November 2015

Indian Foundry Journal
3
Vol 61 No. 11 November 2015
4
CONTENTS
Presidents Communiqu
Vol.61
No.11
November 2015
Energy Conservation : Ferrous Foundry

An Innovative Melting Technique for
Energy Conservation in
Ferrous Foundries
R. K. Jain
45
Editorial
11
History of Metal Castings : Past, Present & Future

Castings in Human Civilisation
N. P. Sinha
CFO Writes
54
15
IIF Annual Awards 2015 :
Nominations Invited
77
NEWS
IFEX 2016 &

Cast India Expo
19
Member Exclusive :
Brakes India Ltd.
64th Indian Foundry

Congress
NCTS News :
Case Study
IIF in Media
87
21
61
News from IIF

Regions & Chapters
Statistics
123
Udyog Aadhaar Memorandum for MSMEs
125
95
62
CET News
zInplant
Price Trend of Foundry

Raw Materials
115
News & Trends
75
107
Workshop for Workers &

Supervisors :
z Sand Quality and Testing
z Mould, Making, Both Green
Sand & Dry Sand
Workshop on :
z Upgrade Your Foundry
Forthcoming Events
135
Advertisers Index
142
The Institute of Indian Foundrymen

IIF Center, 335, Rajdanga Main Road, East Kolkata Township P.O., Kolkata - 700 107
Phone : +91 (033) 2442 4489 / 7385 z Fax : +91 (033) 2442 4491
E-mail : journal@indianfoundry.org z Website : www.indianfoundry.org
5
6
Presidents Communiqu
The Sharing Economy and the Foundry Industry
A phenomenon has been taking root in the developed economies in the recent years.
That is the use of IT and the Internet to disrupt the traditional business models.
This business model known as aggregation, is challenging established businesses
and cosy cartels while leaving the regulators feeling powerless. It also has liberated

earnings potential. It has also created asset light businesses, valued in multi-billions,
in a rather short period. At the same time, providing the consumers with Convenience,

This leads us to the question: What is this Phenomenon and What is the Sharing
!"
#
The
Foundry
Industry should
be prepared for
a big disruption
in this market!
,,
Our
Industry
has to be aware
of the Effect
of the Sharing
Economy.
Uber, Ola and other similar services which have revolutionised intra-city transportation
by their convenience, availability and reliability. So much so, that in the metropolitan
cities of the world, it is no longer required or fashionable to own a car. This is especially
true about the Millenials (youngsters in their twenties). This sharing helps in reducing
the burden on Infrastructure - roads and parking, reduces the pollution levels and
lowers cost and thereby lowering the burden on society. This is a case of the use of
technology to share movable assets i.e. Making the service come to the customer.
$%%&'% % * !'
affect us or is it only a Fad, which we can conveniently ignore?
The Foundry Industry, world over, is dependent on the automotive, agriculture,
construction and goods carriers amongst others. These segments account for over
seventy per cent of the demand. The Foundry Industry should be prepared for a big

%
Look at the fact that an average automobile is only being utilised twenty per cent
of the time in a day. Similarly, in the Intra-City Goods Transportation Segment, the
% %+
%/0 %
is idle, waiting for loads. In agriculture, the equipment utilisation factor is again twenty
per cent. In the Infrastructure Sector, the equipment utilisation factor is not more than
thirty per cent.
The sharing economy or the aggregators can, hypothetically, increase the effective
%/*%%
%
market for the above assets. This can lead to reduction in demand and growth rates in
the immediate future, till the market is able to absorb the additional capacity released
by the Aggregation Model. It will be healthy in the long run, by providing cost-effective

+% %
/
This can and is happening very fast, with many local and global players either
entering with new models or duplicating successful models elsewhere. It is asset light,
environmentally light, infrastructure light and employment generative .
In conclusion, our Industry has to be aware of the Effect of the Sharing Economy. It
may have a small negative impact in the demand in the short run. However, in the near
%
%* % + %

of our Industry, which in turn will lead to prosperity for the Foundries.
$%1
K. Samaraj
7
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9
10
Editorial Board
Editorial
Mr. Ravi Sehgal
- Editor
Fellow Foundrymen & Friends,
Dr. B. Ravi
- Associate Editor
Mr. Baidyanath Dutta

Executive Director, IIF
- Convenor
Dr. P. S. Banerjee
- Member
Dr. S. K. Goel
- Member
Mr. V. Narasimhan
- Member
Dr. N. P. Sinha
- Member
Mr. B. Ramachandran
- Member
Dr. Dewan D. Lal Chopra
- Member
Prof. S. K. Paknikar
- Member
Greetings of the Season! I am sure all of you

celebrated the festivities with family and friends to
usher in a prosperous year ahead. These festivities
and meeting elders in the family take us back to
our childhood. In keeping with the theme and
the mood IIF Journal Team pays salutations and
warm regards to the Unknown Foundrymen, who
through the last 5000 years have not only kept the
technology of castings going, but have come out
with some master-pieces such as the Iron Pillar at Qutub Minar premises
in Delhi or the Moscow Bell / Philadelphia Bell. One of the extraordinary
feats that I myself witnessed is the Iron Bridge at Telford, England a
bridge made completely out of Cast Iron with a span of 100 feet, built
over 200 years ago. All these and many other foundries wonder products
stand proudly today as glorious symbol of our mother industry that has
stood the sands of time, endured wars and famines and serves as historical
monuments of the Evolution of Man & Technology over the centuries.
Mr. Surajit Datta

- Member
Chief Financial Officer, IIF

Mr. G. Mukherjee
- Director, CET
Mr. A. K. Anand
- Director, FIC
Mr. Anil Agashe
- Director, NCTS
Invited Members
Mr. S. K. Saxena
- Chairman,
Eastern Region
Mr. M. H. Velankar
- Chairman
Western Region
Mr. Pradeep Mittal
- Chairman
Northern Region
Dr. Nithyanandan Devaraaj - Chairman
Southern Region
Articles/Write-ups (soft copy) may be

forwarded to : journal@indianfoundry.org
o All correspondence on Editorial Matters,
Subscriptions and Advertisements should

be addressed, The Institute of Indian
Foundrymen, IIF Center, 335, Rajdanga Main
Road, East Kolkata Township P.O., Kolkata 700 107.
o The views and opinions expressed or implied
in the INDIAN FOUNDRY JOURNAL are
those of the authors and do not necessarily
reflect those of IIF. Unsolicited articles and
transparencies are sent at the owners risk
and the publisher accepts no liability for
loss or damage. Material in this publication
cannot be reproduced whether in part or in
whole, without the consent of IIF.
o IIF reserves the right to reject advertisements.
The IIF is not in any way responsible for the
result of any action taken on the basis of the
advertisement published in the journal.
From the ancient Pillars/Bells & Bridges a time has come when designing
of castings through 3D images and converting them straight into casting
forms have become a reality. Technology is moving at a very rapid pace.
This issue is dedicated to the History of Castings over the centuries and I
thank Dr. N.P. Sinha for having compiled all his research into an interesting
presentation, which has been published in this issue.
Speaking of the rapid pace of Technological advancements there is an
urgent need of Technology Upgradation at most of the 4000 odd foundries
in India. With a majority of them under MSME sector the Government
needs to set up a separate fund to assist foundries to upgrade themselves
in order to fulfil the international and domestic demands. Technology
and Quality Upgradation are the two important attributes in enhancing
competitiveness for any manufacturing industry. These upgradations shall
also impact savings in Energy cost, improve productivity and capacities
and most importantly improve the quality of lives of the people working
in the foundry. IIF is working closely with the Government to make this
happen a Technology Upgradation Fund for the Foundries.
The Ministry has been kind in rationalising Duty Drawback Rates for
Castings and they have also received approval of the Cabinet for Interest
Equalisation (Subvention) for Pre & Post-shipment to the tune of 3%,
which would go a long way in the promotion of casting exports. With
a review of history of Castings and keeping manufacturing alive to keep
the countrys youth power and efficiency to the fore, Foundrymen should
strive hard towards Technology Upgradation and projecting Indian
products and brand to the rest of the world this should be our mantra as
we look beyond the festivities.
Enjoy the year and happy Casting Times ahead!!
Ravi Sehgal
Editor
11
THE INSTITUTE OF INDIAN FOUNDRYMEN

Affiliated Member of the World Foundry Organization
[Founded 1950]
Patron-in-Chief
Dr V Krishnamurthy, Chairman, NMCC z Mr B Muthuraman, Vice-Chairman, Tata Steel
IIF NATIONAL COUNCIL (2015-16)

OFFICE BEARERS
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Hon. Secretary
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Elected Members
Mr D S Chandrashekar
Mr K Samaraj
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[All Other Past Presidents

are Invitees to the NC]
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14
CFO Writes
Dear Members and Readers,

In this issue, I shall highlight on the imposition of Swachh Bharat cess @ 0.5% on all taxable services with
effect from November 15, 2015.
The Finance Ministry has clarified that the Swachh Bharat cess will not apply on those services for which
payments have been received prior to November 15 and invoices raised before November 29.
Eating out, telephony and travel will become expensive from Sunday with the Government imposing 0.5
per cent Swachh Bharat cess on taxable services which is expected to yield about Rs.3,800 crore to the
exchequer in the remaining months of the fiscal.
With the imposition of the cess, service tax rate will go up from 14 per cent to 14.5 per cent on all taxable
services.
According to the Government, it expects to collect around Rs.10,000 crore from Swachh Bharat cess for full
year.
So in the remaining months of this fiscal till March 31, 2016, the cess would yield about Rs.3,800 crore to
the kitty. The Swachh Bharat cess would be levied only on the portion of taxable services (after abatement)
and will go towards funding of the cleanliness drive. This means that service tax on restaurant bills will go up
from 5.6 per cent to 5.8 per cent following the levy of 0.5 per cent Swachh Bharat cess. The Finance Ministry
has also clarified that the Swachh Bharat cess will not apply on those services for which payments have been
received prior to November 15 and invoices raised before November 29. The decision to impose 0.5 per
cent cess will translate into a tax of 50 paise only on every Rs.100 worth of taxable services. Explaining the
provisions for the levy of cess, the Ministry said it would be calculated on the abated value or value arrived
as per the Service Tax (Determination of Value) Rules, 2006.
Surajit Datta
FCA, FCMA, AIII, MIIA
15
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64th Indian Foundry Congress
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43

Membership Strength as on October 31, 2015
Those members who have paid their Annual Subscription for 2015-16 and beyond have been included
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Total
51
12
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110
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12
264
Foreign
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Total
27
33
38
10
31
165
315
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Total
175
52
57
32
82
378
652
13
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Total
278
39
48
17
58
410
12
873
531
136
165
68
201
1065
691
37
2903
Grand Total

# #%

!"
& '!"
* '+!"
3
34
9 +!"
APPEAL
4;#<;44;%;3% %= ;!;>#?4%@?B4 33 ;4
%D< 4G4% <4?%%?4; 4 ;4<; 4;!
SANJAY SHROFF
H !#?>33
44
ENERGY CONSERVATION
FERROUS FOUNDRY
$Q,QQRYDWLYH0HOWLQJ7HFKQLTXHIRU
(QHUJ\&RQVHUYDWLRQLQ)HUURXV)RXQGULHV
R. K. Jain
Professor, Dept. of Mechanical Engineering, ITM University, Gwalior
E-mail : rkjain1192@yahoo.co.in
This paper is aimed to study the energy consumption in Indian ferrous foundries and to investigate measures for energy
conservation. The natural sources of energy coal, oil, gas etc. are depleting fast. As per the survey conducted and reports
published by several national and international agencies, energy consumption in Indian ferrous foundries is much more
%& % /$%

%\]X+ /$%%
conducted a series of experimental investigations on the self-designed and developed Rotary furnaces, installed at
S.Harbhajan Singh Namdhari Enterprises, industrial estate, Nunihai, Agra for production of cylinder heads and auto parts,
and at Faculty of Engineering, Dayalbagh Educational Institute (DEI), Dayalbagh, Agra (a self-deemed university.) These
experimental investigations on the rotary furnaces produced excellent results, which are accrued here. The experimental
%% %
% %
+
^_/`z{

^z/|^{/
Keywords : Rotary furnace, oxygen enrichment, preheated air, energy consumption, TERI (The Energy and Resources
Institute), LDO (Light Diesel Oil).
Introduction
Rotary furnace consists of a horizontal cylindrical drum.
The length and diameter of the drum depend upon
capacity of furnace, which varies from 200 kg/hr to 2
tonnes/hr. This drum is mounted on rollers, which are
driven by electric geared motor. Two cones, one side
of which is welded to the drum. The drums and cones
~
z% %
mortar and refractory bricks.
Fig. 1: Layout of rotary furnace.
One of the cones accommodates the burner, which can

+ %\]X%%%
accommodates the duct for heat exchanger. A tap hole is
made approximately in the centre of the drum. Charging
of material is done through the tap hole and other cone,
whereas the pouring is done through tap hole only. A
covered oil tank containing LDO is located at a height

/ z %

and is connected to the burner through pipeline with
suitable diameter and control valves. A pump is installed
to force the oil at desired pressure to the burner. Layout
of furnace is shown in Fig. 1.
Baker[1] explained the working of Rotary furnace.
Baijayanath, and Panigrahy[2] explained that most of the
units are crippled with usage of rudimentary techniques.
The Indian foundry industry needs optimisation of
energy consumption. Pandey, Singh and Sinha[3]

%

`2 pressure

as it reduces melting time and emission levels. Singh^
advocates the use of newer and cleaner technology for
environmental and energy conservation. Aswani[5] has

%z`{
in melting alone. The furnace operation needs attention
of skilled operators to minimise rejection and energy
45
ENERGY CONSERVATION
FERROUS FOUNDRY
losses. Arjunwadkar and Pal[6] stressed the use of

energy-ef+ %&/ $0* ]%z
reports have shown that energy consumption in Indian
ferrous foundries is much more above the required limit.
Basu, Chaudhuri and Roy` conclude that with judicious
applications and implications of correct energy auditing
and monitoring techniques, it is possible to achieve
energy conservation in Indian foundries. EPRI Centre[9]
%
+
% % {
of sensible heat. This sensible heat can be recovered
by using suitable heat exchanger and preheating air,
required for combustion of fuel, upto temperature of
z0/ * %
z
kWh/tonne. Andrew Turner[10], Secretary General, World
Foundry Organization (WFO) stressed upon improving
the melting techniques in foundries by recovering and
%%
%%
scrap, cores and reduce the casting defects by employing
suitable techniques. Mesbah, Khan and Fartag[11] strongly
believe that energy conservation can effectively be
achieved only by utilising effective heat exchangers, as
they are important components for processes where
energy conservation is achieved through enhanced
heat transfer. Kim, Seung[12] have used the fuel-lean
re-burn system. It has maintained fuel lean conditions
in the furnace, in oxygen-enhanced combustion, to
replace additional air system, which reduces energy
+/ [13] developed high
+
lost as sensible heat through the gas especially in high
temperature applications like metal melting in hot brick
chamber. Singh and Chandra, Malik|^ have advocated
%+
of air, proper sealings etc.
Experimental Investigations
Experimental Investigation 1
A.
Operating furnace under existing conditions of

operation
The furnace was operated without oxygen enrichment

and preheating of air as per existing conditions. The
%
% / * % + %
started from room temperature, more air was required,
%

%

melting rate were less, but time and fuel consumption
were more. In subsequent heats, the air was reduced,

%

melting rate increased, whereas the time and fuel
consumption decreased. Observations taken during
%
$||\]X_/_^z
kWh/litre).
B.
Graphical Representation
The graphical representation of energy consumption

without oxygen enrichment of preheated air is shown in
Fig.2.
Melting Operation
The process of melting the charge is carried in following
steps: (1) Preheating of oil and furnace (2) Charging (3)
~^$
*/
Fig.2 : Energy consumption under existing conditions of

operation.
Table-1: Energy Consumption of Furnace without Oxygen Enrichment of Preheated Air

Sl.
No.
Heat
No.
Rpm
Time
min.
Fuel
litre.

