// Implement Goggle tag // Implement Google analytics

Foundry Division

Advanced Casting Capabilities: See What We Can Do

Exontric Metal Works, founded in 2014, is a semi-automatic foundry with a monthly production capacity of 200 MT. We manufacture precision machined components ranging from 3 Kg to 30 Kg, supplying to leading domestic clients in India as well as international markets across Europe, USA, and China. Our product range includes farm equipment, off-road vehicles, heavy commercial vehicles, and a wide variety of engineering components and subassemblies.

Equipped with advanced facilities such as a spectrometer, microscope with image analyzer, and other modern testing instruments, Exontric Metal Works ensures every component meets the highest standards of quality, reliability, and performance. Our integrated processes allow us to consistently fulfill customer requirements while maintaining strict process control.

By producing high-quality castings in-house, we significantly reduce costs and lead times, offering clients a seamless and efficient supply chain. With a strong commitment to technology, innovation, and customer satisfaction, Exontric Metal Works continues to be a trusted partner for industries worldwide.

Features 4

Lorem ipsum dolor amet, consecte tempor incididunt ut labore et dolore tumber tur adipisicing elit.

Features 5

Lorem ipsum dolor amet, consecte tempor incididunt ut labore et dolore tumber tur adipisicing elit.

Features 6

Lorem ipsum dolor amet, consecte tempor incididunt ut labore et dolore tumber tur adipisicing elit.

Features 4

Lorem ipsum dolor amet, consecte tempor incididunt ut labore et dolore tumber tur adipisicing elit.

Features 5

Lorem ipsum dolor amet, consecte tempor incididunt ut labore et dolore tumber tur adipisicing elit.

Features 6

Lorem ipsum dolor amet, consecte tempor incididunt ut labore et dolore tumber tur adipisicing elit.

Our clientele

Our clientele

Manufacturing strength

Box size

20” x 22” x 5” /7” (508 MMX558 MM X177 MM)

Casting Range

3Kg to 30Kg

Capacity

Present - 200 MT

Capacity

Utilization - 80 MT Spare - 120 MT

Our foundry products

Castings for the energy sector
Steel castings for the energy sector
Castings for the machinery industry
Castings for for the machinery industry
Aerospace Components
Custom Casting

Our manufacturing facilities

Pattern shop

Core making

Melting facilities

Moulding line

Sand plant

Fettling shop

Surface coating

Quality control & testing

Pattern Shop

Welcome to the Pattern Shop Division! Our pattern shop is the heart of the foundry process, where we craft the blueprints for metal parts with precision and expertise. Let's explore the importance of the pattern shop and the materials we use:

Importance of the Pattern Shop

The pattern shop plays a crucial role in the foundry process by creating the moulds and cores necessary for casting metal parts. Here's a simplified overview of the process:

1. Design: Skilled patternmakers design the blueprint or pattern for the metal part based on specifications and requirements.

2. Material Selection: The appropriate material is selected based on factors such as durability, machinability, and thermal conductivity.

3. Pattern Creation: Patterns are crafted using various tools and techniques to ensure accuracy and precision.

4. Mould Making: The pattern is used to create moulds, which serve as templates for shaping molten metal during the casting process.

Materials used in pattern making

Cast Iron
Gun Metal In the Metal Form
Aluminum

Core making

Core making is an essential process in casting, allowing for the creation of internal cavities or complex shapes within castings. Our expertise in traditional core making methods ensures high-quality, precise cores that meet industry standards. We specialize in adapting our processes to fit the specific needs of our clients, providing fully customized core solutions.

We utilize the following traditional core making techniques:

  • Hot Box Core Making
  • Cold Box Core Making
  • Shell Core Making

Processes we follow:

  • Pattern Preparation: Core pattern designed to specifications.
  • Sand-Binder Mixture: Sand mixed with a binder.
  • Core Formation: Mixture introduced into a core box.
  • Curing: Thermal or chemical curing.
  • Ejection & Finishing: Core is removed, inspected, and finished.
Curing time

Hot Box: Fast (Thermal curing)

Cold Box: Fast (Room temperature with gaseous catalysts)

Shell: Rapid (Heat-assisted)

Equipment

Heated core boxes for Hot Box and Shell Core making.

