With 2 manufacturing units located in Gudur, AP and 1 manufacturing unit located in Ponneri, TN, all in South India, Nelcast is one of the largest in the foundry industry. Nelcast has a specific, yet continuous production process that caters to every function needed to produce a technologically superior casting component. Complete with melting, moulding and core shops to development and quality control, Nelcast takes every step necessary to creating the right component for every client in the shortest span of time.

Development

The Company has invested in facilities to achieve its goal of speedy product development of high quality castings.

• From initial stages of tooling design, to completion of production tooling, the in-house pattern facilities, equipped with CAD / CAM, have the expertise and experience needed for quick development of new castings.
  
• We utilize Simulations Software for Methoding - This provides a foolproof mechanism to avoid shrinkage defects and to optimize yield while reducing product development lead times.
  
• Our Pattern Shop also ensures that all tooling is well maintained and serviced to ensure maximum life of tooling.

Core Shop

Utilizing our expertise & facilities for making cores of different types, we are able to offer customers the perfect balance of intricacy and economy via utilization of the right type of core for each specific product through our extensive facilities:

• Cold Box core shooters
• Shell core shooters
• No Bake core making facility
• CO2 core making facility
• Core coating & drying facility

Any high quality casting begins with a high-quality mould. This concept is clearly embodied in our investment in technology for producing moulds which result in castings with exceptional dimensional accuracy & superior surface finish.

• Our state-of-the-art Moulding Plant at Ponneri is one of the largest in India and first of its kind in Asia. The Kunkel Wagner DFM-R- High Pressure Moulding Machine with AIRPRESSplus 2000 Technology and active multi piston squeeze head controlled by a Siemens S7/400 PLC to ensure perfect repeatability of all moulding parameters.

In order to optimize the working of the Automatic High Pressure Moulding Line, the Company has also installed a state-of-the-art Automatic Sand Conditioning Plant which incorporates:

• ASR series sand cooler ensures cooling and pre-conditioning of sand
• Latest WM series high intensity sand mixer with automated additions of additives and automatic moisture control system ensures consistent quality of prepared sand.
• Automatic sand quality control equipment

These investments in technology give Nelcast distinct advantages over its competitors such as:

• High productivity (upto 110 moulds / hour)
• Improved dimensional stability leading to better repeatability, finer surface finish and low machining stock.
• Highly intricate castings can be easily made due to the 2 stage moulding technology. Complicated self-cored castings can be accurately developed.
• Patterns can be changed without loss of production through our automated pattern changing device enabling us to cater to products of all volumes without compromising productivity.
• Total reproducibility of casting parameters based on pattern information, quick modification and alteration of these parameters through computer controlled functions.

The High Pressure Moulding Line is well complemented by our DISA Arpa series simultaneous Jolt + Squeeze Moulding Machines:

• DISA ARPA - 450 (5 Nos.)
• DISA ARPA - 900 (4 Nos.)
• DISA ARPA - 1300 (1 No.)

Due to the wide range of moulding machines that Nelcast employs, we are able to service a very diverse product range and can offer customers the most economical solution for their specific product.

Melting Shop

As one of India’s largest foundries, Nelcast has presently a melting capacity of over 800MT of Iron per day. Nelcast uses Medium Frequency Induction melting furnaces for optimal metal availability and power efficiency. The Company has installed multiple Inductotherm DUAL TRAK-R plus furnaces which utilizes the latest technology in its power & control system to apply melting power to one furnace and holding power to another furnace, simultaneously to ensure close to 100% efficiency during the melting process.

• 7X Inductotherm 3MT/ 3000 KW DUAL TRAK-R plus
• 1X Pillar 3MT / 1500 KW
• 2X Pillar 1.5MT / 1300 KW

Laboratory control

At Nelcast, we believe that the key to producing metallurgically sound castings lies in ensuring that the metal used is of the perfect composition. Our laboratory utilizes the most advanced equipment for determining chemical composition,

• 22 Elements ARL Spectrometer, for determining precise chemical composition
• Optical Microscopy equipment with Photographic attachment.
• Sand testing facilities
• Detailed chemical analysis
• Fully equipped physical Lab.

Quality control

Quality is the hallmark of Nelcast. Products undergo rigorous quality checks at every stage of production. In order to ensure the physical & dimensional properties of our products, our Quality Control Department has facilities for:

• 22 Elements ARL Spectrometer, for determining precise chemical composition of the metal.
• Optical Microscopy equipment with Photographic attachment and Image Analyzer.
• Complete Sand testing facilities.
• 3-Dimensional Co-ordinate Measurement Machine
• Tensile Testing Machine
• Hardness Testing Machine
• Crack detection apparatus using permanent yoke magnet.
• Ultrasonic machine for detection of sub- surface defects
• Proof machining capabilities

Machine Shop

In a quest to move its products up the value chain and satisfy customers demand for finished components, Nelcast is upgrading its machine shop into a state-of-the-art machining facility.

Please visit the Machining Division page to know more about our state-of-the-art machining facility.