Fuel
(lit/kg)
Melting
rate
(kg/hr)
Excess
air m3
Excess
air %
Flame
temp.0C
Energy
kWh/
kg
2.0
50.00
92.0
/^
^/
1320.0
/^
1310.0
^/
2.0
^z/
90.0
/^
255.3
1290.0
/^|
||^/
^/^z
2.0
^/
`z/
/^
/`
|^/
/^
1325.0
^/`
2.0
^/
`/
/^
266.0
1220.0
30.10
|^/
^/_
2.0
^/
`/
/^|
266.0
||z/
/^
1350.0
^/||
46
ENERGY CONSERVATION
FERROUS FOUNDRY
Total Energy Consumption
Effect of operating furnace without oxygen

enrichment of air on total energy consumption

{%
%%%
in Fig. 3.
The total energy consumption consists of energy

consumption in(1) Melting the charge
(2) Fuel consumption unit
(3) Plant and equipment
^ &

(5) Shot blasting machine.
The total energy consumption (kWh/tonne) is given in
Table-2.
Effect of 20% excess air with compact heat exchanger,
rotating furnace at optimal rotational speed
temperature, energy consumption
Fig.3 :
{%
%
exchanger.
Again experiment was carried by further reducing excess

{%
%%
at optimal rotational speed 1.0 rpm, preheating LDO

z0C. The observations taken during experiment
are given in Table-3.
|{ %
% %
rotating furnace at optimal rotational speed on energy
consumption
Table-2 : Total Energy Consumption (kWh/tonne) when Furnace Operated without Oxygen Enrichment of
Preheated Air
Sl.
No.
Particulars
Energy consumed
Total energy
consumption
\]X ^| ^|_/_^z^||/^'%

Litre/tonne
^||/^'%
Fuel combustion unit
/z^'
10.323 kWh
X+

|%

//z^ /%
(b) Heating element

3
Plant & equipments
5.595 kW
/z/%
|/^_'z/`z'%
b. Geared motor 2 hp
/%|/^
Pollution Control Equipment:

a. ID Fan 5 hp
b. Motor 1 hp
/z'
|/`z'%
/z^'^/^z'% /
%|/`z'%
Shot Blasting M/c Capacity 3 tones/hr. /`z/^'%

~///`%
Grand Total
/^'%
z/^'%
^|z|/z^|z/'%
47
ENERGY CONSERVATION
FERROUS FOUNDRY
Table-3: Effect of 20.0% Excess Air with Compact Heat Exchanger, Rotating Furnace at Optimal Rotational
Speed of 1.0 rpm, on Energy Consumption
Heat
No.
Flame
Temp.
0
C
Rpm
Time
min.
Fuel
litres
1510.0
1.0
^|/
z/
293.0
0.360
995.0
30.1
^/
3.5656
1530.0
1.0
^/
z/
300.0
0.350
_z/
25.5
316.0
/^
|^/
1.0
39.0
69.0
z/
/^
930.0
20.3
320.0
/^|z|
|^/
1.0
`/
`/
|/z
/^
905.0
20.1
329.0
/z
1550.0
1.0
z/
66.0
^
0.330
`z/
20.2
332.0
/`
|`/
1.0
z/
^/
^/
0.320
`/
19.9
^/
3.1695
|z/
1.0
36.0
63.0
333.3
0.315
`/
20.0
^`/
3.1199
|z`/
1.0
35.0
61.0
^/`
0.305
z_/
19.9
z/
3.0209
|`/
1.0
^/
60.0
352.9
0.300
z``/
20.1
z`/
/_z|^
10
1590.0
1.0
^/
59.0
352.9
0.295
z`/
20.0
`/
/_|`
11
1620.0
1.0
33.0
`/
363.6
0.290
z/
20.0
^/
/`z
Melting Preheated Preheated Preheated

Rate kg/
Fuel
Excess Air, Excess Air Excess Air
hr
Cons.
m3
%
Temp.0C
litre/kg

Energy
Cons.
kWh/kg
Again, experiment was carried out by further reducing

|{ %
% %/
The observations taken during experiment are given in
$^/
If the combustion volume is, more, then more fuel and

|{%
%%%
/^/
time shall be required for reaching a certain temperature.
Effect of Oxygen Enrichment of Preheated Air on

Energy Consumption of Furnace
Hence, it is thought to optimise the combustion volume

by reducing the amount of preheated air and supplying
oxygen externally. Several experiments were conducted,
gradually reducing air to its theoretical requirement

/|/{

|//{

/ $% +
% z/{ %
&
z/{

externally.
Effect of 6.9% Oxygen Enrichment of Preheated Air
on Energy Consumption

% /_{
% z/z/^{ %
Fig.4 :
|{%

heat exchanger.
48
required air, the effect of above on energy consumption

and performance of furnace is shown in Table-5.
ENERGY CONSERVATION
FERROUS FOUNDRY
Table-4 : Effect of 10.0% Excess Air with Compact Heat Exchanger, Rotating Furnace at Optimal Rotational
Speed of 1.0 Rpm, on Energy Consumption
Sl.
No.
Flame
Temp.
0
C.
Rpm
Time
min.
Fuel
litres
Melting
Rate
kg/hr.
|^^/
1.0
^/
59.0
352.9
0.295
`|/
||/^
`^/
/_|`
1656.0
1.0
33.0
`/
z/
/`
z_/
11.3
392 .0
/``
1666.0
1.0
33.0
`/
z/
/`
z/
10,0
396.0
/z_|
|z`/
1.0
32.5
z/
z`/
/`
z/
10.6
_`/
/``
|`^/
1.0
32.0
z/
`/
/`
690.0
10.1
^/
/``
1693.0
1.0
32.0
56.0
z/
/`
`/
10.1
^z/
/zz
|zz/
1.0
31.0
56.0
`z/
/`
z/
10.0
^|/
/zz
Preheated Preheated Preheated

Fuel
Excess Air
Excess
Excess Air
Cons.
m3
Air%
Temp.0C
litre/kg

Energy
Cons.
kWh/kg
Table-5 : Effect of 6.9% Oxygen Enrichment of Preheated Air on Energy Consumption

Heat Rpm Preheated Flame
No.
air temp temp
0
0
C
C
Time
min
Fuel Melting Oxygen Oxygen Preheated Preheated

litre
rate
fuel
Energy cons.
cons
air cons. air cons
kg/hr. consump consum
m3
%
m3
%
lit/kg kWh/kg
1.0
^|/
|z|/ 33.00
56.0
363.0
/`
/zz
39.0
6.9
^_/
z/
1.0
^|`/
|z/ 32.00
56.0
z/
/`
/zz
39.0
6.9
^_/
z/
1.0
^`/
|z/ 32.00
55.0
z/
/`
/zz
`/
6.9
^|/
z/^
1.0
^^_/
|z^/ 31.50
^/
`/
/z
/z^
`/
6.9
^^/
z/^
1.0
^^/
|z/ 31.00
53.0
`z/
0.265
/^
z/
6.9
^^/
z/
1.0
^`/
|z^/ 30.50
52.0
393.0
0.260
/z
36.6
6.9
^/z
z/^
1.0
^/
|z/ 30.50
52.0
_/^
0.260
/z
36.5
6.9
^/
z/^

%/_{%
of preheated air on total energy consumption is given in
Table-6.
Graphical Representations: The graphical

/_{ %
of preheated air on energy consumption of furnace is
shown in Fig. 5.
To further reduce the energy consumption, it is proper
to increase the oxygen enrichment of preheated air. The
%
/^/{

/^/{/$%
+%%
z/^`/^{/
Fig. 5 : /_{%

consumption (kWh/kg).
49
ENERGY CONSERVATION
FERROUS FOUNDRY
Table-6 : Total Energy Consumption (KWh/

tonne) when furnace operated with 6.9% oxygen
enrichment of air
Sl.
No.
Particulars
Fuel consumed
in
melting
LDO=260 Litre/
tonne,
Oxygen
= 36.50/ 200m3/
|`/
3/
tonne
Fuel combustion |/` '% ^/z^'%

unit
_/^^
kg/hr=
a. 2.5 hp (Reillo
burner)
Plant
equipments
Energy
Consumed
Total Energy
Consumption
/ tonne
_/_^z z/'%
z/
91.25kWh
=
kWh
/^z'%
|`//
= 91.25 kWh
& 5.595 kWh
/`z'%
|/^_'%
/z/
1.119 kWh =
b. Geared motor `/ '%
2 HP
_/^^
kg/hr
=
c.Fan-heat
/`z'%
exchanger 1HP
tonne
atmosphere
side and 0.5 HP
furnace side
^
Total Energy Consumption # z/^`/^{

enrichment on total energy consumption is given in
$z/
Effect of 7.7-8.4% oxygen enrichment of

preheated air on energy consumption
Again the experiment was repeated further reducing
{ %&

z/{

`/{/

furnace in different conditions in different consecutive
%/ * % %

%
air temperature increases whereas the time and fuel
consumption decreases. The observations taken during

$`/
Total Energy Consumption # z/z`/^{
enrichment on total energy consumption is given in
$`/
Graphical Representations : The graphical presentations
z/`/{%
%
on energy consumption is shown in Fig. 6.
Comparison of Energy Consumption

The comparison of energy consumption, as per
experimental investigations is shown in Fig. z/
||/z'%
Pollution Control /z'%
Equipment:
/z^'%
^/^z'%
a. ID Fan 5 HP
b. Motor 1 HP
_/^^
melt/hr
^/^z'%
||/z'%
For 1 tonne
5
Shot
Blasting /` z/^'%
M/c Capacity 1 z/^ '%
Tone/hr. Motor 30 tonne
//`%

Grand Total z|/_
z||/ '%
tonne
50
Fig.6: z/`/{%

%
air on energy consumption.
ENERGY CONSERVATION
FERROUS FOUNDRY
Table-7 : Effect of 7.4-8.4% Oxygen Enrichment on

Sl.
No.
1
Particulars
Energy
Total Energy
Consumed Consumption
Fuel consumed in `_/_^z /|z '%

z/^ `/^{ /|z |/^'%
oxygen enrichment kWh 200.9 2160.62 kWh
|/||^/__{ x 0.5 =
theoretically required |/^'%
air, preheated up
^z/0C, using
compact
heat
exchanger). LDO =
`/
Oxygen=
^/|`3/kg =
200.9m3/tonne.
Results
Fuel combustion unit |/`'% ^/`'%

_`
a.2.5
hp
(Reillo
burner)
Plant& equipments
5.595 kWh
/z/
|/^_'%
/|`'%
Pollution
Equipment:
Control /z'%
/z^'%
|/ '%z/z`/^{%

%
a) The fuel consumption per heat (for melting
% `/^/
//^z/_{
||/z
kWh/tonne
^ / ^ z ' %
_`/z
_`/z% kg/hr
||/z'%
For 1 tonne
d) Annual energy consumption reduced from

1.501x106 kWh to 0.926 x106 // /z|6
'%`/{
Shot Blasting M/c /` z/^'%%

Capacity 1 T/Hr. z/^'%%
~///`
kWh
$%
+
%
/^|/`//^_/`z{
c) The energy consumption/tonne reduced from
^|z//'%/'%//^z/|^{
b. Motor 1 HP
Grand
Total
The results of above experimental investigations and

effect of oxygen enrichment of preheated air on energy
consumption of rotary furnace are given in Table-9.
On the basis of above experimental investigations, the

following conclusions are drawn :
a. ID Fan 5 HP
Effect of Oxygen Enrichment of Preheated Air on Energy

Consumption
Conclusion
b.Geared motor 2 HP 1.119kWh =

c.Pump
heat `/ '%
exchanger
1HP _`
% /|`
atmosphere side
kWh/tonne
Pump heat exchanger
0.5HP furnace side
^
Fig.7: Comparison of energy consumption, as per

experimental investigations
^/
2205.00 kWh/
tonne
/

/`{ % % $0*
norms.
*%z/z`/^{%
%
+ %
/
Remarks
The above experimental investigations were carried
out on a 200.0 kg rotary furnace. When operated with
51
ENERGY CONSERVATION
FERROUS FOUNDRY
Table-8 : Effect of 7.7-8.4% Oxygen Enrichment of Preheated Air on Energy Consumption

Heat Rpm Preheated Flame Time Melting Fuel Energy Oxygen Oxygen Preheated Preheated
fuel
Cons.
cons.
No.
air temp temp Min. rate kg/ litres
cons %
air cons air cons %
0
0
C
C
hr.
cons lit/ kWh/
m3
m3
kg.
kg.
1
^^/
|z^/ 32.0
z/
^`/
/^
/zz
^_/
`/
319.0
61.1
^/
|z/ 32.0
z/
^z/
0.235
/z
^_/
`/^
319.0
/^
^z/
|z/ 32.0
z/
^/
0.232
/_z
^`/
`/
|z/
62.6
^^`/
|z/ 31.5
`/_
^/`
0.229
/`
^/`
`/
313.0
/`
^/
|zz/ 31.0
`z/
^/
0.225
/`
^/
`/|
310.0
63.3
^z/
|zz/ 30.5
_/^^
^^/
0.223
/`
^/
`/|
309.0
63.3
^z/
|zz/ 30.5
_/^^
^/`
0.219
2.169
^/
`/
302.0
/^
^z^/
|zz/ /^
_^/z
^/_
/|^
2.119
^/
`/|
_z/
63.6
^z/
|zz`/ 30.1
_`/z
^/
0.210
/z_
^|/
`/
295.0
^/
10
^z/
|zz`/ 30.1
_`/z
^|/
/`
2.060
^/
z/z
_^/
^/_
Table-9 : Effect of Oxygen Enrichment of Preheated Air on Energy Consumption

Particulars
Without
oxygen
enrichment
With 20%
excess air
With 10%
excess air
With 6.9%
oxygen
enrichment
With
7.7-8.4%
oxygen
enrichment
% Savings
compared
to without
oxygen
enrichment
(a) Fuel/heat litres
`/
`/
56.0
52.0
^/
^z/_{
(b) Spec. fuel. litre/kg
/^|
0.290
/`
0.260
/`
^_/`z{
(c) Energy kWh/tonne
^|z/
`z/
zz/
z||/
2205.0
^z/|^{
(d) Annual production

tonnes
360.0
360.0
360.0
^/
^/
|/{
Reduction
(e) Annual Energy

consumption kWh
^|z/ `z/ zz/ z||/^ /^

= 1.501 x
= 1.03 x 106
/__` |/|`|6
= 0.926
6
6
10
10
x 106
z/z`/^{ %

% %

+
/`
energy consumption was 2.060 kWh/kg. This may further
+

/%%+
reduced for larger size furnaces.
References
1.
EHW Baker, Rotary Furnace, Modern Workshop

$% | |__`
/^`
Hummer Press Ltd., London-2nd Edition.
52
2.
/z|6
Baijya Nath, C. Panigrahi, Energy Conservation

Options Among Indian Foundries-A Broad Overview,
* `z
/z/
/ "/ / 0% % / / % +

Energy Measures in Steel Foundry, Indian Foundry
|z
/^_/
^/ %% +
Process and Casting Rejection Control, Indian
||z
/^^z/
ENERGY CONSERVATION
FERROUS FOUNDRY
5.
K. G. Aswani, Minimizing Electrical Energy Expenses,

* ^`|
/_/
Product Development Centre, PPDC, Ministry of

MSME, Govt. of India and IIF, Agra, Feb-2, 2010.
6.
S. H. Arjunwadkar, Prosanto Pal et al., Energy Savings,

Carbon Credits- Opportunities and Challenges for
* * ^|
`
/z/
11. Mesbah, G. Khan, Amir Fartag., A Review on Micro

Channel Heat Exchangers and Potential Applications,
* 0% z
||
/`/
z/ $0* ]% 0

*
^`
//
12. Hak Young Kim, Seung Wook Beek, Experimental

Studies of Fuel Lean Re-burn System for NOx
Reduction and CO Emission in Oxygen Enhanced
Combustion, International Journal of Energy
0%`||
/z|z||/
`/ % % / / 0

Conservation in Indian Foundries Planning and
~% * `z
p.31-36.
9.
EPRI Centre for Materials Production 2010, EAF

Scrap Heating, International Symposium on Energy
|/
/`~
Research Institute, Pittsburgh, Pennsylvania (USA).
|/ $ +

