We have multiple foundries spread across almost a million square feet of production area, dedicated to moulding, melting, shot-blasting, grinding and painting.

MOULDING

We pride ourselves on producing high-quality castings with excellent aesthetics, achieved through our advanced no-bake moulding process. Our state-of-the-art Omega Sinto sand mixers ensure superior moulds, leading to aesthetically superior casting for various applications.

MOULDING TECHNIQUES

We employ two key moulding techniques to ensure the highest quality castings:

HAND MOULDING

We use this for smaller batch sizes and specialized castings, with multiple cores.

AUTOMATIC MOULDING LINE – CAROUSEL 8 STATION

Our 8 Station Carousel system, allows for high volume production of uniform moulds. This process improves consistency, reduces lead time, and enhances overall production efficiency.

ASSEMBLY & POURING

ASSEMBLY

POURING

We pride ourselves on producing high-quality castings with excellent aesthetics, achieved through our advanced no-bake moulding process.

IN-HOUSE SAND TESTING FACILITY

To maintain the quality and integrity of our moulds, we utilize an advanced in-house sand testing facility equipped with the following testing equipments:

SIEVE SHAKER

For testing the grain size of sand to ensure optimal consistency and suitability for moulding

UNIVERSAL STRENGTH MACHINE (DIGITAL)

Measures compressive, tensile, and transverse strength of the moulding sand to ensure the required strength properties for casting.

CORE HARDNESS TESTER

Used to measure the hardness of the sand cores, ensuring that the cores provide adequate support during casting.

MUFFLE FURNACE

Used to test the loss of ignition (LOI) in sand, ensuring the sand’s stability and performance during the casting process.

MELTING PROCESS

We have multiple Inductotherm make induction furnaces, powered by IGBT technology, with pot sizes ranging from 750 kg upto 4 tons.
We ensure the use of high-quality raw materials to produce Grey Iron and S. G. Iron castings. Once the metal is melted, it is poured into the prepared no-bake moulds.

MATERIAL TESTING

To ensure the highest quality of our castings, we utilize state-of-the-art material testing devices that monitor key properties of the molten metal and cast products.

CHEMICAL COMPOSITION TESTING

FERRO LAB

Used to monitor the chemical composition of molten metal, including key elements like carbon, silicon, manganese, and other essential minerals.

SPECTROMETER

This advanced device is used to measure the chemical content and ensure that the metal meets the required material specifications for each casting.

HARDNESS AND TENSILE STRENGTH TESTING

We utilize multiple precision hardness testers to evaluate the mechanical hardness of our castings, ensuring compliance with specified strength and durability requirements and confirming metallurgical integrity.

BRINELL HARDNESS TESTER

Measures the hardness of materials using a spherical indenter, providing valuable data on the casting’s overall strength.

TENSILE STRENGTH MACHINE

This machine tests the strength and ductility of the castings, providing vital data on how the material will behave under various loading conditions.

POLDY HARDNESS TESTER & DIGITAL HARDNESS TESTER

Another effective tools for assessing material hardness, especially useful for evaluating the hardness of thinner materials.

SHOT BLASTING

Our facility is equipped with high-capacity shot blasting machines, upto 96 inches diameter table type machine, to handle large volumes of castings while ensuring consistent and uniform surface preparation.

Shot blasting is performed twice during the casting process:

Before Grinding/Fettling

The first shot blasting removes any loose sand, debris, or imperfections on the casting’s surface, ensuring a smooth foundation for the grinding process.

Before Painting

The second round of shot blasting ensures the casting’s surface profile is optimal for paint adhesion, providing a strong bond and superior finish.

GRINDING

After shot blasting, castings undergo grinding to smooth out rough surfaces, remove any excess material, and achieve the final desired shape and surface finish.

MACHINING

We utilize various machining technologies in our in-house setup to perform semi-machining and final machining of castings, ensuring accuracy and surface roughness as per customer specifications.

MACHINING EQUIPMENT

VERTICAL TURNING LATHE (VTL):

Used for efficient turning operations.

HORIZONTAL MACHINING CENTER (HMC):

Used for milling and horizontal drilling operations..

CNC VTL:

Our Computer Numerical Control (CNC) Vertical Turning Lathe ensures high precision in machining complex components, with automated control for optimized performance.

AUTOMATIC RADIAL DRILLING MACHINES:

Used for drilling holes as per requirements.

Machining technologies in our IN-HOUSE setup to perform semi-machining and final machining of castings

DIMENSIONAL ACCURACY:

To ensure our machined components comply to customer requirements, we have installed a state of the art Coordinate Measuring Machines (CMM) of Mitutoyo make.

DIMENSIONAL ACCURACY:

To ensure our machined components comply to customer requirements, we have installed a state of the art Coordinate Measuring Machines (CMM) of Mitutoyo make.

PAINTING, PACKING, AND LOADING

We take great care in ensuring that the final product meets the highest standards of quality and is delivered safely to our customers. Our painting, packing, and loading processes are designed for aesthetics, protection, and reliability.

PAINTING:

We offer three different types of painting facilities to meet customer-specific requirements:

DIPPING:

The casting is dipped into the paint to provide a uniform coating. This method is ideal for components requiring a Single Pack Primer.

FLOW COAT:

The casting is coated using a flow coating method, providing a smooth and consistent finish. This process is suitable for components which require Two Pack Primer.

SPRAY PAINT:

Spray painting is alternatively used for some components requiring two Pack Primer.

To ensure the required paint thickness, we conduct DFT (Dry Film Thickness) Inspections and Cross Cut Tests. These tests verify that the paint coating meets the required specifications for durability and protection.

PACKING:

We use a variety of packing methods to ensure that the final products reach our customers in stable and safe condition.

PALLET PACKING:

Castings are securely packed on pallets for safe handling and transportation.

BOX TYPE PACKING:

Suitable for smaller components or specialized orders, providing optimal protection during shipping.

PALLET WITH VCI

(VAPOR CORROSION INHIBITOR):
For items sensitive to corrosion, we use VCI packaging to protect against moisture and corrosion during transit.

CAGE TYPE PACKING:

For certain components, cage-type packing is used for secured and efficient transportation.

LOADING/DISPATCH:

We have dedicated loading facilities in all our units, ensuring timely loading and dispatch of products to our customers. Each unit is equipped with separate container loading facilities, with 24/7 CCTV monitoring, to ensure on-time loading in a safe environment.
At Prashant Castech Pvt. Ltd., every step of our casting from moulding to painting, packing, and loading is carefully managed to ensure the highest standards of quality, precision, and customer satisfaction. With our loyal and experienced staff, in-house capabilities, and commitment to excellence, we guarantee that our castings meet the most demanding requirements, providing exceptional value to our customers.