Welcome To

Malnad Alloy Castings Private Limited

Est : 1983
Alloy Steel,
Steel Stainless Steel,
Steel Nickel Base
Castings Manufacturer
 MALNAD GROUP COMPANIES
Malnad Alloy Castings Pvt Ltd since 1985
:Scope:
Manufacture & Supply of Raw, Machined and Hydro tested Castings in Ferrous, Nickel and Cobalt
based alloys
Shimoga Precision Castings Pvt Ltd since 1996
:Scope:
S
Manufacture and Supply of Alloy Steel, Stainless Steel, Nickel Alloy Steel, Cast Iron and Cobalt
Alloy Steel Castings By Investment and Sand Casting Process
Malnad
d Primee Machining
c g Technologies
ec o og es since
s ce 2010
0 0
:Scope:
Manufacture of Precision Machined Components
Malnad Alloyy Castings
g Pvt Ltd (Laboratory
( y Division))
since 2018
NABL Accredited Mechanical and Chemical Testing Lab
)
We are located in…
 Management Contacts

Y. V. Madhukar Jois, Managing Director

+91 990 017 7820
jois@malnad.co.in

Prateek M Jois, Executive Director

+91 966 315 5553
pj@malnad.co.in

Land Lines - (08182) 46141,246142,246143

4
Organisation Chart
Photo Name Department Mail ID Cell phone Issues Handled

Manager
Vynatheyan Marketing vynatheyan@malnad.co.in 8861699975 Enquiry; PO; OA

Manager Delivery dates;

Mahesh C.N Production cnmprd@malnad.co.in 9880741702 Planning Dates
Test certificates
Manager Quality (chemical &
Subhanna N
Subhanna. Assurance nsqa@malnad co in
nsqa@malnad.co.in 9880741703 Mechanical)

Manager Quality
Swamy M.S. Control swamyqc@malnad.co.in 9880741705 NDT Related

Manager Pattern
Manjunath M L Shop manjupatn@malnad.co.in 8861002651 Pattern development
Manager
Subramanya Dispatch and dispatch dates;
Hegde Logistic sharath@malnad.co.in 8861002643 Logistics Details

Process Customer issues/

Mahaveer Jain Engineer mjain@malnad.co.in 8861002642 Customer complaints
 Vision & Mission
The
Th Vision
Vi i off our company is
i to
t