Technical Symposium, organised by Process and
13. Dr. B. K. Basak, Visiting Faculty, IIT, Kharagpur in

various lectures, seminars at IIT Kharagpur, Tech.
Bulletin 2011.
|^/ % % % %

Malik, A Perception for Energy Conservation in
Indian Industries, RAME 2011- Recent Advances in
Mechanical Engineering, B.S.A.C.E.T. Mathura, March
25-26, 2011, Proceed. p. 256-260.
53
HISTORY OF METAL CASTINGS
PAST, PRESENT & FUTURE
&DVWLQJVLQ+XPDQ&LYLOLVDWLRQ
N. P. Sinha
Director, Foundry & Metallurgical Services, Kolkata
Introduction
The human civilisation has progressed from Stone
Age to present days. There has always been the need
for metallic forms in the shape of castings. Castings in
various shapes have been for use for centuries. A mineral
copper pendent was found in northern Iraq that dated
`z(1,2). The historians and archaeologists say
that castings existed in 5000 BC, but no authentic proof
has been found. However, today we know that castings
existed more than 5000 years ago (3300 BC).
When liquid metal is poured in a mould cavity made of
% + %
/
Since its discovery, metal castings have played a critical role
in development and advancement of human culture and
civilisation. After 5000 years of technological advances,
metal castings play a greater part in our everyday lives
and it is more essential than it has ever been. Today in
%% %+
of aerospace, automobile, engineering, rocketry, and at
the domestic front, they are all due to development of
castings. From the days of metallic head of the arrow
for survival to present days of industrialisation, castings
have been a constant companion. The historians have
suggested casting's development period as :
Bronze Age (3300 - 1200 BC) : Bronze Age originated
in Turkey, Iran and Iraq which are known as cradle of
civilisation.
Iron Age (1200 BC - 1600 AD) : The Chinese mastered
the technique in 1000 BC, which they used for mass
production of cast tools and farm equipments. In Europe,
iron products were cast thousand years later which
included gun barrels and bullets.
were made of copper, which was easily available and

having low melting temperature could be melted in
small earthenware pots with charcoal. A copper statue of
frog(3) from Mesopotamia was found dating back to 3200
BC (Fig.2a). Another statue of copper, a dancing girl^
(Fig.2b) was found in Mohenjodaro, India dating back
to 3000 BC. Later when tin was found, it was discovered
that by adding tin in copper, the alloy was made harder
and the castings made was stronger, which could be
sharpened better for hunting and making various other
items for personal safety use.
Fig. 1 : Oldest Mummy OTZI had a Hammer with

Copper Head-3300 BC.
The casting development started in Middle East and then

the technique was spread to Egypt, Mongolia, China and
India. The early metallic shape was made by hammering
copper. Then by melting in crucibles and pouring into
Industrial Age (1600 AD onwards): Also known as the

age of technical revolution. This age saw the increased
demand for cast products. Apart from decorative
castings, cast iron was widely used for machine tools
and household articles. With development of steel,
casting demand increased in automobile, Railways and
aerospace castings.
A copper head casting in an axe was found in the hand
of oldest mummy OTZI in 3300 BC (Fig.1). In early days,
castings were used for hunting and personal safety items
like arrow head, hammered knives. The early castings
54
(a)
(b)
Fig 2 : (a) Frog, oldest casting-3200 BC, Mesopotamia and

(b) Dancing Girl-3000 BC, Mohenjodaro, India.
lost wax moulds, which was made by wax pattern and clay
moulds, as it is done in investment castings today (Fig.5).
The progress in casting technology is aptly illustrated
by the evolution of investment casting process for the
production of ancient Chinese non-ferrous artifact(5) to
its adaptation for sophisticated ferrous castings for their
defence armament applications.
Fig. 5 : %%

1]|^]
Wt 616 g].
History of Metal Castings
Fig 3: Lost wax castings.
Iron Pillar
Fig. 4 :*

]%]z~%
Rust Resistant, High Phosphorus content, Built during the
reign of Chandragupta II, even after 1500 years
it has not rusted].
Castings led to the progress of each civilisation

z OTZI, the mummy from 3300 BC carried a copper
age
z
zz#

by copper age
z Bronze Age (3300 BC 1200 BC) : Bronze age
originated in Turkey, Iran and Iraq
z Iron Age (1200 BC onwards) : Chinese mastered the
foundry technique in 1000 BC
z Industrial Age : 1600 AD onwards
Important Finding of Castings in Ancient Periods

3300 BC - OTZI, the oldest mummy had an axe with
cast copper head
z 3200 BC - A frog cast in copper found in Mesopotamia
z 3000 BC - A dancing girl casting in copper found in
Mohenjodaro, India
z 3000 BC - Weapons and cult objects were found in
Middle East and in India
z z%

z ^ %
z 233 BC - Cast iron pillowshares poured in China
z 330 AD - Iron Pillar (Qutub Minar) Delhi
z ]+
*
z 1000 AD - Chinese made iron castings
z
55
CHRONOLOGICAL DEVELOPMENT OF CASTINGS

MANUFACTURING PROCESSES
CASTING
MOULDING
MATERIALS
z
z
z
z
z
z
z
LOAM SAND
BENTONITE
CO2
CEMENT SAND
RESIN SAND
SHELL SAND
CERAMICS
MOULDING
PROCESSES
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
CLAY CASTINGS
z
HORSE MANURE/CLAY
z
CASTING
z
STONE MOULDS
z
WAX PATTERN
z
SAND CASTING
z
DIE CASTING
SHELL MOULDING
z
INVESTMENT CASTING
V PROCESS
PERMANENT MOULDING
CENTRIFUGAL CASTING
HAND MOULDING
SWEEP MOULDING
MACHINE MOULDING
CONTINUOUS CASTING
DISAMATIC
3D SAND PRINTED CASTING
METALS
MELTING
COPPER
BRONZE
CHILLED IRON
GREY IRON
MALLEABLE IRON
STEEL SS, Mn,
CrMo
HIGH & SUPER
ALLOYS
z
z
z
z
z
WOOD CHARCOAL
COAL
OIL FIRED
GAS FIRED
ELECTRIC
INDUCTION
ARC
LASER
The early Bronze castings were used for domestic purposes but soon it
found place in armoury. Swords, daggers were made in stone moulds
which increased the production and quality of castings. Heavy cannons
were made of brass and used in wars. Moghul King Babur invaded India
| +%% % %%
he won the war. The other casting marvels are the Iron pillar(6) 330 AD
Qutub Minar, Delhi. Even after 1500 years in open, it has not rusted
/^/ ~ |z| % %

gun powder. The worlds largest cannon was made in India, by Raja Jai
%
|z/z/*% %
barrel 20 ft and needed four elephants to pull it. In 1061, Chinese made
]*$ ^^%%|`
metres and weighed 53 tonnes (Fig.6).
Present Castings
By year 1600, castings in iron and non-ferrous metals were developed
%%%
/$%+*
bridgez % % /`/
The Arch bridge 100 ft long is made of cast iron segments. Even the
56
Fig. 6 : Dongyong Tower.
suspension hangers are made

/*|z`|
and still in use everyday. Bell
castings are must for churches.
The biggest bell in Moscow was
|z % |_/
tonnes (Fig.9).
in
Benjamin
Huntsman`
% + |`_ %
+ eel ingot in crucible
furnace, which was forged
to different shapes by Tilt
(a)
(b)
Fig. 7 : ~|z|' =*
%**|z]$\% '%/
Fig. 9 : Biggest Bell in the world, Tsar Bell, Moscow,

0|_/$|z]/
Fig. 8 #X *

| |z`|]/
hammer operated by power of water wheels. With the

+ |`
range of alloy steels
was developed, which
made critical castings
for shipbuilding viz.
impellers and weapons
for military armoury.
*|``0 +
% +
ed
+
~
|/{
|{ / ~
steel had the special
property
of
work
hardening and could last longer than carbon steel under

severe wear conditions. It could also sustain impact.
Manganese steel soon found application in mining and
crushing industry. Later with the invention of railways,
it found further application for railway track and chain
wrap for excavators and military tanks (Figs.10 & 11).
Fig. 10 : Railway Bogie and Wheel.

57
Fig. 13 : ADI Gear Box.

Fig. 11 : Manganese Steel Crossings.
* |_^ ~r. Kieth Millins invented Spheroidal Graphite

Iron (SG iron) which has strength and ductility of steel,
machining, castability and damping properties of cast
iron. SG iron found universal application in auto (Fig.12)
and machine tool industry. Castings from a few grams to
z% "/
Further research on S.G. iron led to the development of
Austempered Ductile Iron (ADI) and compacted graphite
Fig. 14 : Cylinder block in C. G. Iron.
The castings of recent past and present have made some

engineering marvels which make us wonder where we
would have been without the castings. The River Don,
three-cylinder steam engine(9) at Kelham Industrial
~ % + |_ ]

|/$%|_z_
for rolling mill rolling heavy sections. Even after 110
years, the engine is still running (now only for visitors at
the museum) (Fig.15).
Fig. 12 : Auto castings in S.G. iron.
irons (CGI). ADI is ideal for high duty applications and

& + %
good machinability (Fig.13). Castings requiring resistance
to thermal shock, damping properties and good
machinability, may be made of Compacted Graphite
iron (CG iron). CG iron is widely used for production of
/|^/
58
Fig. 15 : River Don Engine.
Fig. 16 : Fat Bomb Shell Production in Foundry.
The largest steel castings(10,11) in the world, 350 tonnes

has been m % + %
/|z/ $%
has made it possible to make the ultimate Blood
Hound(12)/|`
%@X
|^%@/$% %
engineers to break the land speed record. It has been
%
|
%|`_
km per hour) with acceleration 0 to 1000 mph in 55
seconds. The testing is due in December 2015 in South
|^/
Fig. 18 : Blood Hound Rocket Car.
sand plant, moulding machines and core shop (Fig. 20,

21 & 22). The powder metal and laser melting can also
bypass the melting furnace.
Fig. 19 : 3D Printed Pattern.

(Courtesy : Newby Foundry Ltd., Birmingham, U.K.)
Fig. 17 : Biggest Steel Castings in the world, 350 tonnes, by

% + |^/
Future Castings
Foundry technology is not sitting on its past laurels.
The future of casting has a completely new technology
in store. The latest 3D sand printing technology, which

|__z"%
inroads in aerospace and precision castings (Fig.19). The
patterns could be 1000 x 600 x 500mm and moulds could
^|/~
by 3D printing process(13) do away with the conventional
Fig. 20 : Worlds largest core [Worlds largest commercial 3D

+

@/
59
Fig. 22 : Aluminium Casting from 3D Sand Mould.

Fig. 21 : 3D Sand Mould.
At times I wonder, where we would have been without

Bullet Trains, Supersonic planes, Blood Hound rocket
car and our modern household appliances, which are
assembly of castings.
Acknowledgement
The author wishes to thank Prof. A. K. Chakrabarti for his
valuable suggestions and help.
References
1.
2.
3.
History of Casting Industry, Kimura Group, Japan 05

- Source Internet.
Tylecote, R. F ., Casting Copper and Bronze in Stone
Moulds, Bulletin of Historic Metallurgy Group, Vol.
z/|_z\ /
Simpson Bruce L., History of Metal Casting Industry,
]*\|__z/
60
^/ ~ " ] " ~%

+z/
5.
China Foundry, Vol. 12, No. 3, May 2015, p. A3.
6.
Balasubramaniam, Ramamurthy, Story of the Delhi

Iron Pillar, Foundation Books, 2005.
z/ %* %

|^/
`/ % % +
England, 2013.
9.
Visit by author to Kelham Industrial Museum,

% + |^/
10. Foundry Trade Journal International, England, Vol.

|`_/z
//
||/ *~0
^
/`/
|/ @X* %%|^/
13. Foundry Trade Journal International, England, Vol.
|`/_|
/||^/
NCTS News
Case Study
Quantity Up but Quality went Down

Problem
Continuous improvement projects, initiated through
KAIZEN activities, hit upon an idea to increase ladle
capacity as a means of improving productivity in mouldpouring. Ductile iron pouring on automated moulding
line showed intended results in the number of moulds
made every day, but without substantial increase in the
quantity of good castings delivered to the customer.
%%%%% +
% +
pouring-productivity.
The Changed Process

The incremental volume in liquid metal per ladle
afforded 3 additional moulds to be poured over the
previous practice of 7 moulds per ladle. There were no
delay and the moulding line had an uninterrupted run.
$%%
+ %
the last mould poured and was therefore considered as
a compliant to quality system protocols.
There was a rise in pinhole defects (seen upon machining)
and deterioration in nodule shape in standard test
coupons from last moulds. One corrective step was taken
to increase residual magnesium to a higher band width
that took care of nodularity issue but pinhole tendency
persisted.
What went Wrong?

When the capacity of the ladle was enhanced, the
diameter as well as the height increased. Increased
diameter exposed more of the metal to radiation heat

loss and the three extra moulds poured accounted for
additional heat loss through conduction as well. In a
validated gating system, such substantial losses in metal
temperatures are unwelcome and ductile iron is prone to
%
/
Measurement of temperature, when the tenth mould was
poured with the bigger ladle, indicated a drop of 100C
compared to the temperature at the seventh mould from
the smaller ladle.
Problem Solving
Clearly the corrective action was to eliminate this
additional drop in temperature and ensure that the
three extra moulds poured were well within previously
established band width.
Solution
$% % + %
following improvements were incorporated:
z
Provision of a thin layer of ceramic blanket between

the steel shell and the refractory lining, to minimise
conducted heat loss
Light weight insulating cover on the ladle to contain

radiation heat loss
Remarkably, the fade of magnesium too came down and

it was then possible to operate with original parameters
for residual magnesium for achieving required nodularity.
61
IIF IN MEDIA
62
IIF in Media
63
IIF in Media
64
W.e.f. July 2015
NATIONAL CENTRE for TECHNICAL SERVICES

104, Sharmad Residency, Sheelavihar Colony, Off Karve Road, Pune - 411038 (INDIA)
Tel. : +9120 2543 7374 / 2542 2902 z E-mail : iifncts@iifncts.org
PRICE LIST
CDs/DVDs
Sl.
No.
Product
Description
Price (`)
1.
Set of Two DVD

(Part 1 to 3 & Part 4 to 7)
Introduction to Casting Defects: Blow Holes, Shrinkage, Inclusions, Scab, Discontinuities,

Pinhole Porosity and others in Ferrous as well as Non-Ferrous Casting
3,900 Per set
2.
CD - 101
Melt Quality Control & Productivity in Foundry
700 each
3.
CD - 102
Efficient Cupola Operation & Productivity in Foundry
4.
CD - 103
Computer-based programme on Microstructures of Cast Iron
3,400 each
700 each
5.
CD - 104
Temperature Measurements & Instruments and Thermal Analysis Techniques
2,100 each
6.
DVD - 105
Green Sand Moulding Practices (alongwith Technical Booklet)
2,100 each
7.
DVD - 106
Interactive CD on Manufacturing Techniques & Heat Treatment of S. G. Iron
3,400 each
8.
DVD - 107
Efficient Aluminium Melting Practices (English/Hindi)
2,800 each
9.
CD - 108
Gravity Die-Casting Techniques for Aluminium Casting
3,400 each
3,400 each
10.
DVD -109
Shell Moulding Process
11.
DVD -110
Investment Casting Process Defect Control Instructor
4,000 each
12.
DVD -111
Divided Blast Cupola Process & Technology
2,600 each
13.
DVD 112
A Journey Through Cold Box Process
3,400 each
14.
DVD 113
Analysis of Defects in Aluminum Castings Compendium of Case Studies
3,400 each
15.
DVD 114
Aluminium High Pressure Die-Casting
3,400 each
16.
DVD 115
Inoculation of Cast Irons - Science and Practices
2,500 each
17.
DVD 116
Green Sand Moulding Technology Emphasis on Sand Control
2,000 each
Books
1.
Efficient Cupola Design and Operation
200 each
2.
Green Sand Preparation and Control Mr. A. R. Krishnamoorthy
500 each
3.
High Manganese Steel Casting
325 each
4.
Pattern Design Practical Guidelines
460 each
Green Sand Practices For Defect-Free Casting Mr. S. Subramanian
650 each
Technical Information Sheets

1.
NCTS INFO SHEETS

Full set of 120 Nos.
Details of Each sheet available on Website
2,800 per set
Terms and Conditions:

1. Above prices are inclusive of packing and forwarding charges for IIF Members & Technical Institutes. IIF members will get 20%
discount on list price on presenting membership number.
2. Material will be sent by courier on receipt of payment.
3. Please send at par cheque / D. D. in favour of The Institute OF Indian Foundrymen NCTS, payable at Pune.
4. The above prices are for India only.
Website : www.iifncts.org
65
66
67
68
69
70
71
72
73
74
Price Trend of Foundry Raw Materials

