Iron Casting Capability — Variex Enterprise LLP

Manufacturing Scope

Core Processes

→SG (Ductile) Iron Casting — Automated RHINOLINE green sand moulding line (GGG40–70 grades)
→CI (Grey) Iron Casting — High-damping automated green sand moulding (FG200–300 grades)
→Core Making & Shell Moulding — 3× Shell core shooter machines for complex internal passages
→Multi-Axis Precision Machining — Pallet-changing VMCs, CNC turning, VTL, milling, drilling & grinding
→Automated CED (Cathodic Electrodeposition) Coating — In-house anti-corrosion E-coating with real-time bath monitoring
→Fettling & Surface Cleaning — High-speed shot blasting, grinding and degreasing

Technical Parameters

Infrastructure Overview

A fully self-contained manufacturing ecosystem ensuring seamless quality from raw molten melt to finished, painted components.

Unit 01 · Foundry

Automated green sand foundry engineered for high repeat accuracy, dense microstructure, and zero shrinkage defects.

▸Induction Furnaces: 500kg dual crucible (1 no.) + 300kg uni crucible (1 no.)
▸Moulding Line: RHINOLINE auto moulding line (600×600×175/150mm box)
▸Moulding Speed: 45–50 moulds per hour continuous rate
▸Moulding Machines: 2× Pneumatic moulding machines
▸Sand Plant: Automated sand preparation with 200kg & 500kg sand mixers
▸Core Making: 3× Shell moulding machines (Core Shooters)
▸Surface Finishing: Shot blasting machine & dedicated pattern room

Unit 02 · Machining

Comprehensive 250 Tons/month machining facility equipped for high-precision finish machining and close tolerances.

▸Twin Head VMC: 2 nos. for simultaneous machining
▸Twin Head Pallet Changer VMC: 5 nos. for non-stop cycling
▸Single Head / Rotary VMC: 12 nos. (table up to 800×600×700mm)
▸CNC Turning Centres: 6 nos. (handling turning up to Ø360mm)
▸Vertical Turret Lathe (VTL): 1 no. for large diameter parts
▸Special Purpose Machines (SPMs): 6 nos. (incl. Timing Mark & Tool Grinding)
▸Conventional Fleet: 13× Lathes (7ft & 4ft), 10× Drilling, 2× Milling, 1× Cylindrical Grinding, 2× DTC

Unit 03 · Coating

Automated Cathodic Electrodeposition coating plant delivering superior corrosion resistance and uniform coverage.

▸Protective CED Coating: High-adhesion anti-corrosion layer for harsh environments
▸Uniform Finish: 100% paint penetration into complex cavities & deep bores
▸Automated Bath Control: Real-time monitoring of pH, conductivity & bath chemistry
▸Salt Spray Test Chamber: In-house chamber for accelerated corrosion testing (ASTM B117)
▸Chemical Lab Setup: In-house alkali, acid, and film thickness evaluation
▸Reliable & Eco-Friendly: Low VOC, uniform thickness, and cost-effective process

Quality Assurance

End-to-end quality controls covering raw material, molten chemistry, sand properties, machining metrology, and coating durability.

✓Optical Emission Spectrometry: Real-time chemical composition verification
✓Molten Metal Control: Pyrometer temperature tracking & Carbon Equivalent (C.E.) meter
✓Sand Testing Lab: Sand Siever, Permeability Tester, Moisture Tester & Rammer
✓Mechanical Testing: BHN Hardness Tester, Rockwell Hardness Tester & Tensile Testing Machine
✓Metallographic Analysis: Metallurgical microscope with digital image analyzer (nodularity & graphite type)

✓3D CMM Metrology: Carl Zeiss CMM (500 × 500 × 600 mm) for critical coordinate inspection
✓Surface Roughness: Zeiss Surface Tester for precise Ra & Rz parameter validation
✓Leakage Testing: 4× Auto Leakage Testing Machines with custom fixtures
✓Millipore Testing: Part cleanliness and residual particle gravimetric analysis
✓CED Inspection Unit: Salt Spray Chamber & wet chemical lab for bath & coating verification