Gas generation and injection systems for Cold Box making.

Specialized core-making machinery for all processes.

Cycle time

Hot Box & Shell: Quick due to thermal curing

Cold Box: Slightly slower, chemical curing

Materials used

Sand: We use high-quality, uniformly graded silica sand across all processes.

Binders: binder name.

Hot Box & Shell Core Making: Thermosetting resins like phenolic and furan.

Cold Box Core Making: Polyurethane, furan, or phenolic urethane binders.

Melting Facilities 

Our melting facilities play a vital role in transforming solid metal into molten form, crucial for casting and shaping processes. Using high-temperature techniques, we ensure efficient melting with precise control over temperature and composition, guaranteeing high-quality production.

Inductotherm Hybrid Furnace

The Inductotherm Hybrid Furnace combines coreless induction and channel melting technologies, offering flexibility in alloy use and efficient large-scale aluminum casting.

Furnace Name: Inductotherm Hybrid Furnace

Furnace Type: Induction and Electric Arc Combination

Furnace Size: Configurable from 5 to 25 tons

Melting Capacity: Up to 25 tons per hour

Power: Ranges from 250 kW to 6,000 kW

Duration for Melting: 30 minutes to 2 hours

Casting Range: Suitable for various casting processes

Materials Used: Steel, aluminum, copper, and alloys

Spare Capacity: Typically 60% of total capacity

Used Capacity: Up to 80% for effective operations

Temperature Range: Up to 1,600°C

Inductotherm Dura-Line Furnace

Dura-Line® induction melting furnaces are designed for rugged use, offering high-power density in a midsize package. Built with heavy cast refractory, stainless steel reinforcement, and copper power coils, they ensure durability and efficiency. These furnaces feature hydraulic or hoist tilting, single-trunnion action, and "nose-tilt" pouring. Ideal for efficient melting with budget-friendly options, they provide a wide range of capacities while ensuring structural integrity and easy maintenance.

01. Furnace Name: Inductotherm Dura-Line® Furnace

02. Furnace Type: Coreless Induction Furnace

03. Furnace Size: Available in various configurations to suit different operational needs

04. Melting Capacity: Up to 25 tons per furnace (depending on model)

05. Power: From 250 kW to 12,000 kW

06. Duration for Melting: 45 minutes to 3 hours, depen

Tenova Consteel® Electric Arc Furnace (EAF)

The Tenova Consteel® EAF is engineered for high efficiency and reliability, boasting a melting capacity of 30 to 420 tons per hour. Operating at power levels of 10 MW to 180 MW, it achieves temperatures up to 1,800°C. The melting duration typically ranges from 45 to 90 minutes, with an operational capacity utilization of 85-90%. This furnace is versatile, processing various materials such as scrap metal and pig iron, making it an ideal choice for modern melt shops.


Moulding Lines

Molding lines are automated systems in foundries designed for the mass production of castings. These lines integrate various processes, including sand preparation, molding, and core setting, enabling efficient and consistent production. With the capability to produce high volumes, molding lines can manufacture complex shapes with precision. Features like quick-change systems and modular designs enhance flexibility and adaptability to different production needs. They significantly reduce cycle

Casting Materials:

Compatible with iron, steel, and aluminum alloys.

Casting Range:

  • Weight Capacity: 0.5 kg to 50 kg per casting.
  • Size: Molds can be customized up to a maximum dimension of 1,200 mm × 1,000 mm.
  • Moulds Per Hour: Capable of producing up to 1,200 molds per hour.
  • Annual Volume: Designed for an annual production capacity of over 100,000 molds.

Additional Features:

  • Modular design for enhanced customization.
  • Advanced automation

Casting Materials:

Compatible with iron, steel, and aluminum alloys.

