving on & on to built up the infrastructure for making export of C.I. castings, of all categories, all over the world. Our dream came into reality with its export operation in the year 1990 and it is now a Govt. Recognized Export House. Our Export business operation extends mainly to UK, USA, & AUSTRALIA. The annual export of the Company are well above 12000 MT.
Our clients from different destinations send us the orders with working drawings which we tailored by developing patterns and supply. We also develop patterns to our client’s specific requirement.
We have consolidated the production of all Gray Iron Castings to our unit at Howrah. We have two coal fed cupola furnaces. It provides a combined melting capacity of 100 MT quality Gray Iron Casting per day. All common grades of cast iron are produced daily and special grades are made available by arrangement. Thus the annual production capacity is 24000 MT.
Our Product Range
The company manufactures all Grey Iron Castings with weights varying from 5 kgs to 1000 kgs. The major products manufactured are as follows :
MANHOLE FRAME & COVERS
CATCH BASIN GRATE & FRAME
MANHOLE RISER RINGS
MANHOLE STEPS
FANCY COVER & GRATE
EXTENSION RINGS
WATER METER BOXES & THEIR ADAPTER RINGS
VALVE BOXES
VALVE BOX ACCESSORIES INCLUDING RISERS, EXTENSION & BASES
LIDS FOR PLASTIC/CONCRETE UTILITY BOXES
SURFACE BOXES
CURB SERVICE BOXES & THEIR EXTENSIONS
FIRE HYDRANT BOXES
COUNTER WEIGHT
SOIL & RISIN WATER PIPES & FITTINGS
TRENCH GRATINGS WITH FRAMES ( BOLTED & NON BOLTED)
BALLAST WEIGHTS
AGRICULTURAL CASTINGS
MULTIPART GASLIGHT FRAMES & COVERS
UTILITY ACCESS FRAMES & COVERS
TREE GRATES
ORNAMENTAL CASTINGS SUCH AS GARDEN BENCHES, LAMPPOSTS DECORATIVE RAILINGS, LITTER BINS, WHEEL GUARD ETC.
ANCHOR FOR BOATS
GRILLS OF ASSORTED TYPE & SIZE
CASTINGS FOR CUSTOMISED THE APPLICATIONS.
Our production range can be broadly categorized to the following :
Sanitary Castings of circumference of 62” and more
Industrial Castings
Precision Castings / Ornamental Castings.
Quality Process
The company believes in quality management and special attention is paid on the quality of the product. All the castings are manufactured as per ASTM – 48 CLASS 30 & 35, COPRO, DIN, BS1452, EN124 & other equivalent standard.
We have the gadget and equipment for testing TENSION of high accuracy by testing machine, analysis of molten gray/SG/malleable iron before pouring by CARBON SILICON ANALYZER AND MEASURING TEMPERATURE OF MOLTEN METAL BY PEAK LACHING DIGITAL TEMPERATURE INDICATORS.
Continuous efforts are made to improve the Grade & quality of the casting, which has shown us the way to upgrade the castings from ASTM 48 CLASS 35 ONWARDS.
We have the most up to date dry and weight modified system of Pollution Control Device with emission level far below the norms required by pollution Control Board of Govt. of India.
Our products conforming to National & International specifications e.g. IS, ASTM48, COPRO, DIN, BS & EN are highly acclaimed by our overseas clients after stringent Inspection by their authorized Inspectors and Technical Inspection and Testing Agencies.
The management set up is a piece of art and is maintained in such a way that planning production, Maintenance, Inspection & dispatch goes on smoothly without hindrance . Not only the quality of our product but the quality perception of the people, participating in the process backed by competent management is the key to our success.
Production Process
Our production process are as follows: SELECTION OF RAW MATERIAL AND TESTING (For all material)
Pig iron, Hard Coke, Limestone and other raw material is purchased with reputed companies and Govt. Organisations. The Chemical report is attached with the Invoices All the inputs are again tested in the highly sophisticated foundry Lab.
MELTING
All the raw materials are inserted into Coupla Furnace with a perfect combination of airflow, and the temperature of the furnace. There is a constant check in temperature of the molten material with a temperature meter and the ratio of Carbon ,Silicon is constantly monitored by Carbon Silicon Analyser.
MOULDING (For all material) All the dry mould is made up of sand and its mixtures: Sand is the key factor for any foundry. Quality of the sand depends for the surface finish of the castings. The Sand is mixed here in the high Capacity 1000 Kg fully automatic Sand Mixer Plant.
