Project name:- Reclamation of Waste foundry sand

Company Name:- Deccan Crest Engg. Pvt. Ltd

Project Leader :- Vithoba Malgaonkar

Qualification :- B.E. Chemical Engg.

Current Position :- Co Founder

Mission of our startup is to reclaim the waste foundry sand economically. Especially for
small and medium-scale foundries which will make them fully or partially independent on
relatively expensive fresh sand and save their waste sand dumping cost.

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 Founding Team

Mr. Vithoba Malgaonkar, Dr. Mohd Moiz Khan, Mr. Rohit Vishwakarma,
Process & Design Research & Development Marketing

Prof. S.M. Mahajani, Prof. G.N. Jadhav, Devdutt Adr, Shraddha Mandre,
Technical Advisor, Technical Advisor, Foundry Finance
IIT B IIT B Consultant

Full time employees = 4 2

 Introduction : Foundry overview
• About 70 % of the cast metal objects around
us, from bathroom taps to airplane gearboxes,
are manufactured in foundries.

• India is the second largest producer of the

casting in the world ( 14 MMTPA).

Source – Global casting report 2020

Fig :- Foundry Process

Fig:- Dumped
waste Foundry
sand, Kolhapur
Fig:- Casting Process Fig:- Desired Castings
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 Problem
• Around 5000 foundry units in India

• Sand dumping 10 million tons per annum (IIF,

2016).

• Waste foundry sand contains toxic heavy metals

and particulate matter.

• Diseases (cancer, chronic cough etc.) because of

sand dumping .

• Sand mining per annum is

Fig:- Dumped waste Foundry sand, Kolhapur

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Fig :- Sand mining site, Phonda, Sindhudurg
 Severity of the Problem :- Need for
Reclamation
• Survival of small scale (~1 TPD) foundries at
stake

• Government has banned sand mining at

various places across the country

• No convenient dumping sites are available

near foundry cluster

• Cost of fresh sand gone up by 80 % in past

10 years while fright by 125 %

• Environmental issue can be threatening to

the survival of foundry

• No indigenous cost effective reclamation

technology is available
We conducted 107 interviews
across the country and their
priorities are listed above.
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 Our Solution

(Indian Patent Application No. 201721023693)

Fig:- Pilot plant installed at Kolhapur

• Plant capacity is 4 TPD ( Tons per day).

• Till now we have reclaimed 200 tons waste green sand. 6

 Field Trials: Malati Founders Pvt. Ltd.

Fig :- Casting was made by using our reclaimed sand at Malati

Fig:- Reclaimed sand dispatched to Malati
Founders pvt. Ltd.,
Founders Pvt. Ltd., Kolhapur for mold making

• Fresh Sand cost = 2950 Rs/ton

• Reclaimed Sand cost = 1200 Rs/ton

• Savings on sand of Malati Foundry by using our reclaimed Sand = 59.32 %

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 Work Plan & Budget Breakup
Work Required Budget
i) Reallocate the plant in industrial area near the 6 Lakhs
foundries.
ii) Our team members will do the marketing.
iii) Reclaim 50 tons waste green sand and sell this to
foundries.

i) Reclaim 100 tons waste green sand & sell this to 3 Lakhs
foundries.
ii) Reduce waste sand dumping of 10 foundries fully or
partially.
iii) Reduce the dependency of foundries on expensive
sand mining.

i) Enhance the plant capacity ( 200 TPM) to cater the 3 Lakhs

need of 15-20 foundries.

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 Month 1-Month 3 Month 4-Month 6 Month 7-Month 8

90 days 90 days 60 days

Set up
Continuous
Chemical
reclamation plant
in industrial area
(capacity 125
TPM)
Marketing by
Team Members

Reclaim 300 ton

waste CO2 sand
& sell this to
foundries

Enhance the
plant capacity
from 123 TPM to
250 TPM