“Become global leader for the supply of finished cast components

in wide range of materials with highly committed and socially
responsible employees”
Our Mission is to
*To meet the casting requirements of the country using latest state
of the art-technology in wide range of materials at competitive
cost.
*Provide stable employment and develop highly skilled technical
manpower and develop wide vendor base.
*Adopt
p environmentally y sound and safe technology gy and create
awareness on energy conservation.
*Serve the community around through welfare schemes.
 Our Progress…
‰ 1985 – Started with 175 KW furnace & 30 MT/Month capacity.
capacity
‰ 1991 – Addition of 250KW furnace & Capacity Enhanced to 100 T/Month.
‰ 1993 – Well known foundry status from IBR .
‰ 1995 – Implemented QMS & Certified for ISO 9001.
‰ 1996 – Implemented integrated ERP system.
‰ 1998 – Certified by AD 2000 MarkBlatt.
‰ 1999 – Enhanced Furnace capacity from 250 to 350 KW & 150T/Month capacity.
‰ 2000 – Qualified for PED Certificate.
‰ 2004 – Direct Export Business Started.
‰ 2006 –Enhanced Furnace Capacity from 350 to 450 KW increasing production to
275T/Month .
‰ 2006 – Added Machine shop.
‰ 2007 – Started LEAN activities.
‰ 2009 – Approval by BV Marine Division.
‰ 2012 – Added testing facilities like PMI, Height Master & Surface tester.
‰ 2012 – Separated processing of stainless steel and carbon steel in different areas.
‰ 2013 – Added 750KW Furnace increasing production to 625T/month
 Our Progress…
‰ 2013 – MAGMA Simulation Software installed
‰ 2014 – Lloyds Foundry Approval.
‰ 2015 – Certified EMS-OHSAS; Highest sales; DNV Foundry Approval
‰ 2015 – New building 31360 sq foot for processing of above 500kg castings
‰ 2015 – Mould
M ld Carousel
C l 8 Station
St ti semii automatic
t ti system
t
‰ 2016 – Fork Lift for Pattern Movement
‰ 2016 – NORSOK Certification for 4A, 5A and 6A Grades
‰ 2016 – Upgraded ISO 9001-2008 to 2015 Version
‰ 2016 – Solar Roof Top Cells 100 KW Capacity Installed
‰ 2016 – 25MT Shake Out Machine With Material Handing EOT Crane 25 /10 MT
‰ 2016 – Mechanized HT Quenching System to facilitate quenching within 50 sec.
‰ 2016 – IBR Well Known Foundry status & certified for Carbon & Alloy Steel up to
2400 Kg single piece.
‰ 2017 – Installed 3MT Capacity Table type Shot Blasting Machine.
‰ 2017 – ISO 14001-2004
14001 2004 upgraded to 2015 Version.
Version
‰ 2018 – Thermal Reclaimation plant
‰ 2018- NABL approved Mechanical & Chemical Lab
‰ 2018- Automatic Scrap p Baling
g Machine
 Our Strength
™ State of Art Omega Semi Automatic Mold Carousal for consistent mold
quality for small & medium casting production with 120 molds/shift
capacity.
™ Mechanised Quenching system for Heat treatment Process.
™ 10 WPS-PQR Certified Operators for various grades witnessed by TUV,
Lloyds & DNV.
™ 10 Qualified Welders for handling the welding activities of various grades
™ More than 15,000 Patterns with 6000 patterns live!. Traceability through
ERP maintained location system and Product code.
™ Exclusive storage
g arrangement
g for p
preservation of p
patterns.

™ 50 to 60 New Products being developed every month.

™ More than 750 fully machined cast components exported / month.

 Our Sales…!!

90 84
90
75 76.52
80 69.03
70
65.39 63.6
60 54.24
50
37.91
40
30
20
10
0
2009 2010 2011 2012 2013 2014 2015 2016 2017

Sales in Cr. INR
Highlights :
¾ Highest sales for financial year 2015 - 15.15 M USD.
¾ Business with Export
p 5.8 M USD
 

Certificates & Awards

                                
™ ISO 9001:2015

™ ISO 14001:2015

™ OHSAS 18001:2007
                               
™ Well Known Foundry Status IBR
Since 1983

™ PED
                                                                                

™ AD MERKBLATT

™ Lloyds, Bureau Veritas & DNV

Foundry Approval

™ NORSOK Process Approval for

4A 5A & 6A
4A,

™ Export Excellence Award By Govt.

Of Karnataka

™ Export Excellence Award By IIF

 Product Mix
Clas s 150
Ball Valve 2” to 30”
to 1500
Valve components Clas s 150
Globe Valve 0.5” to 12”
Pump components
u p co po e ts to 900

Hydraulic Components Gate Valve 0.5” to 12”

Clas s 150
to 900
General Engineering Check Clas s 150
0.5” to 12”
Turbine component Valve to 900

Defence Components Control
0.5” to 16”
Clas s 150
Valve to 2500

5% 5% 5% Butterfly
Valve
2” to 40”
Clas s 150
to 1500

5% Diaphragm
2” to 12”
Clas s 150
Valve to 300

10% Pis ton

2” to 8”
Clas s 150
Valve to 300
70% Double clas s 150
2” to 24”
dis c to 300

Check clas s 150

2 " to 12 "
Valve to 300
Customer Base

China
Major Customers
 Foundry Capacity
™ Total Capacity - 625 MT/Month. Utilized Capacity - 350 MT/Month
(in view of recession in market).
™ Maximum Single Piece Weight We Can Produce is 2400 Kgs.
 3/19/2018