All the moulding are done by the skilled workers under the supervision of experienced supervisors.
After the moulding all the moulds are dried by blow Lamps to remove excess moisture from the mould.
Before pouring when the moulds are ready this is re-inspected by the floor in charge to inspect the workmanship of the moulders.
Temperature is checked in the Spout and in the ladle before pouring of molten material into the moulds.
Material is kept into the moulds for at least 5 Hrs for gradual reduction of temperature.
FETTLING (For all material) The material which is taken out of moulds are sent to proper chipping yard. Here the following process is followed :-
Separation of rejected material.
Through brushing is done through hand for removal of sand.
Chipping is done to remove runners and risers with materials.
Grinding is done with the grinding machine to remove sparks and finse.
Buffing is done whole over the surface of the casting after grinded.
Through inspection is done at last and the material is sent for machining.
MACHINING After Fettling the castings are sent to machining section. The foundry is equipped with in house machine shop. The machining of the grey Iron Castings are done with the extreme accuracy. Drilling and Tapping is also done in the machine shop.
PAINTING (For all material)
Before painting the material is once again inspected and then sent to the painting area. Here the painting is done by the process of Dipping and brushing. Painting is done so that minimum 4-micron thickness is achieved. After this painted material is left for at least one day to dry up completely.
PACKING & DESPATCH (For all material)
Here the material is packed in the wooden crated or the Mild Steel crates as per requirements of the buyer.
Global Operations
We have been constantly receiving trade enquiries for sundry kits from different sources, without previous business connection, in and abroad which has helped us to establish links with those clients with prospect of future business relationship. Some of these links are from JAPAN, EUROPE & UAE.
We have our own representative at US who not only works as a link between us and our clients there but also takes up promotional prospect of our products in USA.
Features
Large Corner Webs The flange has been optimized so that there is an increased area where the load is concentrated, giving a reduction of measurable strain between 30% to 50% in the bedding.
Bonding Ribs Rib design significantly improves bonding to the bedding material creating a greater resistance to lateral shift. This helps avoid early separation and cracking of the bedding material which can cause premature failure.
Rib Positioning Positioning of the ribs plays a critical role in reducing the risk of cracking the bedding material. The position opposite the cover seating areas reduces the risk of frame deflection and ensures that impact to the surrounding materials is limited.
Flange Stiffness The thickness of the flange at the corners prevents bending caused by dynamic loading. Prevention of bending in this area reduces disturbance of the bedding material.
Certificates & Awards
ISO 9001 : 2000 CERTIFICATE
CERTIFICATE OF RECOGNITION AS STAR EXPORT HOUSE
Facilities
O.T. CRANE FACILITY There is an OT Crane installed with capacity 6 MT with span of 65 Feet and 125 Feet long. Which facilitate to left the molten material directly from Copula to the mould. We offer facilities for Melting , Moulding, Grinding, Machining, Finishing, Laboratory facilities for both physical & chemical properties, crating and dispatch – all under one roof.
The facilities which helps timely delivery of finished products are as follows:-
The in-house Grinding shops for better finishing and timely delivery of finished products.
Two sets of 80 HP capacity Diesel Engine are fitted with blower separately for each Cupola.
The in-house pattern shops for quick and timely development of patterns.
The in-house Grinding shops for better finishing and timely delivery of finished products.
Our laboratory houses the following equipments :-
Strolhein Apparatus for Carbon Testing : Capable of Temperature: 1500 Degree centigrade.
Muffle furnace (Capable of Temp.1100 degree centigrade.
Hotplate
Chemicals and Glass Apparatus for testing percentage Silicon, Manganese, Sulfur phosphorous etc.
PHYSICAL TESTING EQUIPMENTS
Ultimate Tensile Strength Machine Capacity 200 KN
Hardness Tester ( Brittleness)
Load Testing Machine Capacity 300 KN
SAND TESTING EQUIPMENTS
Rapid Moisture Tester for Green & Floor Sand
Mould Hardness Tester
MOLTEN MATERIAL TESTING EQUIPMENTS
Carbon Silicon Analyzer: for Molten Metal Testing of C.E, Te, Si, Tensile & Hardness also.
Temperature Recorder : To Check Temperature of Molten Material of Spout and pouring Temperature.
EPP Composites Pvt. Ltd. Exporter and wholesaler of roofing sheets such as frp roofing sheets. Also offering a wide range of frp doors, grp pipes, frp pipes, frp cable trays, frp gratings, frp marine products, frp ladders and railings system. Also offers industrial railings etc.
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