Ferro-Chrome, Ferro-Si / Pure Mg, Ferro-Mn, Steel Scrap, Pig Iron, LAM Coke, Al Ingot
US Cents/lb
FOB China Port
Ferro-Chrome
NOTE : Freight from China to India Port is about 60-80 USD PMT for container load.
USD/Tonne Ex Plant China
Ferro-Si / Pure Mg
USD/Tonne FOB China Port
Ferro-Mn
75
Price Trend of Foundry Raw Materials

MELTING STEEL SCRAP IN ` PER KG INCLUSIVE OF EXCISE
PIG IRON IN ` PER KG INCLUSIVE OF EXCISE
` / KG
LAM COKE
` / KG
PRICE OF AL INGOT
` / KG
76
IIF Annual Awards
Nominations are invited for
ANNUAL AWARDS
of The Institute of Indian Foundrymen
for the year 2015

Awards will be presented at the

January 29-31, 2016 z Coimbatore
to IIF members based on nominations received under various
categories. Unless otherwise stated, the period considered for
the Awards is 1st April, 2014 to 31st March, 2015
(Last date for receipt of Nominations is December 20, 2015)
LAKSHMAN RAO KIRLOSKAR AWARD
for Foundry of the Year

Sponsor: Kirloskar Oil Engines, Pune (open only to company members)
Criteria for Selection
(i)
Qualitative and quantitative improvement in the last 3 years and

various steps taken to increase production by adopting advanced
technology.
15 points
(ii)
Qualitative and quantitative improvement in the last 3 years and

various steps taken to increase productivity by reduction
of man-hours.
15 points
(iii) Energy savings effected with energy audit (enclose energy

audit report)
10 points
(iv) Waste reduction by effecting waste management

criteria value of savings
10 points
(v)
10 points
Innovative technology
(vi) New process controls introduced
10 points
(vii) Quality management for overall quality improvement
10 points
(viii) Safety management No. of accidents during the year
10 points
(ix) HRD promotion efforts
10 points
Total :
100 points
Nominations for this award should be accompanied by a

adequate explanatory notes covering each of the above criteria; b) At least 6
colour photographs showing excellence in various aspects of the foundry i.e. sand
conditioning, moulding/core making, melting, pouring, fettling, heat treatment viz plant
& equipment and foundry products.
77
IIF Annual Awards
Gargi Huttenes Albertus
Green Foundry of the year Award

Sponsor: Gargi Huttenes-Albertus Pvt
Ltd, Mumbai (open only to company
members)
Minimum Qualifying Criteria
The foundry should have consent to
operate from the State Pollution Control
Board.
Please enclose, copy of current consent
and copy of yearly or half-yearly
statement for the previous year as
submitted to the concerned authorities
i]
The foundry should have taken steps

to install Pollution Control Equipment
to improve the quality of air and
water.
Please submit the following:

a) List of equipment installed with
technical details and photographs
b) Methods adopted for record keeping
& reporting.
15 points
K. R. Santhanam Memorial Award

for Foundryman of the Year
ii] The
foundry
should
submit
waste
of greenery to foundry operational

10 points
a) Steps taken to reuse/recycle spent

foundry
materials/wastes
and/

accrued
5 points
vi] Evidence of commitment of top

management
to
environmental
protection
in
terms
of
an
environmental
policy
and
environmental management system.
the following
management:
details
b) Method of waste treatment and

disposal
5 points
c) Energy conservation activities
5 points
Total:
iv] Actions taken in eco-friendly

packaging of both incoming and
outgoing products.
10 points
v] Details with photographs of the area
inside and outside the foundry
building clearly indicating the actions
taken for developing greenery. Ratio
Criteria for the award will be contribution to:

Process Improvement
Material Substitution
Use of New Technology
Cost Reduction
Increase in Production
Increase in Productivity
Energy Savings
Quality Improvement. including

ix) HRD Promotion Efforts
10 points
10 points
10 points
10 points
15 points
15 points
10 points
10 points
10 points
Total: 100 points

78
15 points
iii] The policy and practice of the foundry

in obtaining Safety Data Sheets from
the supplier for each chemical used
in the foundry.
5 points
The nominee for Foundryman of the Year Award

should be a member, life member, fellow member
or employee of a company member and (a) should
be at least a Diploma-holder with a minimum of 10
years of experience related to the foundry industry or
employee of a company member (b) should have a
minimum of 15 years experience of which at least 5
years should be in the foundry industry.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
for
5 points
vii] Measures introduced to reduce/
prevent noise pollution. 10 points
viii] Foundry should submit healthcare
and welfare measures adopted for
personnel.
10 points
ix] Foundry should submit safety
measures that have been put in
place and training of personnel to
handle emergency measures in case

10 points
x] Use of alternate energy resource building, construction, transportation
etc.
10 points
Total: 100 points
Nominations for the

award
should
be
forwarded to IIF- HO
by the Company where
the person is currently
employed. Nominations
for
Foundryman of
the Year award should
be accompanied by

adequate explanatory
notes covering each
of the above criteria
and highlighting the
individual contribution
made by the nominee
under each of the
criteria.
Photographs
(optional)
may
be
submitted to substantiate the nomination for
the award.
IIF Annual Awards
IIF REGION OF THE YEAR AWARD
Awarded by IIF
company members, weightage will be as per Annual
Sales Turnover i.e. 2, 4, 7, 10. Weightage for others,
except student Members =1.
10 points max
The period for this award is 1st July, 2014 to 30th June, 2015.
Nominations should be sent by the Chairman or the Hon.
Secretary of the Region to IIF-HO
vi) Technical Activities
Criteria for the award

i)
a) Organised one Seminar/Workshop relating to the

Presidential theme
5 points
(a) For conducting Regional Council Meetings (1 point per

meeting) minimum 1 meeting per quarter
5 points max
b) Ensured Chapters under its jurisdiction have conducted

technical activities
5 points
(b) For conducting Regional Council Meeting at other than

! "
(1 bonus point per meeting)
5 points max
c) In-plant technical lecture or technical lecture organised

in educational institutions by Region or by Chapters
under its jurisdiction
5 points
Sub-total: 10 points max

ii) Annual Report and Annual Audited Accounts
a) Timely submission by the Region

5 points
vii)
Attendance at NC meetings by nominated members of

the Region (Chairman, Hon Secretary, other nominated
members) proportion of attendance
5 points
viii)
Technical services rendered for quality improvement,

energy savings, increased productivity, decreased
rejection etc. Please submit documentary evidence
5 points
b) Ensure timely submission by the Chapters under its

jurisdiction
10 points max
iii) Chapter Activities
a) Ensured that Chapters have conducted technical
meetings
5 points
b) Ensured that Chapters had held regular Chapter council
meetings
5 points
ix)
Each Region should promote public relations with the

Government Departments and also hold regular press
conferences bringing to light the problems faced by the
foundry industry, particularly relating to availability of
input materials, central levies like excise, customs duty
on capital goods, import of scrap, reduction of power
tariff etc.
5 points
c) Ensured that Chapters have submitted Monthly Activity

Reports in the regularly prescribed form for the month
within 7th of next month
5 points
Sub-total: 15 points
iv) National Foundry Day Celebration
a) On 17th August or within a week before or after 17th
August
6 points
x)

v) Membership Growth
Membership growth over the year in percentage will be
calculated giving due weightage to type of member. For
Submission of Technical Proceedings

Submission of Technical Proceedings of seminar
conducted by Region or by Chapters under its jurisdiction
at HO
5 points
b) Quality of National Foundry Day and Social Gettogether

2 points
c) Chief Guest for NFD must be a person of stature in
industry/Government
2 points
Service to foundry industry
xi)
Indian Foundry Congress

Participation
in
terms
of
delegates/technical
presentations/souvenir and mobilisation of other
resources, assistance provided to conduct the Congress
wherever it is held
5 points
Total: 100 points
The proposal for nomination should cover a brief write-up on each of the above points.
79
IIF Annual Awards
VISWAMITRA KAPUR MEMORIAL AWARD
for IIF Chapter of the Year

Sponsor: Gargi Industries, Mumbai The period for this
Award is 1st June, 2014 to 31st May, 2015
vi) CET/Technical Activities

a) Lectures arranged: point per lecture 4 points max
The Chairman or the Hon Secretary of the Chapter concerned

should send the nomination to IIF-HO with details of criteria as
stated below:
i)
a) Timely submission of Annual Audited Accounts to HO

10 points
b) Timely submission of Annual Report to HO
b) Lectures by outstation speakers within the Chapter or

arranged outside the Chapters jurisdiction: 1 point per
lecture
2 points max
5 points
# $% ''*

vernacular: 2 point per lecture
6 points max
d) Full day/two or more days seminar/workshop/clinic

ii)
6 points max
Timely receipt of Monthly Activity Reports (in prescribed

form supplied by the HO) by 7th of the following month
Each such report will earn 1/2 point
6 points max
e) Promoting CETs Modular Educational Programme

(Module I: Pre-Diploma, Module II: Diploma, Module III,
Post Diploma and Module IV: Examination): point per
student registered in CET education courses
iii) a) Chapter Council Meeting (1/2 point for each meeting

with a ceiling of one each month)
4 points max
b) Attending Regional Council meetings by Chapter
Chairman and Hon Secretary (1/2 point for each
meeting)
5 points max
12 points max
vii)
Activities in this area are expected to encourage improved working methods/processes leading to savings
through increased yields, lower rejection, cost reduction
etc. Service should be provided to at least two foundries

iv) Celebration of National Foundry Day
a) Celebration of NF Day on August 17th or within a week
before or after August 17th
6 points
b) Quality of NFD programme & social get-together 4
points (Chapters must present mementos to members
completing 25 years)
5 points
viii)
v) Works Visit
a) Each visit within the Chapters territory

2 points (max 6)
b) Each visit outside the Chapters territory
2 points (max 4)
Membership Growth
Membership growth over the year in percentage will be
calculated giving due weightage to type of member. For
company members, weightage will be as per Annual
Sales Turnover i.e. 2,4,7,10. Weightage for others,
except student members =1
10 points
Only one visit in each quarter will be considered
Technical Service rendered to Foundries
ix)
Formation of Student Groups

Formation of Student Group with at least 2 programmes
5 points
Total 100 points
Chairmen or Hon Secretaries of the Chapters should send

details with a brief write-up of each of the above criteria
MEMBERSHIP GROWTH AWARD FOR IIF CHAPTERS
Awarded by IIF
The period for this Award is 1st January 2015 to 31st December, 2015
Membership Growth over the year will be calculated in numbers giving due weightage to type
of member. For company members, weightage will be as per Annual Sales Turnover i.e. 2, 4,
7, 10. Weightage for others, except student members = 1 Award to be given in two categories:
Large and Small Chapters.
80
IIF Annual Awards
BEST TECHNICAL PAPER : OTHER THAN NON-FERROUS
AWARD Awarded by IIF

The best technical paper will be adjudged from the papers (other than non-ferrous) published in the
Indian Foundry Journal during the period, April 1st, 2014 to March 31st, 2015.
Award will be given in two categories: FERROUS and GENERAL
The Awards are intended to be a recognition for outstanding contribution. In the event of the Committee

recommend any award for the year. Reprints from IFC/ WFC/SEMINARS/CONFERENCES will not be
considered.
YOUNG FOUNDRYMAN OF THE YEAR AWARD
Awarded by IIF
Nominee for Young Foundryman of the Year Award shall be from Industries that
are members of IIF. He or she nominated for the Award should be:
+
' $
8 9 8

should have a minimum of 8 years of experience related to the foundry
industry.
b) The maximum age limit for the eligible candidate will be 40 years.
The criteria for the award will be for excellence in combination of the following:
a) Process/Quality Improvement
10 points
b) Material Substitution
10 points
c)
Use of New Technology
10 points
d) Cost Reduction
10 points
e) Increase in Production
10 points
f)
Energy Savings
10 points
g) Books/papers published (details of journals)
10 points
h) Exposure to Foreign Organisations
10 points
i)
Participation/Paper presentation in National and International
j)
SOLI COMMISSARIAT
BEST PAPER AWARD
(Silver Medal)
For the best Technical Paper presented at
the Congress.
If the paper has more than one author,
the author making the presentation will
be given the Award. Both content and
presentation will be taken into account
in deciding the award. Reprints from IFC/
Seminars
10 points
WFC/SEMINARS/CONFERENCES will not
Awards received, if any
10 points
be considered.
Total : 100 points
CASTING OF THE YEAR AWARD (SHOWCASE YOUR
COMPANYS CASTING CAPABILITY) Awarded by IIF

Eligibility
a) Participation is open to all Indian

foundries
b) Foundry/owner of foundry must be a
member of IIF
c) Casting may be of any metal, any
end-application, size/ weight produced
using any casting process.
The awards will be given in two categories:
1) Ferrous: Cast iron, SG iron or steel
casting
> ' ?@@K
> # 9?@@kg
2) Non-Ferrous: Aluminium or Copperbased

> ' ?@@K
> # 9?@@K
Criteria
Entries will be evaluated on the following
criteria:
> X
> Z 8
process
>
market
Terms
a) Application
should
be
accompanied with details of the casting
and photographs from three angles.
Judge(s) of the panel or their

representative may visit the foundry to
inspect the casting, if necessary.
b) If required, the casting will have to be
sent to the designated location at the
cost of the applicant. (The applicant has
to rebook the casting at his own cost).
c) Applications from small-scale units will
have to be accompanied by a copy of

d) Photographs received along with the
application may be used by IIF for
tradeshows, displays and for publication
in the Indian Foundry Journal.
81
IIF Annual Awards
EXPORT EXCELLENCE AWARD Awarded by IIF

Criteria
This award is categorised into large/
medium/small-scale industries
For the purpose of awards, the following

categories:
A] 1. Large-scale Foundries
All foundry units which are in
operation
and
whose
annual
production is 20,000 tonnes and
above.
2. Medium-scale Foundries
All foundries whose tonnage of
production is 10,000 - 20,000 tonnes
per annum.
3. Small-scale Foundries
All foundry units whose tonnage of
production is 2,500 - 10,000 tonnes
per annum.
B] Products
manufactured
by
the
Foundry should cover automobiles/
tractors/defence and other engineering
industries.
C] Eligibility Criteria
Nomination for any category
a) The minimum export turnover for a
large-scale foundry is Rs 100 crore and
above
b) For a medium-scale foundry it is Rs 25
crore to Rs 100 crore
c) For small-scale foundry it is Rs 1 crore
to Rs 25 crore
d) Of the three categories, all foundries
should provide data of export for a
period of 3 years, clearly indicating
the growth rate of exports on a year-
to-year basis 15-20% for largescale, medium-scale and small-scale

foundries in terms of total sales value
/ volume.
The following details should be provided
along with the nomination :
a) Tonnage and type of castings
produced. b)
Quality control for
participating in the export promotion/
exhibition.

d) Products exported in tonnage and
value.
e) Countries to which exports are made.
f) Nominations should be sent along with
either the published annual report/

evidence of annual production/export
performance.
JAYASWAL NECO QUALITY AWARD

Sponsor: Jayaswal Neco Industries
Ltd, Nagpur (for excellence in quality).
A] This award is being instituted from the
year 2009. The award will be given to
a foundry which achieves outstanding
quality performance during preceding
12 months.
B] The criteria for award consists of the
following considerations:
1) Quality Performance
2) P r oc es s
Ma n a g e me n t
I m pr ov em e n ts
3) Energy
Conservation
&
Management
4) Shop-Floor Practices
C] The application will be in two parts:
i) Reply
to
the
enclosed
questionnaire.
ii) A brief self-assessment report
highlighting the high points of
the various initiatives taken by
your organisation and the
results achieved. This report
should contain points not covered
by the questionnaire, if any.
Please do not repeat what is
already
addressed
in
the
questionnaire. Self-assessment
report should be restricted to 10
pages of A4 sheet including
graphs, photographs and other
supporting documents.
82
D] Guidelines
for
preparing
the
application
\ ^ _`{
\
`
\

data in the form of graphs, bar
charts substantiating claims made.
\
has received Awards for good
performance, enclose letters of
appreciation from customers.
Please
enclose
copies
and
photographs commemorating these
events, if any. These may be for
quality of product, service, delivery,
cost reduction, innovations in casting
design resulting in weight reductions, reduction of machining times,
ease of handling etc.
The following required information
is applicable to one manufacturing
plant and therefore data pertaining
to that plant only must be submitted.
\ |'
application is sent
\

\ |' }
the company is part of a corporate
group)
\ |'~ 9
corporate group

\ |'the chief executive (site)

- Mobile number, E-mail
\ |' ~ 9
- Designation, fax, phone, mobile
number, e-mail
\
9
\ '
\ % 9 }@?`?