2400 Kg Butterfly Valve

2 00 K
2700 Kg CCasting
i E Exported
d
from Malnad

17
 Typical Lead Time

SECTION TIME REQUIRED

Pattern Development 3 weeks

Sample Castings (Including Radiography 45 Working Days (From the date of receipt Pattern
Test) ready for molding)

Sample Machining 3-4 Weeks (From Receipt Of Castings)

Production Castings 45 Working Days

Production Machining 75 Working Days

All the above lead time depends on the size & complexity of the castings.
 Material Of Construction
™ Carbon Steel
ASTM Grades WCB,WCC,WC6,LCB,LCC,WC9
™ Alloy Steel
C5,C12,C12A
™ Stainless Steel
CF8, CF-8C, CF8M,CA-15,CD4MCU,CD4MCUN, Grade 4A, 5A, &
6A, CN7M,CF-3,CF-3M, CG8m,CA6NM, SS420.
CA40, SS410, SS430, 17.4PH
™ Nickel Base Alloys
CW12MW CW2M,CW6M,CW6MC,CU5MCuC,N7M,N-12MV.
CW12MW, CW2M CW6M CW6MC CU5MCuC N7M N-12MV

All the above grades corresponding to DIN and Indian Standards.

 Pattern Methoding And Mounting

Magma Simulation Pattern Mounting

 Manufacturing - Molding

NO BAKE SYSTEM
Continuous Mixer 12MT/Hour 1no
Continuous Mixer 6MT/Hour 2nos
C i
Continuous Mixer
Mi 1 5MT/H
1.5MT/Hour 2
2nos
Batch Mixer 150Kgs 2nos
Mechanical Sand Reclamation 8MT/Hour 1no
M h i lS
Mechanical Sand
dRReclamation
l i 4MT/H
4MT/Hour 1
1no
 Manufacturing - Molding
Core Making Mold Coating

.
 Manufacturing - Melting

Medium Frequency
Induction Furnaces
750 KW 3000 Kg & 2000 Kg
C ibl
Crucible
450 KW 1500 Kg & 1000 Kg
Crucible
175 KW 300 Kg & 150 Kg
Crucible
One Crucible is standby in all the above cases.
 Manufacturing – Post Pouring
¾ Shot Blasting g Machine
1MT hook type - 1 No
5MT hook type - 1 No
¾ Shot blasting machine
Table type
yp 1 MT - 2 Nos.
Table type 3 MT - 1 No
¾ Aluminum grit blasting
Machine 750 Kg - 2 Nos.
Room Blast - 2 Nos.
¾ Pedestal grinding
Machine 3HP - 1 No
¾ Swing frame
Grinding g Hp
p - 4 Nos.
¾ Flexible shaft with variable
Speed 2.5 HP - 25 Nos.
¾ Subcontracting Facilities:
3 Groups p within the campus
p with
capacity 20 & 80 MT/Month.
6 Subcontractors outside with
total capacity 350 MT/Month
 Manufacturing – Heat Treatment
g
Mechanised Quenching
3&7
7.5
5 Ton Furnaces
System

Furnace Name Capacity (KW) Tonnage capacity

All 6 furnaces are Electric PLC Controlled
HTA 100 2.5 Tones
2 Water Quenching facilities with 60000 &
HTB 60 2 tones
75000 liters with cooling system.
HTC 100 3 tones
All furnaces are validated as per API 6A ;
HTD 100 4 tones
THE 40 1 tone
NORSOK in the presence of external
HTF 150 7 .5
5 ttones agency
Malnad Alloy Castings Pvt Ltd ( Laboratory Division)
NABL ACCREDITATION FOR CHEMICAL AND MECHANICAL LAB
Chemical Tests
´ Optical Emission Spectrometer
´ Intergranular Corrosion test
´ Pitting Corrosion test
Mechanical Tests
´ Tensile strength
´ Yield
i ld Strength
S h
´ 0.2% Proof Strength
´ % Elongation
´ % Reduction in Area
´ Brinell Hardness (HBW 10/3000)
´ Bend Test (Root; face; side )
´ Impact Test (Charpy “V”)
´ Inclusion Rating
´ Micro Examination Graphite Flakes/ Nodules
Type and Size, Distribution Characteristics and
Matrix Analysis
´ Determination of Volume Fraction of Phase
 Testing Facilities (NABL Lab)
Spectro Analyzer with Three Base Metal - Iron, Nickel and Cobalt with 25
elements including Nitrogen And Oxygen.