Casting Range:

  • Weight Capacity: 0.5 kg to 50 kg per casting.
  • Size: Molds can be customized up to a maximum dimension of 1,200 mm × 1,000 mm.
  • Moulds Per Hour: Capable of producing up to 1,200 molds per hour.
  • Annual Volume: Designed for an annual production capacity of over 100,000 molds.



Sand Plant

A Sand Plant is essential in metal casting, managing sand preparation and ensuring the quality of cast products. Key components include the High-Speed Intensive Mixer (DISA) for optimal sand mixing, Sand Coolers to regulate temperature, and an Auto Sand Mix Control System to maintain consistency. These systems ensure the sand is properly conditioned for the molding process, enhancing casting precision and productivity, and improving the overall efficiency of metal foundries.

DISAMIX Sand Mixer

The DISAMIX is a next-generation bentonite-bonded foundry sand mixer engineered for high-speed, energy-efficient performance in green sand foundries. Designed to meet modern foundry needs, the DISAMIX

Specifications:

Model: S100

Capacity: 100t/h

Parameter: S100

Mixer Capacity: 100t/h

Batch Capacity: 3000 kg

Installed Power: 160 kW

Water Consumption: 20 l/min

Mixer Height: 2970 mm

Net Weight: 17 Tonnes



Water Reservoir

Fast and precise pre-water dosing

Intensive Mixing

fast and complete mixing with short cycle times.

Industry 4.0 Ready

advanced data-driven process control, real-time production monitoring

Sand Multi Controller (SMC)

Automates sand moisture control and ensures consistent quality

Pneumatic bond injection

Pneumatic bond injection

Discrete Element Modelling (DEM)

technology employed for optimal mixing performance.

Fettling Shop

Fettling is the crucial process of cleaning and finishing castings to remove excess material and ensure compliance with specifications. Common equipment in a fettling shop includes shot blasting machines that use high-velocity abrasives for thorough cleaning, grinding machines for refining surface finishes and dimensions, robotic fettling systems that automate grinding and polishing tasks for improved productivity, and vibratory finishing machines that effectively polish and deburr castings. 

These machines play a vital role in maintaining quality control in foundries, enhancing the overall efficiency of the production process.


DT Continuous Through-Feed Tumblast Machine

The DT Continuous Through-Feed Tumblast Machine is designed for efficient and cost-effective blast cleaning of castings and forgings in foundries. Utilizing advanced wheelblast technology, this machine automates the cleaning process, ensuring optimal results while minimizing manual handling and operational costs.

Technical Specifications:

  • Model: DT-11-350
  • Blast Wheel Power: 37-45 kW (depending on model)
  • Abrasive Flow Rate: Variable, adjustable based on the throughput and cleaning requirements
  • Workpiece Size: Max. diagonal size ranges from 400 mm (DT-11-350) to 1150 mm (DT-14-850)
  • Blast Chamber Dimensions: Specific to each model; designed to accommodate the maximum workpiece size effectively

Materials Used: Abrasive materials (e.g., steel shots, grits)


Surface Spray Coating

Spray coating is a widely used technique for applying a uniform layer of coating material to various substrates using a spray gun. This method accommodates multiple coating types, including paints, varnishes, and protective finishes.

Specifications:

  • Spray Pressure: 20-60 psi (air spray), 2000-3500 psi (airless spray)
  • Coating Thickness: 20-100 micrometers per layer
  • Curing: Air-drying or baking, depending on the coating material

Materials Used:

  • Coating Material: Paints, varnishes, epoxies, polyurethanes
  • Chemicals: Solvents, pigments, binders, and additives

Important links
  • About
  • Foundry division
  • Machine shop
  • Quality Assurance
  • Download
  • Contact
Location

Plot No. 13, Besides Jafrani Weight Bridge, MIDC - Shiroli, Kolhapur - 416122, Maharashtra, India.

Contact
  • (+91) 937 093 2787
  • sales@amaeytech.com
© Content Copyright
Amaey Tech All rights reserved.
Terms of Services and Legal Policies
Powered by Caastfusion.
A product by Exontric Systems