Rs. Cr.)
\ '' '
commercial production
\ %|'
\ _$_''
\ '

\ | }
0.0 Company Outline

Please provide a brief write-up covering
the following points:
0.1
History and background of the
organisation
@ !

0.3
Whether joint stock company,
partnership, family-owned, owner/
manager type
0.4
Major
achievements
and
milestones in the life of the
company
0.5
Type of foundry: Jobbing/captive
0.6
Alloys
and
alloy
families/
technology used
IIF Annual Awards

0.7
@
1.0
1.1.
1.1.1
Customer^
'
Quality Performance:25 points
Customer Satisfaction
Does the organisation have
a formal system for capturing
''
1.1.2 Is a customer complaint analysis
done customer-wise, processwise viz defects as-cast, during
machining,
delivery-related,

^
explain the system
1.1.3 Please provide data on the
rejection values and trends for the
above break-up
1.1.4 What is the system you have
in place for resolving customer
'
What are the proactive steps to
a)
Reduce customer complaints
b)
Prevent recurrence of complaints
c)
Horizontal
deployment
of
corrective & preventive actions,
provide case histories if any to
support the above
1.2. In-house Rejection
1.2.1 Give detailed data & break-up
of in-house rejection viz melting,
moulding, coremaking, fettling

trends over the months and years
wherever possible.
1.2.2 Explain the efforts to reduce inhouse rejection
1.3
Cost of Quality
1.3.1 Does your organisation measure,
monitor overall cost of quality,
8

2.0
Evaluation by Customers:
15 points
2.1
List out the awards, citations
received
from
customers
starting from current year going
backwards
2.2
Do your customers rate your
}8 " "
9
so, please attach copies of the
reports
2.3
Please provide summary of audit

conducted by your customers.
Please
provide
copies
of
3.0
3.1
3.1.1
3.1.2
3.1.3
3.2
3.3
3.3.1
3.3.2
3.4
3.4.1
3.4.2
3.4.3
4.0
improvement actions initiated by

you and customers observations
on these
Process
Management
/
Improvements:
20 points
Vendor Management
Do you have a criteria for vendor

Does your organisation have internal standards/acceptance criteria
for raw materials & other supplies
coming from unorganised sector
viz sand, bentonite and other
'
Please provide copies of a few
specimens and list of all the items
for which these systems are in
use
Do you recognise performance of
good vendors by way of awards,
vendor meets, support to vendors
by way of training, technical
"9

Low-Cost Automation
Give examples of low-cost
automation.
Process Improvements
Improvement in Casting Design
Give examples of improvements
made, which have resulted in
'
Improvements in Manufacturing
Processes
Give examples which have
resulted in reduction of rejection
both in-house and at customers
end during machining.
Environment
Management
Processes
Does the organisation have
9
List some steps and achievements
by the company
What are systems of waste sand

9
'
Provide a list of pollution control
equipment and Equipment for
recycling consumables
Energy Management:15 points
Please answer yes or no for each
of the questions listed below and
give a brief write-up covering all
aspects and whatever data you
can share.
4.1
4.2
4.3
4.4
4.5
4.6
5.0
5.1
5.2
5.3
6.0
6.1
6.2
6.3
Does your organisation have a

long-term energy management /
conservation plan covering for eg
various energy inputs used - coke/
furnace oil/electrical energy from
grid, self-generation/renewable

Have you laid down energy
consumption norms operationwise say for melting, heat
treatment,
process
heat,
'

Do you have norms units per
heat/batch, per shift, per tonne of
' '
Does the company have metrics
to monitor energy consumption at
various stages as well as overall
units per tonne of despatch
and energy consumption as a

Does the company analyse the
electrical energy bill in terms of
unit consumption, additional levy
for maximum demand, low power

Have you got energy audit
conducted for your organisation
and undertaken improvement

Shop-Floor Practices: 5 points
Does your organisation follow 5S

What are the methods adopted to
9
Illustrate
with
photographs
the
effectiveness
of
the
implementation.
Employee Involvement:
10 points
Do you have a suggestion
' '
suggestions per employee per

Do you have small group activities
'9' *

Do you have a safety committee
99 K '
the trend of accidents, near'

steps do you take for employee
9
Total : 100 points
83
IIF Annual Awards
CHANDRAN MENON MEMORIAL AWARD FOR APPLIED
RESEARCH & INNOVATIVE TECHNOLOGY

Sponsor: Menon &
Kolhapur to encourage
actively pursue applied
9
metalcasting.
Menon Ltd,
foundrymen to
research and

Criteria for selection

The nominee for the award shall be
a scientist / technologist / practising
foundryman and member of IIF.
3.
1. Should have at least 5 years experi

$

research institution /engineering
college/polytechnic with foundry
technology as part of mechanical/ 4.
metallurgical engineering.
2.
Should have made outstanding

contribution
towards
the
advancement of metal casting Nomination should be supported by:

or technology based on original a) Report of the work carried out by
K

9'
the nominee during the 5 years
new materials, processes, quality
preceding the nomination with focus
standards, energy savings including
on foundry materials, processes
8 ' " ' *
and equipment.
technological excellence.
b) Summary of achievements for the
eligibility of the award.
The new developments should have
9
" ' c) At least 3 references of the people
the immediate user requirements
who know the nominee and his
leading to cost savings, improved
work.
performance,
commercial
d) A list of papers along with prints
exploitability.
published by the nominee.
Should have published papers e) Any other information relating to
in foundry journals/presented in
pending patents, commercial use of
foundry
congresses/workshops/
technology developed in support of
seminars-National/International.
nomination.
FOUNDRY KAIZEN AWARD
(Open to IIF Company Members only)

M
'' { '
competitive in the global scenario. IIF would like to recognise
{ ''

%
excellent work done inside foundries is otherwise hidden, if not
given a good exposure.
Area for Kaizen:
Slide 3-4 Kaizen theme / problem description / problem

X*
'$
Slide 5-7 Data collection and root cause analysis

the problem.
|' '

{ ''
Mention the real root cause of the problem
the areas of:
Slide 8-9 Kaizen idea and countermeasure / solution
Foundry operations, energy savings, yield improvement,
The idea mooted by the employee to be mentioned
logistics loss improvement, management practices, rework
The action plan attempted to eliminate the root cause.
minimisation, downtime minimisation, changeover time Slide 10-11 Countermeasure implementation and
' ' " '9' "
'9' "
sustenance
use of new materials to enhance performance of cast products,
Provide appropriate photographs to show the before
product development initiatives in terms of weight reduction
and after status. Since when have the
and increased strength.
countermeasures been implemented.
Guidelines:
Nominations have to be submitted as a power point format as
follows:
!
"

_ " {

| { 9

implemented.
Slide 2
Kaizen Team
Names of the key persons involved
84
Slide 12 Horizontal deployment

{
and if so replicated, the number of places it was

Slide 13-14 #
$
Indicate the qualitative and quantitative savings that

{

Slide 15 Kaizen sheet

No. of slides should not be more than 15 in any
case.
IIF Annual Awards

Evaluation Criteria:
Nominations will be evaluated on the basis of:
1. Clarity of the problem and its severity
10 points
2. Root cause analysis
10 points
3. Solution
10 points
4. Time taken to implement
10 points
5. Savings monetary/time/process/qualitative
20 points
6. Implementation success and sustenance
20 points
7. Horizontal deployment
10 points
8. Team / Individual contribution
10 points
Total
100 points
Rules:
1. Only company members can send their nomination.
2. Each company member can send only one nomination
3. All nominations must be as per the prescribed guidelines
only.
4. Nominations should be submitted in soft copy as well as
hard copy.
' *

+
old.
6. Nominations should include the enclosed Foundry
; <> ?

*

can also be downloaded from www.indianfoundry.org
7. IIF may depute a team to visit the foundry to evaluate the
nomination.
5S EXCELLENCE AWARD
(Open to IIF Company Members Only)

4. Organisation structure for 5S
Objective
5 points
Many Indian foundries are successfully adopting 5S practices. 5. 5S vision statement and objectives
The fully implemented 5S practices result in increased morale, 6. Waste disposal procedures and efforts to

" " 8

follow sound environmental practices

' 'K '

7. Implementation steps adopted
competitive in the market place.
%

To motivate and recognise the member companies, IIF has initiout of 5S initiatives
ated the 5S Excellence Award.
9. Sustenance plan
Categories of Award
Total :
The 5S Excellence Award, in the form of a trophy, will be
awarded to the winner company members in three categories
Rules:
\'

20 points
20 points
20 points
10 Points
100 points
1. Interested company members should send a

assessment form along with supporting documents.
\
'

self
2. Nominations should be submitted in soft copy as well as

hard copy.
\#

Evaluation Criteria
Nominations will be evaluated on the basis of:
1. Stages completed
5 points
2. Photographs of before and after 5S

(min. 5 areas)
3. 5S manual, if any
5 points
10 points
5 points
3. Companies falling under MSME category must submit their

4. Please send the enclosed Self Assessment Sheet duly

5. IIF may depute a team to visit the foundry to evaluate the
nomination.
All nominations should be submitted in four sets,

two hard copies and two soft copies in CD/DVD, addressed to:
Executive Director

!" "

"K% ^"K@@?@
%@````$\~@````?\'

85
86
0HPEHU([FOXVLYH
Auto Component
Industry is shining
example of the vision,
adaptation and
overwhelming cost
competitiveness
V. Narasimhan
BRAKES INDIA LIMITED

FOUNDRY DIVISION
rakes India established its Foundry Division in 1981 at Sholingur, 120 km from Chennai.
~$%+% %
grown to the level of 140,000 MT in 2014-15. Brakes India Ltd. has a Permanent Mould
facility, seven Disamatic moulding lines and a Knkel Wagner High Pressure Horizontal
Moulding line with state-of-the-art equipment and in-house Pattern and Die Shop with
CAD / CAM / CAE facility.
Brakes India Foundry specialises in the manufacture of Ductile Iron castings in the Sand
Foundries. Exports constitute 50 per cent of the turnover, the thrust destinations being
Germany, France, U.K. Sweden, Japan, South Africa and U.S.A. The product-mix focuses
on safety critical parts such as Brake Calipers, Engine Components, Steering Knuckles,
Torque Plates, Turbo Charger components, Powertrain components and Compressor parts.
~* + *X$|_^_#
%~*X|^| %
~X|`| ~|| /
IIF: How do you sketch the countrys Foundry

scenario?
V. Narasimhan : In the new normal our competitive
advantages of the past will not be relevant. For example:
Cheap labour. Productivity has to be increased manifold
with adequate automation. Quality will be the key factor.
Adaptability to the changing circumstances is very
important. Consolidation of the industry will be more
pronounced.
IIF: What are the strengths and weaknesses of Indias
Foundry sector?
VN : Strengths: Committed workforce, Demography,
Availability of educational and training facilities,
Innovation in our DNA, Cultural advantages and our
history in Foundry Technology.

Weaknesses: Very low productivity, lack of economy
of scale with fragmentation of the industry, less
employability of the youngsters, failure to modernise
ahead of time.
IIF: To what extent Indian castings are acceptable in
the global market?
VN : $% +% %
expectations on the Quality and Delivery front. However,
with the advent of modern, mechanised foundries, the
image is changing especially due to the efforts put in
by the Foundry Industry in the Automotive and Auto
Component Sectors.
87
Member Exclusive
IIF: How quality conscious are Indian foundrymen?
VN : Indian Foundrymen overall are yet to realise that
quality is the single most important criterion for the
success and the future of foundry industry. Quality
+
%
is instilling a sense of purpose into the minds of
Foundrymen. Entry barriers specially in the areas of
exports are blessing in disguise.
IIF : Brakes Indias role in the auto component sector

in India and abroad.
IIF: Mention the major internal as well as external

challenges faced by the foundries in India and what
are the ways out?
VN : Internal challenges: Cascading nature of taxes and
duty structure, prevalence of widespread corruption and
%
% + %
make up for the lost time are the internal challenges.
External challenges are our lack of competitiveness,
inability to qualify through entry barriers, to improve
communication and establish a sense of reliability and
+ % /
IIF: What is the present status of the countrys auto
component industry?
VN : Auto component industry is shining example
of the vision, adaptation and overwhelming cost
competitiveness coupled with high level of Quality. The
rate of growth on the export front bears testimony to
the above.
IIF : According to you, what should be the relationship
among castings buyers and suppliers?
VN : $%%
% +
supplier basis which it is not today. It is based on so many
/ $ +
dependence must be established. It should be clear that
nobody is doing anybody a favour, simply somebody is
providing a service and somebody is compensating for
it.
88
VN : Brakes Indias Vision was to export at least 50% of

the turnover to the West and achieve benchmark Quality.
That we have found acceptance with BMW, Daimler and
/ X %
on the quality front is something that we are proud of,
which has facilitated the increase in our turnover by 25
times in 20 years.
IIF: Achievements and Awards won by Brakes India.
VN : Deming Prize for TQM, Special Award for the
Practice of TPM besides First Category and Consistency
Award earlier, Best Supplier Awards from International
Customers; establishing a name for ourselves all over
the world.
IIF: Environmental consciousness of the Company
and policy adopted in this respect.
VN : We recognise the society as an important stakeholder
/X%%
front especially in the area of Green Manufacturing
needs to be mentioned.
IIF : HR and Health & Safety Policy of the Company.
VN : Human Resource is very important for Brakes
India and it is the reason for the progress made by
the Foundry. Futuristic and innovative HR policies have
been the key. Foundry industry is supposed to be
+ %

in substantially improving the quality of work-life in
the Foundry by imaginative approach going beyond
occupational health and safety.
IIF : Future roadmap of Brakes India.
VN : We will continue to grow organically. We have
already set up 3 manufacturing facilities and the
endeavour will be to work towards new products, new
markets and new territories.
89
90
Examination on Foundry Technology WINTER (DEC. 2015)

Production / Manufacturing etc. where Foundry is a
1. Module-I
Eligibility : Class 10 passed of 10 + 2 schemes or
&&+/
Registration : Eligible candidates are to register
% ~ *+/
Once registered, student will receive Syllabus and Study
Materials of all the 10 subjects. Students willing to register
have to send a DD of `2,000/- drawn in favour of The
Institute of Indian Foundrymen payable at Kolkata.
Examination Fee : ` 100/- for each paper or `900/- for
TEN papers at a time.
Student Question Bank : Last years question papers are
available against payment of `50/- per set (inclusive of
mailing charges).
2. Module-II
subject, are not required to have any practical

/
%%

%

#

%%& %=

/=
approved foundry or related organisation before he/

% % % + + %

Institute.
Syllabus
: Cost of Syllabus along with Registration
Form is ` 100/-. Candidates need to send the amount

by a Demand Draft in favour of The Institute of Indian
Foundrymen CET payable at Kolkata.
Eligibility:
Study Materials : For Study Materials, please contact CET
Class 10 Passed of 10 +2 in Science or its equivalent

with Physics, Chemistry and Mathematics.
at IIF Center, Kolkata
ITI Passed or Module -I of IIF passed.
% ~ * /
Practical Experience: |X

in foundry or allied industry before/after successful
completion of the course. However, candidates with less
% | X =

%% & %

|X

=

~ **+/
Syllabus: Cost of Syllabus along with Registration
Form is ` 100/-. Candidates need to send the amount
by a Demand Draft in favour of The Institute of Indian
Foundrymen payable at Kolkata.
% ~ ** /
this purpose, a candidate should submit Registration
/ + %] ` 800/- to
get his/her Registration Number.
Examination Fee: `500/- for each paper or Rs.2000/- for
appearing in FIVE papers under one Section at a time.
3. Module-IV

10+2 in Science or its

this purpose, a candidate should submit Registration
+ %] `1000/to get his/her Registration Numbers.
Examination Fee : `600/- for each paper or `2500/- for
appearing in FIVE papers under one Section at a time.
Note : All Demand Drafts are to be drawn in favour of
The Institute of Indian Foundrymen, CET payable at
Kolkata in advance as per requirement.
Schedule of Examinations : 7 to 11 December, 2015
Last Years Question Papers : Available on Payment of
` 50/- per year (inclusive of mailing charges).
All Communications to be Addressed to :

Centre for Education and Training
IIF CENTER, 335 Rajdanga Main Road
East Kolkata Township P.O.,
Kolkata - 700 107
Ph : (033) 2442-4489 / 7385, (Direct) 40630074
E-mail : cet@indianfoundry.org / cet1@indianfoundry.org
Website : http://www.indianfoundry.org
equivalent with Physics, Chemistry and Mathematics.