Group of Specification, standard

Specification
products, materials or (method) or technique
items tested used

NABL SCOPE –OES Method

Ferrous / Low Alloy ASTM E415:2015 /

Steel IS 8811:1998 (Ra 2012)

Ferrous / Duplex ,
ASTM E1086:2014 /IS
Super Duplex ,
9879:1998 (Ra 2009)
Stainless Steel

Nickel & Nickel alloys

ASTM E 3047:2016
Testing Facilities (NABL LAB)
Group of Specification, standard Range of testing/ Measurement
Specific tests or types
products, material (method) or technique Limit of detection Uncertainty ( )
of tests performed
s or items tested used (%) (%)

Intergranular-
Duplex
Corrosion Test – ASTM A923: 2014 Qualitative NA
Stainless Steel Method A

Intergranular
Corrosion Test
Stainless Steel
Wrought / Cast ASTM A 262-2015 4 mils/year @ 27
IGC Practice B upto 100 mils/year
Products mils/year
y

Bend Test (Visual)

IGC Practice E NA
Qualitative

Pitting corrosion 2 0.17 g/m2 @ 0.60

Stainless Steels ASTM G 48 – 2011 0.1 – 4.0 g/m
g/m2
Test – Method A
Testing Facilities (NABL Lab)
Group of Specification, Range of
Specific tests or Measurement
products, mat standard testing/
types of tests Uncertainty
erials or items (method) or Limit of
performed (± )
tested technique used detection

Tensile Test 9.0 @ 554 N/mm2

ASTM A370-
A370
Yield Strength 2017 100 – 1500 9.0 @ 324 N/mm2
ASTM E8/8M- N/mm2
0.2% Proof 2016 7.0 @ 448 N/mm2
Strength IS 1608-2005
Ferrous
% Elongation (Ra 2011)
Metals ISO-6892 Part 2.1 % @ 35 %
1 – 80 %
% Reduction in 1-2016
& Area 1.4 % @ 67 %

Alloys Mandrel
diameter
Bend ASTM A370- 15mm,25mm NA
Test 2017 ,60mm
Qualitative
Testing Facilities (NABL LAB)

Group of
Specification, Range of testing/ Measurement
products, Specific tests or types of
standard (method) or Limit of Uncertainty
materials or tests performed
q used
technique detection ((± )
items
it tested
t t d

Ferrous & Non ASTM E10-2017

Ferrous Metals Brinell Hardness (HBW IS 1500 Part 1- 4.0 @ 154 HBW &
2013/ 120-450 (HBW)
Including Weld 10/3000) 7.0 @ 202 HBW
Metals ISO – 6506:1-2005
6506:1 2005
Testing Facilities (NABL LAB)

Calibrated using NIST USA samples

Specific
Specification,
Group of tests or Range of Measurement
standard
products, material types of testing/ Limit of Uncertainty
(method) or
s or items tested tests detection (± )
technique used
performed

Ferrous & Non

Ferrous Metals 4 – 240
Impact 6 Joules @ 84
(Including Weld ASTM E23 – Joules (Room
Test Joules
Metals & All 2016 temperature
(Charpy (-46°C)
Weld Metals to minus
“V”)
Like Plates, 196°C)
Rods, Pipes Etc)
Testing Facilities (NABL LAB)
Specification,
Group of Range of
Specific tests or standard
products, testing/
types of tests (method) or
materials or Limit of
performed technique
items tested detection
used

ASTM E3:E3
2011 (RA 2017)
Ferrous ASTM E407-07 100x,200x,40
Micro Structural
Metals And (RA 2015) 0x, 1000x
Characterization ASM Metals (Qualitative)
Alloys
Hand Book
Vol. 9: 2004

Micro
E
Examination
i ti ASM Metals
Nodules Type Hand Book
S.G. Iron Vol. 9: 2004
100x
Products and Size, ASTM A247:
(Qualitative)
Distribution 2016
Ch
Characteristics
t i ti
 NDT Testing Facilities

¾Magnetic
g Particle Inspection
p
¾Ultrasonic Test
¾Die Penetrate Test,
¾RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters.
¾5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard.
 NDT Qualifications
LIST OF N.D.T QUALIFIED INSPECTORS AND OPERATORS - M.A.C.P.L.

SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY

EN-3197CERT/NDT-0564-16 √ R.T 23‐Sep‐2021

P2MG03905 √ L.P.T.
1 Mr.M.S.SIDDALIGESWARA SWAMY M2MG03905 √ M.P.T. 5‐May‐2019
R2MG01905 √ R.T
RT
BNDT/134/UT/II/10 √ U.T. 22‐Oct‐2019
BNDT/114/PT/II/10 √ L.P.T.
BNDT/115/MT/II/10 √ M.P.T.
2 Mr.C.U.KESHAVAMURTHY
√
22‐Oct‐2019
BNDT/116/RT/II/10 R.T
BNDT/117/UT/II/10 √ U.T.
BNDT/124/PT/II/08 √ L.P.T.
BNDT/125/MT/II/08 √ M.P.T.
3 Mr.A.VIGHNESHWARA MANJA
√
20‐May‐2019
BNDT/129/RT/I/10 R.T
BNDT/130/UT/I/10 √ U.T.
HYD/B/266 √ L.P.T.
4 Mr N SURESH RAO
Mr.N.SURESH 20‐Apr‐2019
HYD/B/266 √ M.P.T.
HYD/B/263 √ L.P.T.
5 Mr.DOULATH PASHA 20‐Apr‐2019
HYD/B/263 √ M.P.T.
BNDT/123/PT/I/08 √ L.P.T.
6 Mr.GAJENDRA 20‐Apr‐2019
BNDT/122/MT/I/08 √ M.P.T.
BNDT/117/PT/I/08 √ LPT
L.P.T.
7 Mr.K.MANJUNATHA 20‐Apr‐2019
BNDT/116/MT/I/08 √ M.P.T.
BNDT/118/PT/I/08 √ L.P.T.
8 Mr.KRISHNA 20‐Apr‐2019
BNDT/119/MT/I/08 √ M.P.T.
HYD/B/268 √ L.P.T.
9 Mr.NANJAPPA.N 20‐Apr‐2019
HYD/B/268 √ MPT
M.P.T.
Quality/Testing Facilities

0.50” Flow Bore Casting

 Other Testing Instruments :-

™ Ultrasonic Thickness Gauge

™ PMI

™ Digital Poldie Hardness Tester

™ Ferrito Scope
p

™ Radio Active Contamination Detector

™ Digital pH Meter

™ Digital Lux meter; Sound meter; Tachometer

™ Casting Comparator From Steel International France

™ Infrared Temperature measuring instruments 500 °C & 1600 °C

 Manufacturing – Machine Shop
In House Machine Shop equipments & Facilities

™ Vertical Machining Centre.

™ CNC Turning Centre.

™ Conventional Lathes

™ Radial Drilling Machine

™ Conventional Milling
g

™ Hydro Testing Machine for 150/300/600

& 900/1500/2500 CLASS

™Malnad hydro procedure in line with

ASNT and EN standards

Thermal Reclaimation Plant
 Web Access To Customers
™ Website address: www.malnad.co.in (59.90.137.114)

™ Customers will be given with unique login id & Password

™ Data Available: Order Acceptance, Order Status, Test

Certificates (3months) Dimension Ins Report, NDT
Reports & Pattern List
™ Automated mail generation is developed to inform the
suppliers
li th
the receipt
i t off th
the material
t i l against
i t our PO

40
 On Going Projects-2017-18
™ In house Radiography facility for Iridium and Cobalt
Sources with film development And for handing 3ton
castings