Practical Experience :
$
/
(b) Engineering Graduates in Metallurgy / Mechanical /
Candidates appearing in
Module-I Examination
are eligible to write in Vernacular.
91
EXAMINATION PROGRAMME FOR WINTER 2015 (7 to 11 DECEMBER, 2015)

Module-IV SECTION : A
Day/Date
10:00 am to 1:00 pm
2:00 pm to 5:00 pm
Monday/07.12.2015
Matematics (A-1)
Introduction to Computing (A-2)
Tuesday/08.12.2015
Physics (A3)
Chemistry (A4)
Wednesday/09.12.2015
Mechanics of Solids and Fluids (A5)
Introduction to Materials (A6)
Thursday/10.12.2015
Workshop Technology for Foundrymen (A7)
`
Friday/11.12.2015
English for Technical Communication (A9)
Engineering Drawing (A-10)
Day/Date
10:00 am to 1:00 pm
2:00 pm to 5:00 pm
Monday/07.12.2015
$% |

~% /]
Tuesday/08.12.2015
$ ~
0 ^
~
~
Thursday/10.12.2015
+z
$%`
Friday/11.12.2015
*_ % %
Elective II any one of the following each group
a) Technology of Iron Casting
a) Welding Technology
SECTION : B
b) Steel Foundry Technology
*
c) Non-Ferrous Foundry Technology
~%\
%~/
Module II PART:A
Day/Date
10:00 am to 1:00 pm
2:00 pm to 5:00 pm
Monday/07.12.2015
Matematics (A-1)
Engg. Physics (A2)
Tuesday/08.12.2015
Applied Chemistry (A3)
English for Communication (A4)
Engg. Drawing (A5)
Introduction to Computing (A6)
Thursday/10.12.2015
$%]z
Introduction to Engg. Materials (A8)
Friday/11.12.2015
~%/_
PART : B
Day/Date
10:00 am to 1:00 pm
2:00 pm to 5:00 pm
Monday/07.12.2015
$%|
~ ~
Tuesday/08.12.2015
~$%

^
$ /0 &

$*

Thursday/10.12.2015
* ~z
Elective -I (any one of the following)

*
/X
% **

~% ]***
Friday/11.12.2015
Elective-II (any one of the following)

a) Technology of Cast iron (EIV)
b) Technology of Cast Steel (EV)
$% ~*
Module-I
Day/Date
10:00 am to 1.00 pm
2:00 pm to 5:00 pm
Monday/07.12.2015
English (P1)
Physics (P2)
Tuesday/08.12.2015
Chemistry (P3)
Mathematics (P4)
Engineering Drawing (P5)
Workshop Technology (P6)
Thursday/10.12.2015
Pattern Construction (P7)
Moulding Technology (P8)
Friday/11.12.2015
Melting Tech./Cupola Melting Emission Control (P9)
Cast Metal Technology (P10)
92
93

6/1, GIDC Estate, POR-391 243, Dist. Vadodara,
Tel. : 2830132, 2830636, Fax : 2830131, Website : www.shreesponge.com
E-mail : ankit.mehta@shreesponge.com, marketing@shreesponge.com, shreesponge@yahoo.com
Mobile : +91 98240 47078, + 91 90999 69217
94
NEWS FROM IIF REGIONS & CHAPTERS
News from IIF

Regions & Chapters
Eastern Region
Howrah Chapter/ER
Workshop on Niryat Bandhu &
Export Risk Management
$%X + % ]"
$ @ ~
% *X 0 %

%
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Howrah Chapter
The Embraceable
Moulding Practices

%

%

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% /
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% **%%

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95
~/ & + % %
%

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0

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their sizes to resort to
%&

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Kolkata Chapter
Workshop on Casting Design &
Simulation
%
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X/|
96
Northern Region
NR/Delhi Chapter
Chapter Day Celebration
**]%%
%0
] **]%%

/|/
* % % %
~/ % * % \ /
%
X
/
$%

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Southern Region
Coimbatore Chapter
IIF Student Chapter Meeting in
Coimbatore
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97
Chennai Chapter
Energy Conservation Through
Industrial Empowerment
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Recent Trends in Investment

Casting
and
3D
Printed
Prototypes
* %
~/ % %
* /

% /

% &
/$%

% % %
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/ % %

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Non-Destructive
of Ferrous and
Castings
Bangalore Chapter
% **

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Non-Ferrous
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99
Western Region
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IIF Student Forum Inaugurated
Foundries A New Approach $

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Gating System for Non-Ferrous

Casting
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Surveying of Heat Treatment
Furnaces
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102
103
104
105
106
CET NEWS
Inplant Training Workshop for Workers and Supervisors
roduction of quality castings complying to

+

standards using latest technologies requires
use of modern sophisticated equipments. Only
skilled and educated workforce can run such
state-of-the-art machines. Migration to higher
technologies call for better quality of manpower.
The Centre for Education & Training (CET), an IIF
centre of excellence organises in-plant training
workshops regularly where domain experts
from industry as well as academies deliberate
on various foundry operations and give practical tips to
% % % %

face in their day-to-day activities.
These in-plant workshops have already become popular
% / +

%%
+ %

their workers/supervisors, are sending repeated requests
for holding such workshops in their plants.
CET organised the following 7 days in-plant training
workshops at Britannia Engineering Works:
Topic
Date
Observation of Casting Defects and June 10, 2015

Discussion/Interaction
Sand Quality and Testing
June 17, 2015
Mould Making both Green Sand & Dry June 24, 2015
Sand
Core Making (CO2 and Resin Bonded)
July 1, 2015
Melting of Cast Iron in Induction Furnace
July 8, 2015
Remedial Actions for Reduction in

Casting Defects
July 15, 2015
Test
July 22, 2015
On June 10, 2015, Dr. N. P. Sinha, Chairman; Mr. Gautam
Banerjee, Course Coordinator and Mr. G. Mukherjee,

Director, CET had been at Britannia Engineering Works
where they observed the production process and
castings with different types of defects. Some of their
observations were as under:
Castings at Britannia are made of IS:210, Grade FG 200
with compositon:
Carbon-3.203.50%, silicon-1.82.3%, manganese- 0.600.80% sulphur-0.60-0.15% and phosphorus-0.2% (max.).
Castings are with uniform wall section thickness,
pressure-tight against gases and liquid. Leakage in
castings was a serious issue.
Shrinkage, internal porosity, hot tears and other defects
are likely to occur where thicker sections meet thinner
sections. In case of water-tight castings, slight sponginess
at heavy section normally does not result in leakage;
however, gas-tight castings cannot afford the slightest
defect.
The expert faculties noted that unsoundness of castings
at Britannia was due to combination of one or more of
the following factors:
Expansion in soft moulds, unsuitable chemical
composition,
underfeeding,
incorrect
pouring
temperature and degree of nucleation, higher rate of
phosphorus, high pouring temperature.
Workshop on Sand Quality & Testing

Mr. S. K. Sasmal made his in-depth presentation
on the above topic at the companys conference
hall of Britannia Engg. Works on June 17, 2015.
$%
+
types of sand like zircon sand, chromite sand
etc. He explained their basic properties,
advantages and disadvantages. He also covered
different sand testing methods and described
the procedures for checking suitability of sand
for mould making.
The presentation was made in an interactive manner
when the speaker observed that the foundry could

easily switch over to green sand moulding from dry sand
moulding. This would lead to lesser rejection rate.
107
CET NEWS
Workshop on Mould Making, Both Green Sand & Dry Sand

This in-plant workshop was organised by
CET at Britannia Engineering Works on
June 24, 2015. Castings produced in green
sand mould following the suggestions that
had been made at the earlier workshop
held on June 17, 2015 were shown to the
faculty Mr. G. Banerjee and CET Director
Mr. G. Mukherjee. These castings were
defect-free.
Considering the existing mouldmaking processes, the
faculty dwelt upon Hand Moulding: Floor with only cope
% %

with skeleton pattern and pit moulding.
Thereafter, Mr. Banerjee discussed different sand
moulding systems like Green sand moulding; Dry sand
moulding; Dry sand core moulding; No-bake moulding
both two-part and three-part; Sodium silicate family
including sodium silicate-ester, sodium silicate di /%
Investment casting; Vacuum moulding.
While throwing light on machine moulding, Mr. Banerjee
explained the operations of Jolt rollover machines,

Simultaneous jolt-squeeze machines, Flaskless moulding
and High pressure moulding lines.
Further, Mr. Banerjee discussed various steps of designing
moulds and cores. According to him, the technocrat
has to study the casting design and make necessary
corrections, if required. He referred to the rules to be
followed while choosing the position of casting in the
mould. He then discussed the points to be considered
while working out mould joint.
Mr. Banerjee also dwelt on Jolt type moulding and Jolt
squeeze type moulding machines. He touched upon
High pressure moulding line.
CET-Shimoga
Seminar on Upgrade Your Foundry
ET and Shimoga Chapter of IIF in

association with DISA India Ltd.
organised this seminar on Oct. 17, 2015 at
Country Club, Shimoga.
Mr. M. N. Suresh, Chairman, IIF-Shimoga
Chapter while delivering welcome address
called for supplying modern foundry
equipments at affordable cost so that
foundries with increased competitiveness
can access international markets.
Mr. Vijay Naidu, Managing Director of DISA India Ltd.
in his presentation outlined the global casting industry
scenario. He then explained vertical and horizontal
processes of producing castings. He described vertical
+ % % %

respect of productivity enhancement leading to cost
reduction. However, for complicated cores, the speaker
said, horizontal process is preferable. He referred
to DISAs offer of complete end-to-end solution for
moulding line, sand plant, sand conveying system and
108
shotblasting system.
Mr. Satyanarayana V.N., Vice President, DISA India Ltd.
made his presentation on Arpa moulding machine of
different sizes with the average productivity ranging from
30 to 60 moulds/hr. He also dwelt on typical Disamatic
foundry and Disamatic 030 that uses top-end vertical
technology affordable to Indian foundries.
The third speaker detailed on shotblasting machines.
$%
+ & %
participants.
Mr. G.V. Kiran Kumar, Hon. Secretary, IIF-Shimoga Chapter
offered vote of thanks.
109
110
111
112
113
114
NEWS & TRENDS

Foundry
Caldeaz to Partner
with Kreon of France
Maus to Acquire
Savelli and Fritz
Hansberg of Italy
Maus, a leader in automatic grinding
and vertical turning, would acquire
both Savelli s.p.a., a manufacturer
of moulding lines and sand plants
for green sand foundries and Fritz
Hansberg, a manufacturer of core
making equipment of Italy. The
new arrangement would provide
foundry automation and machining
equipment.
With the coremaking technology from
Fritz Hansberg and the moulding line
technology from Savelli, Maus would
complete its portfolio as a full global
solution provider for foundries. As
the foundry equipment industry is
concentrating, the groups presence
would further be strengthened in key
markets like Europe, USA and China
and position it as a reference point
for the industry.
In April 2015, Maus srl has also
entered into joint venture with
Palmer Manufacturing & Supply
Inc., a producer of no-bake foundry
equipment with a well-recognised
presence in the foundry industry in
USA, to consolidate and expand their
brand as well as sales network in
North America. In the joint venture
agreement, share of Maus and Palmer
is 70:30.
Caldeaz Manufacturing Technologies

of South Africa, a provider of 3D
engineering
solutions
through
products, services and software to a
vast range of manufacturers within
the disciplines of 3D scanning, 3D
measurement, reverse engineering,
and 3D printing, also known as
rapid prototyping, has formed a new
strategic partnership with Kreon
Technologies of France for the growth
of their 3D scanning capabilities.
Kreon Technologies is a pioneer
in 3D non-contact measurement
technology providing complete noncontact measurement solutions for
quality control, reverse engineering,
surface
inspection
and
rapid
prototyping throughout the entire
design and manufacturing process
for industries like automotive,
aerospace, medical, dental, foundry
as well as general engineering. Their
technology can also be used for
heritage applications. Solutions of
the company help manufacturers to
reduce production times and bring
their products in the market faster
eliminating errors as well as increasing
productivity and quality. A range of
3D scanners are included in their
products which can be integrated on
3D CMMs, CNC machine tools and a
range of measuring arms.
non-contact measurement tracking

solution. A new version of its 7-axis
Ace measuring arm has also been
announced.
All laser scanners of Kreon
incorporate a unique, integrated
Renishaw touch probe capability so
that it can be used as a traditional
touch probe device or as a high-tech
laser scanner.
Kamtek to Open New

Aluminium Casting
Facility
Kamtek of USA, whose parent
company is Magna International
Inc. of Canada, is planning to
invest $530 million for expansion
of
its
Birmingham,
Alabama
operation including opening of a
new aluminium casting facility for
meeting the demand of automakers
for lighter parts. As part of their latest
expansion programme, the company
would invest $80 million in the new
148,000 sq. feet aluminium casting
facility and $450 million for expansion
of their existing operation in Valley
East Industrial Park, Birmingham at
more than 200,000 sq. feet.
The new aluminium casting facility

and the expansion programme would
demonstrate their commitment
to customers including MercedesBenz and Volkswagen. Their current
Kreon recently launched AirTrack operation in Jefferson County
robot solution, a touch-and-scan represents investment of $473
robotic inspection cell powered by million. Kamtek acquired Ogihara
Metrolog X4 i-Robot software, which and has re-invested heavily in the
% + operation over the years.
115
Automobile
BMW to Invest More

in India
of petrol and diesel for meeting

+ /
Fuels meeting Euro IV or Bharat
*
+
supplied throughout India by April
2017 and BS-V or Euro-V grade fuel
by April 1, 2020. BS-IV fuels contain
50 parts per million (ppm) sulphur
whereas BS-V and BS-VI grade fuel
contain 10 ppm sulphur.
At present, BS-IV auto fuels are

being supplied in whole of northern
BMW is planning to increase their India covering J&K, Punjab, Haryana,
investment in India to improve Himachal Pradesh, Uttarakhand,
localisation of their products because Delhi, parts of Rajasthan and Western

+/ UP. Rest of the country has BS-III
The company has already invested grade fuel. Goa, Kerala, Karnataka,
Rs.490 crore in India apart from Telangana, Odisha, Union Territories
0/^+/
of Daman and Diu, Dadra and Nagar
According to the companys Make- Haveli, Anadaman and Nicobar
in-India strategy, level of localisation would get BS-IV fuel from 1st April
would be increased from 50% at 2016 and the rest of India would
present, stepping up from assembly receive supply from 1st April, 2017.

/ $% To reduce pollution and greenhouse
are focusing on premium products gas emissions, use of gas as
in India. Their Chennai plant has a transport fuel (CNG) in cities is being
capacity of production of 13,000 encouraged. Feasibility studies are
units.
also going on for using LNG as a
A volume of 30,000 to 40,000 units transportation fuel for inter-city
& % movement of heavy vehicles.
production capacity and they are
prepared for the same. Indian
condition is more favourable to them
than that of China, Brazil and Russia.
Long-term investment planning is
also there. In future, they may start
exporting from India.
Hinduja to Invest $1
India to Introduce
Billion in Africa
Euro VI Emission Hinduja Group has committed to
invest $1 billion in Africa in the next
Norm by 2020
+
India is planning to shift to Eurooil, chemical, trading, infrastructure
VI emission compliant petrol and
etc. Investment will take place
diesel by 2020, to cut carbon
in a phased manner to suit the
emission. A revised Auto Fuel Policy
development of the country across
% +%%
three different time horizons short,
introduction of BS-VI fuels by 2020.
mid and long-term.
X + &
With this Go Africa strategy, the
Rs.80,000 crore in upgrading quality

= %

%
Leyland, which is the second largest

bus and truck maker in India, would
increase bus as well as truck exports
to the continent from the present
12,000 units to 25,000 units over the
next three years. Exports contribute
15% to the turnover at present
which might increase to 33% over
% % / +
part of this growth is expected to
come from Africa. Hinduja Group is
present across various countries in
sectors like automobiles, banking,
infrastructure, energy, technology
etc.
Ford to Design in
India
Ford is looking at designing a new
% * / * % +
automobile major to design a vehicle
in the country. The company would
design the new Fiesta at their research
and development (R & D) as well as
engineering facilities in Chennai,
which is expected to be launched in
2017 to cater to the domestic as well
as export markets.
The company would enhance
investment in India for capacity
expansion at their Chennai plant as
well as establishing a new and global
engineering and technology centre.
Global Business Service operations in
the areas of IT, product engineering,
data analytics and manufacturing
would also be there.
To use India as their design centre
would surely enhance ranking of India
in global automobile manufacturing.
With two manufacturing facilities
in India at Sanand and Chennai,
the company has already been
showcasing
Indian
automobile
manufacturing at a global scale with
exports of 60% of the vehicles.
116
Development and demonstration

of technologies for common use
by cluster of industries.
pig iron from India during JanuaryJune 2015 was Thailand at 1,51,181
tonnes, accounting for 39.2% of total
exports of pig iron from India. Taiwan
z Development and demonstration
was in the second place at 88,000
of technologies for Government tonnes sharing 22.8% followed by
%
Saudi Arabia at 35,296 tonnes with
projects.
9.2% share during January-June
Around 200 projects involving 2015.
Strengthening the interface among +
Govt. Policy
industry, R&D establishments and establishments, both in public and
academic Institutions has been private sectors, have so far been
proposed by the Department of supported by the Department
+ * 0% involving DSIRs share of Rs.100 crore
]*0 % + in total project cost of around Rs.250
crore. The projects cover products
commercialisation.
and processes in various industries
An +

Objectives
including mechanical engineering, Niryat Bandhu @ Your desktop in
earthmoving export-import business has recently
z Providing
catalytic
support metallurgy,
for
the
development
and machineries, industrial machinery been launched under the Niryat
demonstration of innovative etc. Details of eligibility criteria for Bandhu Scheme of the Directorate
need-based technologies for applicants as well as application General of Foreign Trade (DGFT).
increasing
competitiveness procedure are available in www.dsir. Objective of the Niryat Bandhu
Scheme is to reach out to new and
gov.in
among industries.
potential exporters to make them
z For
strengthening
the
able to get into international trade
Business & Trade
interface among industry, R&D
as well as boost exports from India.
establishments and academic
With the objective of Skill India in
Institutions.
view, DGFT has joined hands with
Research & Development
Technology
Development and
Demonstration
Program of DSIR

Programme for
Exports and Imports
Sector of Interest
z
For any sector, leading to

industrially useful applications.
Project Proposals
z
Technology development projects

should aim at development of
a new product or process with
attractive market potential.
Nature of Proposals Supported

z
Development of new or improved

product resulting in prototype
development.
Development of a new or
improved process resulting in
establishing a process know-how
etc.
Absorption and upgradation of

imported technology.
Priority technology development

projects of PSUs.
Pig Iron Exports from

India Hit High in June
2015
Pig iron exports from India hit the
highest level in 15 months in June
2015 at 1,17,989 tonnes, which is
67% higher compared with exports
of 70,822 tonnes during May 2015.
In June 2015, Taiwan was the top
importer of pig iron from India.
Second largest export destination
of Indias pig iron was Thailand at
21,181 tonnes, accounting for about
18% of total Indian pig iron exports.
Saudi Arabia was at third place at
5000 tonnes.
Cumulative pig iron exports from

India during January-June 2015
were 3,85,618 tonnes, compared to
cumulative exports of 4,77,421 tonnes
during January-June 2014, with a
decline of 19.2%. Largest importer of
Indian Institute of Foreign Trade

(IIFT) for launching an innovative
online programme for exporters
and entrepreneurs. This online
programme would enable them to
learn the essentials of export-import
business through direct transmission
of the lessons on their desktops.
Online question-answer sessions
would also be there for addressing
the concerns with experts from IIFT.
A digital resource library would
be available to them online. This
programme is likely to serve the
objectives of both Digital India and
Skill India.
Courses have already begun from
October 2015. Course comprises 20
sessions of 2 hours each between 6 pm
to 8 pm. On successful completion of
the programme, participants would be
+%]"$
and IIFT. Online registration can be done
at http://niryatbandhu.iift.ac.in
117
KAYBEE FOUNDRY SERVICES PVT. LTD.

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118
119
120
121
122
STATISTICS
Engineering Exports from India During April-September 2015
Top 25 Destinations (Country)
Growth %
AprilSeptember
2015 (US$
Million)
AprilSeptember
2014 (US$
Million)
Growth %
709.29
-20.87
3583.19
3737.99
-4.14
227.73
583.21
-60.95
2219.41
2913.50
-23.82
Sri Lanka
154.18
506.01
-69.53
1467.33
2044.50
-28.23
UK
198.84
306.43
-35.11
1177.42
1402.22
-16.03
Singapore
174.98
190.54
-8.17
1130.39
1311.31
-13.80
China
214.58
321.52
-33.26
1057.43
1439.90
-26.56
Germany
184.86
186.66
-0.96
1046.77
1087.82
-3.77
Malaysia
84.29
47.80
76.34
856.36
347.44
146.48
Mexico
148.16
193.41
-23.40
834.47
845.78
-1.34
South Africa
103.25
99.74
3.52
785.20
1324.01
-40.70
Italy
122.17
153.61
-20.47
755.13
864.46
-12.65
Bangladesh
120.62
140.13
-13.92
687.99
756.50
-9.06
September
2015 (US$
Million)
September
2014 (US$
Million)
USA
561.25
UAE
Country
Japan
66.83
85.32
-21.67
687.21
431.24
59.36
Saudi Arabia
113.99
181.75
-37.28
655.67
843.19
-22.24
Korea RP
107.69
128.95
-16.49
654.40
670.48
-2.40
Nepal
54.72
147.11
-62.80
610.96
731.57
-16.49
Turkey
116.55
118.04
-1.26
609.26
869.35
-29.92
France
77.86
86.19
-9.66
531.49
517.07
2.79
Nigeria
85.50
110.74
-22.79
520.01
642.78
-19.10
Thailand
62.57
97.53
-35.85
459.38
532.52
-13.73
The Netherlands
73.12
69.75
4.83
436.33
425.47
2.55
Iran
50.54
115.38
-56.20
419.10
631.33
-33.62
Indonesia
74.98
86.33
-13.15
409.91
620.75
-33.97
Belgium
95.44
50.94
87.36
371.16
345.27
7.50
Brazil
60.90
73.84
-17.52
363.70
417.07
-12.80
Total of Top 25 Countries
3335.60
4790.22
-30.37
22329.67
25753.52
-13.29
Total Engineering Exports
4719.35
6329.06
-25.4
30720.99
35136.00
-12.6
70.7
75.7
72.7
73.3
Share of Top 25 Countries (%)

z
Out of top 25 countries, only 4 countries namely Malaysia, South Africa, The Netherlands and Belgium recorded positive
growth in September 2015.
Indian engineering exports to USA continues to be the highest with negative growth both in September 2015 and AprilSeptember 2015.
Out of 218 destinations for exports of Indian engineering goods, the top 25 nations account for 72.7% of the total, during
April-September 2015.
During April-September 2015, growth rate of the top 25 countries taken together recorded fall in exports by 13.3% which is
higher than the fall in Indias total engineering exports by 12.6%.
123
124
Udyog Aadhaar Memorandum for MSMEs

Online Filing
The Ministry of Micro, Small and Medium Enterprises (MSME), Govt. of India in order to promote ease of doing
business for MSMEs, has notified the Udyog Aadhaar Memorandum (UAM) under the MSMED Act, 2006 vide Gazette
Notification [SO No. 2576(E)] dated 18-09-2015.
A one-page simple Registration Form for online filing of UAM has been introduced which replaces the filing of
Entrepreneurs Memorandum Part I&II. The filing of UAM can be done online on http://udyogaadhaar.gov.in by the
concerned MSME unit.
However, for the MSME units having EM-I or EM-II or SSI registration prior to MSME Act 2006, it shall not be
mandatory but it is preferable for them also to file the same.
The detailed notification and Applicable Forms can be downloaded from the link: http://msme.nic.in/Web/doc/
GazetteNotification2576.pdf
Exports of Auto Components from India During April-September 2015

Growth %
AprilSeptember
2015 (US$
Million)
AprilSeptember
2014 (US$
Million)
Growth %
378.25
-13.12
2082.31
2252.94
-7.57
12.35
8.11
52.29
87.56
47.87
82.92
7.46
12.23
-39.02
63.23
61.98
2.01
Export
Destination
September
2015 (US$
Million)
September
2014 (US$
Million)
Exports to World
328.61
Mexico
UAE
Nepal
4.76
9.05
-47.39
55.45
43.74
26.77
Sri Lanka
5.87
3.99
47.07
31.98
22.14
44.46
Belgium
5.45
5.68
-3.99
31.44
30.66
2.56
Nigeria
2.38
4.13
-42.22
26.87
26.16
2.70
Spain
4.10
3.32
23.54
20.39
20.14
1.25
The Netherlands
3.91
2.76
41.68
19.57
18.15
7.85
USA
71.53
73.26
-2.36
460.01
473.07
-2.76
Turkey
34.73
33.88
2.50
182.67
204.39
-10.63
Thailand
16.75
21.53
-22.23
99.56
113.77
-12.49
UK
15.67
20.07
-21.91
97.99
106.18
-7.72
Germany
16.21
16.24
-0.19
92.45
103.03
-10.28
Brazil
12.41
17.61
-29.50
91.93
107.58
-14.55
Italy
10.41
10.87
-4.30
67.86
82.98
-18.22
Bangladesh
10.65
16.31
-34.68
61.84
83.71
-26.13
z
z
USA remains the topmost destination for exports of auto components and parts from India with share of more than 22%
during April-September 2015.
Turkey and Thailand achieved the second and third positions importing 8.8% and 4.8% respectively of Indias exports of auto
component and parts during April-September 2015.
125
PHOOLCHAND BHAGATSINGH
ESTD.1957
Reliable Source for :
Noble Alloys & Ores
Ferro Alloys
Calcium Silicide
Lumps/Granules/
Powder
Ferro Aluminium
Ferro Boron
Ferro Chrome
Al : 30% / 35%min
B : 15% min
Ferro Molybdenum
57% min HC
HC
Cr : 60% min,
C : 5-8%
MC
MC
Cr : 50-55%,
C : 2% max
Ferro Niobium
63% min LC
LC
Cr : 60% min,
C : 0.03% / 0.05% / 0.1% max
Ferro Titanium
30 - 35%
Nitrited Low Carbon Ferro Chrome Cr : 60% min, N :8-10%
Ferro Vanadium
68 - 72%, Al : 2%max
50% & 80%
Moly Oxide
57% min
Ferro Manganese
HC
Mn: 70% min.
MC Mn: 70% /80%,
LC
Mn : 70% /80%,
P : 0.01% max /0.35% max
Si : 0.5% max/1.5% max P :

Si : 1% max /3% max
P :
C : 0.1%max,
P :
0.1% max /0.4% max

0.15% max /0.35% max
0.15% max
'!^_`j#+
Chromicte Sand
Cr2O3
';;=#z +
Perlite Ore
SiO2
46%min
Ferro Silicon Zirconium
Si : 70% min, Al : 1.5% max, C : 0.1% max

Mg : 5-7%, Si : 40% min
Mg : 8-10%, Si : 40% min
Zr : 15% min. Si :38% min
Ferro Sulphur
Silico Manganese
S : 50% min
Mn : 60% min, Si: 15% min
Ferro Silicon
Ferro Silicon Magnesium
71%min
{<"z|'}+
FC : 90% min
Base Metals & Alloys

Antimony
Bismuth
Calcium Aluminium Alloy
Minor Metals
99.65% min
Arsenic
99.99% min
Antimony Trioxide
: 75 / 25%
99% min
99.5% min
99.65% min
Aluminium Ingot
Al : 99.7% min
Aluminium Alloy
Al : 85%, Si : 10%
Copper Phosphorus
85 / 15%
Nickel Metal
Ni : 99.9% min
Chromium
99% min
Cobalt
Lead Ingot
Pb : 99.97% min
Cerium Misch Metal

Manganese Flakes
99.7%min
Tin Metal
Sn : 99.85% min
Megnesium
99.9% min
Manganese Briquettes 97% min
Nickel Oxide :
75 % min.
Secondary Zinc Ingot 98.5%

Zinc Metal
Zn : 99.95% min
Titanium Scrap
Ti : 99% min
Ahmedabad Branch
Menganese Metal Lamps

Molybdenum Metal
Selenium Metal
(Powder 200 mesh/Granules)
99.8%min
99.9% min
Cobalt Oxide
Silicon Metal
(553/441/3303/2202)
Delhi / Faridabad / Mandi Branch
70% min
Si : 99% min
Chennai Branch
Phone
: 02718 - 261073
Phone
: 011-2351 1194 /2351 3657
Fax
: 02718 - 261074
Fax
: 011-2351 1182
Fax
044 - 2590 3006
E-mail
: ahmedabad@phoolchand.com
E-mail
: faridabad@phoolchand.com
E-mail
chennai@phoolchand.com
Contact
: Mr. Shalaj Gupta

09375033830
mandi@phoolchand.com
Contact : Mr. Ajay Gupta
9811084240 / 9313281075
Mr. Santosh Khandelwal
(Chennai) Mr. Shameer Babu : 09381060001

(Coimbatore) Mr. G. Ramesh : 09443062100
9310611122 / 9313611008

!"#$'*+#;<=>???>!'?@@+[@???
Contact Person : Mr. Rajiv B. Khandelwal - 09820080250/09323880250, Mr. Sanjiv B. Khandelwal - 09323160250,
Mr. Mahavir J. Jain - 09820189931/ 09321044897, Mr. Rajesh J. Jain - 09869214950,
Mr. Aakash S. Khandelwal - 09324612137, \=;"];;z www.phoolchand.co.in
126
STATISTICS
Engineering Exports from India - Destinations (Regionwise)
(US$ Million)
Engineering Exports from India - Regionwise Share

April-September 2015
April-September 2014
[Source : EEPC]
127
128
64th IFC/IFEX 2016 Special Issue of

INDIAN FOUNDRY JOURNAL (IFJ)
Dont Miss this Opportunity of

in the IFJ
A Once-in-a-year Opportunity
IFJ is stepping into the 62nd year of its
journey with 4000+ readership
January 2016 issue of IFJ will be a Special Issue to commemorate
64th Indian Foundry Congress (IFC) and IFEX 2016 Exhibition
Advertisements will be accepted on first-come-first-served basis at usual rates
mentioned below :
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: Rs. 4,800/z Payment is to be made by Bank Draft /
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of Indian Foundrymen, Payable at
RQDGYDQFHSD\PHQW
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Last date of
receiving
advertisement
material along with
payment :
5th January 2016
Further details and order Form are available from :

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Tel : + 91 33 2442 4489 / 7385, Cell : 098745 44146
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129
130
131
132
133
134
Forthcoming Events
IFCE 2015

!"
December 2-3, 2015
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December 2-4, 2015
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ARPA 450 Moulding Box

700L x 600W x 275HT
Pin Centre 780 120 Nos.
Year of Manufacture 2012
Please contact us:
imc@infinity-mfg.com
Cell: 9367450055
Coimbatore
136
*
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METEF 2017
!"