Planned Projects
™ Energy Management System
™ Rain water harvesting

41
 EMS Measures
™ Bio Diesel as a Replacement for Petroleum Diesel
™ Transparent sheets in order to avoid electric lights in day time
™ Roof Top Solar Cell with 100KW capacity
™ Solar Lights to reduce usage of Hydro Electricity during day time
™ CETP of capacity 25000 liters installed
™ RO plant
l t having
h i capacity it off 1500lts/hour
1500lt /h capacity
it hhas b
been iinstalled
t ll d

100 KW Roof top static RO plant 50+ Plants planted

solar
l cellll installed
i t ll d in
i 1500lts/hour capacity A
Across Th
The Company
C
hall number 7 Compound
 3/19/2018

SHIMOGA PRECISION CASTINGS PVT LTD

45
 3/19/2018

Our Progress

™ 1996 – Start up of Production .

™ 2001 - Started
St t d ERP
™ 2002 – ISO 9001 Certification.
™ 2008 – Added new building for shell activity
™ 2009 – Started Wax formulation in house
™ 2010 – Started Manufacturingg of Ceramic cores
™ 2013-14 – 7.8 Crore sales(INR)
™ 2014-15 – 15 Crore sales (INR)
™ 2016 – ISO 9001 upgraded to Latest version 2015
™ 2017 – EMS & OHSAS Certifications under progress

SHIMOGA PRECISION CASTINGS PVT LTD

46
 3/19/2018

Facility Details

™ p
Total Installed Capacity y - 40MT p per Month.
™ Utilized Capacity – 25 MT per Month.
™ Single piece we can pour up to :40 Kgs
™ Experts in-Steam Trap, Control Valve components
™ Special grades: Stellite-6
Stellite-6,Stellite-21,NNRD2,Monel-
Stellite-21 NNRD2 Monel-
M35, Ultimate Alloy, Duplex steel apart from
standard Austenitic,, Martensitic Steels

SHIMOGA PRECISION CASTINGS PVT LTD

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 3/19/2018
Various Stages Of Investment Casting

SHIMOGA PRECISION CASTINGS PVT LTD

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 Customer Base

SHIMOGA PRECISION CASTINGS PVT LTD

3/19/2018

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Manufacturing Experience
Ball Valve 15MM TO 25 MM Class 150 to 300

Globe Valve 0.5” to 2 ” Class 150 to 900

Gate Valve 0.5” to 2” Class 150 to 900

Check Valve 0.5

0 5” to 2”
2 Class 150 to 900

Control Valve 0.5” to 3” Class 150 to 2500

Butterfly Valve 2
2” to 4”
4 Class 150 to 1500

Diaphragm Valve Upto 2” Class 150 to 300

Piston Valve Upto 2” Class 150 to 300

Double disc 2” to 4” Class 150 to 2500

Check Valve

SHIMOGA PRECISION CASTINGS PVT LTD

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 3/19/2018

MALNAD PRIME MACHINING TECHNOLOGY

54
M Malnad Prime Machining Technology Private Limited, a Sister concern of Malnad Alloy Casting,
A is well equipped to machine up 10” size Valves.
C We have following CNC machines with the table size details. We can supply the castings in
H completely machined & Hydro tested condition.
I Machines Specification
Size
X Y Z
N HAAS VF2 762 406 508
VMC
I VCS 430A 560 430 510
550 MAX TURNING  DIA 650 ‐ MAX TURNING LENGTH 700
N VTL
650 MAX TURNING DIA 800
MAX TURNING  DIA 800   ‐ MAX TURNING LENGTH 750
MAX TURNING LENGTH 750
G HMC HORIZONTAL CENTER NEXUS 5000‐2 730 730 740
CNC ‐ Turning MAZAK E160C 165 ‐ 330
9C Lathes
Conventional Lathes
F 9C Lathes
9C Lathes
Radial Drilling Machine
A
C
I
L
I
T MALNAD PRIME MACHINING TECHNOLOGY
Y
 3/19/2018

Thank You

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