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STUDY NOTE AVAILABLE FOR PRACTISING FOUNDRYMEN

CET WORKSHOP STUDY MATERIALS
Casting Defects
`
z
Analysis of Casting Defects - Causes &
Remedies (CI, DI) - Vol.I ................................ 350
z
Analysis of Casting Defects - Causes &
Remedies (Steel) - Vol.II ................................. 350
Cast Iron / Ductile Iron
z
Alloy Cast Iron ............................................. 800
z
Ductile Iron Foundry Practice ........................ 550
z
Ductile Iron Production ................................. 550
z
Ductile Iron Technology Defects Analysis and In-mould and
Stream Treatment ......................................... 550
z
Grey Cast Iron Technology ............................ 350
Energy and Pollution Management
z
Air Pollution Measurement and Control
in Foundries .................................................. 350
z
Energy Management and Audit
in Foundries ................................................. 350
z
Energy Efficiency & Pollution Control .............. 350
Foundry Furnaces
z
Cupola Practice ............................................ 350
z
Induction Furnace and Electric Arc
Furnace (Operation Optimisation of
Melting, Refractory Lining and
Maintenance) ................................................ 350
Foundry Practice
z
Advances in Casting Technology .................... 400
z
Special Casting Processes .............................. 350
z
Some Aspects of Foundry Practice .................. 350
Foundry Metallurgy
z
Basic Metallurgy of Steel Castings ................. 450
z
Metallurgy for Foundrymen .......................... 350
Handbook
z
Cast Iron ....................................................... 350
z
Foundry Raw Materials .................................. 350
Methoding
z
Casting Simulation Case Studies.................... 950
Price (including Postage)
Conventional Methoding, Simulation

`
and Solid Modelling ...................................... 350
z
Engineering Methoding Practice
in a Foundry ................................................. 350
z
Gating System Design for Steel Casting ........ 350
z
Methoding Principle for Ferrous Casting
Major Pattern Making Technique
& Methods .................................................... 350
z
Methoding/Solidification Related
Defects and Their Remedies for Iron
and Steel Castings ....................................... 550
Moulding
z
A Guide of Sand Control Practice
in Ferrous Foundries...................................... 350
z
Mould and Core Making (B-2) ....................... 350
z
CO2 - Silicate Moulding Process .................... 350
z
Moulding Practices for Grey Iron Castings ..... 200
z
Moulding Processes and Sand System ........... 350
z
Moulding Sands and Processes for Steel
Castings ....................................................... 350
z
Resin Binders & No-bake Related
Equipments .................................................. 350
Repair/Welding/Machining
z
Application of Welding in
Foundry Casting ........................................... 350
z
Machining Technology for Cast
Iron Castings ................................................ 200
z
Repair and Reclamation Technology
of Casting .................................................... 350
Steel
z
Steel Foundry Technology .............................. 450
Testing
z
Heat Treatment of Quality
Ferrous Castings .......................................... 350
z
Inspection and Quality Control ...................... 200
z
Non-Destructive Testing ............................... 350
z
Laboratory and Shop-floor Testing for
Ferrous Foundry ............................................ 350
z
CET GUIDE NOTES FOR MODULAR EXAMINATION

Module-IV
`
z
Advances in Casting Technology (B-8) ............ 400
z
Energy Efficiency & Pollution
Control (B-7) ................................................. 350
z
Engineering Drawing I & II
(Module IV) (A-10) ......................................... 400
z
Foundry Management (B-5) ........................... 500
z
Foundry Mechanisation
Automation (B-10) [E-IIc] ............................... 350
z
z
z
z
z
z
Fuels, Furnaces & Refractories (B-4) ............... 450

Introduction to Materials (A-6) ......................... 350
Metallurgy of Cast Alloys (B-6) ......................... 350
Physical Metallurgy for Ferrous and
Non-Ferrous Alloys (B-9) [E-Ic] ...................... 350
Principles of Methoding &
Casting Design (B-2) Vol.II .......................... 450
Steel Foundry Technology (B-9b) .................... 450
Technology of Iron Casting (B-9) [E-Ia] ........... 350
Contd. to p.139
137
Vol 61 zNo. 11 zNovember 2015
Ace Designers Limited

Foundry Division (Established : 2013)
Vision : Large-Scale Producer of World-class Casting and Machine Tools.
Mission : We will recognise our responsibilities as corporate citizens to faster progress, to promote general welfare of the
society, create an environment to our staff to grow and advance to prosperity and thus promote a sense of belongingness.
We will exceed customer expectations through reliable product, on-time delivery, cost-effective solution with an added
assurance of prompt service.
Capacity: 1000 MT/ Month Total Area: 16000 SQ. MTR No. of Employees: 125
Weight Range: Grey Iron: 300 kg to 6000 kg - SG Iron: 500 kg to 3000 kg
Infrastructure
Melting : 4 MT Dual-track, Medium Frequency Induction Furnace.
Moulding and Core Shop : IMF-make Continuous Sand Mixer 60 MT cap/ 10 MT cap, Moulding Line with Rollover.
Infrared Oven / Gas Oven, Closing Station with Mould Handler, Pouring & Cooling line, Mould Pusher & Shake-out.
Thermal and Mechanical Reclamation

Fettling: Shot Blasting Machine, Stress Relieving Furnace and Primering.
Laboratory
Spectrometer, Mechanical Testing, Sand Testing, Carbon Silicon Analyser, Temperature Measurement.
Other Information
^% %?4 ;?%[ <G!
Typical Parts
Lathe beds, Grinding beds, Columns, etc.
Customer Sectors
Machine Tools, Pumps, Earthmoving, Agriculture, Printing, General Engineering, Energy.
Contact Persons:
Mr. E. R. Badreesh, General Manager, Foundry; M: +91 9845995165, E-mail: erb@acedesigners.co.in
Mr. Ramesh A., Deputy General Manager; M: +919845102870, E-mail: ramesh_a@acedesigners.co.in
C

Works:
Ace Designers Ltd.
Ace Designers Ltd. Foundry Division
Plot No. 7&8, Phase-II
Sy. No. 53/4 to 53/8, Minnapura Village

Thyamagondu Road, NelamangalaTq.
Bangalore - 562132, Karnataka
Peenya Industrial Area

Bangalore - 560058, Karnataka
138
CET GUIDE NOTES FOR MODULAR EXAMINATION (contd.)

Testing of Metals and Alloys (B-3) ................. 400
Theory of Foundry Processes (B-1) ................. 350
z
Workshop Technology for
Foundrymen (A-7) ......................................... 700
Module : II
z
Basic Mechanical Engineering (A-9) ............... 350
z
Casting Technology (B-1) ............................... 350
z
Electrical Technology and
Electronic Devices (A-7) ................................. 350
z
Engineering Drawing - I (A-5)............................ 350
z
Heat Treatment of Castings &
Related Equipments (B-5) .............................. 350
z
Industrial Management (B-7) ......................... 400
z
Introduction to Engineering
Materials (A-8) .............................................. 350
z
Melting & Casting Technology (B-3) ............... 350
z
Mould and Core Making (B-2) ......................... 350
z
Pollution Control and Occupational
Health in Foundry Industry (B-8) (E-II) ............ 400
z
z
Principles of Methoding &

Casting Design (B-8) [E-III] Vol.I .................. 450
z
Special Casting Processes (B-4) .......................... 350
z
Technology of Cast Iron ................................. 350
z
Testing and Inspection in Foundry (B-6).......... 400
Module : I
z
Cast Metal Technology (P-10)......................... 100
z
Chemistry (P-3).............................................. 100
z
Cupola Melting Emission Control (P-9) [B] ...... 100
z
Engg. Drawing (P-5) ...................................... 100
z
English (P-1) .................................................. 100
z
Mathematics (P-4).......................................... 100
z
Melting Technology (P-9) [A] .......................... 100
z
Moulding Technology (P-8)............................. 100
z
Pattern Construction (P-7) .............................. 100
z
Physics (P-2) .................................................. 100
z
Workshop Technology (P-6) ............................ 100
50% Discount on CET Guide Notes for Students registered in IIF Courses
All payments should be made by at Par Cheque or Demand Draft favouring The Institute of Indian Foundrymen CET payable
at Kolkata.
Please Contact : Centre for Education and Training (CET), The Institute of Indian Foundrymen,
IIF Center, 335, Rajdanga Main Road, East Kolkata Township, P.O., Kolkata - 700 107, Phone : 033 2442 4489 / 7385,
Fax : 033 2442 4491, E-mail : cet@indianfoundry.org
139
Investment Opportunity in Metro Railways Approved

Foundry in NCR Region
(Just 65 Km from New Delhi Airport)
Looking for Joint Venture / Collaboration Opportunities for a world-class Foundry, with an installed capacity of
3,000 tonnes/annum Grey and Ductile Iron castings
Provision to expand the capacity to 9,000 tonnes/annum
High EBITDA Margin potential of 30%
Concession of 50% Central Sales Tax
Capable of producing 1-400 kg single-piece castings
Strong Customer Base with supplies to Delhi Metro, Bosch, Toyota amongst other global buyers
Equipped with Induction Furnace, Moulding & Automatic Sand Plant, Spectrometer and a complete in-house
Testing facility
Complete in-house Machine Shop with CNC Turning and Vertical Machining Centres
Strong Technical team on-board, capable of manufacturing export quality castings across sectors
Currently supplying to Automotive, Railways, Hydraulics industry etc.
Strategically located, within close proximity of Suzuki, Hero, Honda Car & Bike, Eicher plants
Cheaper and abundant power availability, with 100% captive power source.
For more information, please contact:

M: +91 99584 30257
Email: foundryjv@gmail.com
Foundrymen!
Reduce Your Energy Bills
Improve Efficiency of Your Plant
Services of a resourceful, experienced Foundryman is now available to reduce your Energy Bills,

Energy Bill Scrutiny to avoid payment of unnecessary
items, and also to identify process operations needing
improvement.
Improvement in Thermal Processes to save Fuels like
LPG/CNG and others.
Review of Furnace Operational and Energy
Consumption Parameters.
Reduction in Maximum Demand by Improving
Power Factor.
Implementation of Energy Audit in units having more

than 300 KVA Power Demand.
Installations of Foundry Equipment, Furnace
Transformers, Water Lines, Hydraulic Equipment in a
Foundry.
Liaisoning with Government Electrical Inspectors to
get approvals of Electrical Installations; and getting
Electricity Duty Exemption, wherever applicable.
Annual Maintenance Contract for the entire foundry.
Background of the Foundryman: (i) Started Foundry career in 1972 as a Trainee in SLM Maneklal Foundry in
Ahmedabad, (ii) Worked with Bhagwati Spherocast Pvt. Ltd., Ahmedabad, (iii) Worked till 2013 for almost 30
years with Vishal Malleables Ltd., Ankleshwar, initially as Works Manager, and later as Director, (iv) After 2013,
worked as Technical Advisor to Indsur Global, Halol.
If interested, please contact:

G. D. Raval
Apple Engineering
4 Niravkunj, Opp. Ramvatika, Braruch-392 001, Mobile: 09377761888 E-mail: gajendra.raval123@gmail.com
140
DVDs on Workshops/Trainings
Conducted Recently by Renowned Faculty
Prepared by
Centre for Education & Training of IIF

z
Elementary Metallurgy for Foundrymen

(1-DVD ) CET/DVD/MET-1
Price :
(Inclusive of Postage)
: ` 850/Operating Aspects on the Use of Resin
Binders & No-Bake Equipment
(2- DVDs) CET/DVD/NO-BAKE-1
Price :
: ` 1,150/Technology of Ductile Iron & Defect
Analysis of SG Iron Castings
(2- DVDs) CET/DVD/DI-1
Price :
: ` 1,550/Austempered Ductile Iron (ADI) and
Compacted Graphite Iron (CGI) CET/DVD/DI-2
Price :
: ` 850/Subjective Moulding Process for
Improvement in Methoding CET/DVD/
METHOD-1 &
Metallurgical Aspects of
Methoding for Steel & Ductile
Iron Castings
Price : (2 DVDs)
: ` 1150/Casting Defects and Remedies
(Ductile Iron, Grey Iron & Steel
Castings) (2 DVDs) (CET/DVD/
CAST-DEFECT-1)
Price :
: ` 1150/Metallurgy Made Easy for
Foundrymen (1 DVD)
Price :
: ` 850/-
Sand-Related Defects and Their

Remedies in Producing Quality
Casting (1 DVD)
Price :
: ` 850/-
Safety Operation and Maintenance

in Induction Melting System (2 DVDs)
Price :
: ` 1150/-
Selection Installation and Maintenance of

Refractory Lining in Coreless Induction
Furnaces (1 DVD)
Price :
: ` 850/-
Practical Pathway to Rejection Control in

Grey and Ductile Iron Casting Production
(1 DVD)
Price :
: ` 850/-
Foundry Process of Core and Mould Making

Relevant to Ductile and Grey Iron Castings
(1 DVD)
Price :
: ` 850/-
Using Casting Simulation to Increase the Yield

and Reduce Rejections in Castings
Arun Pandion (1 DVD)
Price :
: ` 850/-
Analysis of Casting Defects in Foundry by

CAE Tapan Roy (1 DVD)
Price :
: ` 850/-
All payments should be made by at Par Cheque or Demand Draft favouring The Institute of Indian Foundrymen
CET payable at Kolkata.
Please Contact : Centre for Education and Training (CET)
IIF Center, 335, Rajdanga Main Road, East Kolkata Township P.O., Kolkata - 700 107
Phone : 033 2442 4489 / 7385, Fax : 033 2442 4491
E-mail : cet@indianfoundry.org
141
SERVING FOUNDRY INDUSTRY SINCE 1979
0XIDFU
FERRO
VANADIUM
FERRO
MOLYBDENUM
PREMIER ALLOYS & CHEMICALS PVT. LTD.

320, Bhanu Enclave, Sanjeeva Reddy Nagar, Hyderabad 500 038
Phone: 040-23810018
Fax: 040-23810326
23715884
23097123
23817332
www.premieralloys.in E-mail: premier@pacpl.com
ADVERTISERS INDEX
ABP Induction Systems Pvt. Ltd. .................................. 6
Graphite & Mineral Products......................................86
RSJ Industries................................................................. 114
ACE Designers Ltd........................................................ 138
IFEX 2016 ............................................................................19
S. S. Khardekar India Pvt. Ltd. .................................. 120
Ajay Syscon Pvt. Ltd. ................................................... 103
Inductotherm (I) Pvt .Ltd. .............................. 4th Cover
Apple Engineering ....................................................... 140
Industrial Minerals ....................................................... 144
Auto Design Online..................................................... 105
IVP Limited ........................................................................71
Sinto Bharat Mfg. Pvt. Ltd. ...........................................42
Baroda Machinery Mfgrs. .......................................... 104
J. K. Foundry Engineers .................................................74
Snam Alloys Pvt. Ltd........................................3rd Cover
Bhartia Nagpur ............................................................. 145
Kastwel Foundries ............................................................. 9
Span Met Tech Enterprises Pvt. Ltd. ...................... 106
Cast India Expo 2016 .....................................................20
Kaybee Foundry Services (P) Ltd............................ 118
* /\ / ..................................................70
Kelsons Enggrs. & Fabs.................................................66
Coatings & Coatings (I) Pvt. Ltd. ...............................73
Krishna Ceramic Industries ....................................... 118
Daka Monolithics Pvt. Ltd. ............................................ 3
Laempe Foundry Technology Pvt. Ltd.....................14
The Advertiser (foundryjv@gmail.com) .............. 140
EHP INDIA ....................................................................... 133
Metal Power Analytical (I) Pvt. Ltd. ........................ 109
The Advertiser (cell : 93674 50055)....................... 136
Electro Power Engineers ................................................. 8
MPM Pvt. Ltd. ................................................................. 111
Titan Engineers ............................................................. 122
Electrotherm (India) Ltd. ...............................2nd Cover
Neco Group of Industries. ........................................ 132
Forace Polymers (P) Ltd. ...............................................16
NCTS ................................................................................. 131
Frontier Alloy Steels Ltd............................................. 112
Phoolchand Bhagatsingh .......................................... 126
Versatile Equipments Pvt. Ltd. ................................. 119
Gargi Engg. Enterprises Pvt. Ltd. ...............................13
Premier Alloys & Chemicals Ltd. ............................ 142
Vijayesh Instruments Pvt. Ltd. ................................. 128
Gargi Huttenes-Albertus Pvt. Ltd. ............................... 4
Protech Info Services Pvt. Ltd. ................................. 143
Wesman .............................................................................17
Gargi Industries ..............................................................10
Rhino Machines Pvt. Ltd. ..................................... 68,113
Winoa Abrasives India Pvt. Ltd. .................................72
Gibson Centritech Pvt. Ltd. ..........................................69
Royals Enterprises ................................................124,130
Yashi Foundry Tools .......................................................93
142
Saru Aikoh Chemicals Ltd. ...........................................18

Sarvamangala Engineers Pvt. Ltd........................... 121
Shree Sponge Steel & Forging Ltd...........................94
Sree Sakthi Equipments Co. ........................................90

Standard Alloys Industries ........................................ 110
SQ Enterprises Pvt. Ltd. .............................................. 134
Techno Crat Foundry Chem ........................................89
Toyo Metallurgicals Ltd. ............................................. 146

Vacunair Engg. Co. Pvt. Ltd....................................... 139
Vardhan Works Pvt. Ltd.............................................. 128
143
144
145
146

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