KLRF Super Casting

Engineering since 1974

Established in 1974, in the industrial hub of Coimbatore, Eltex Super Castings is a pioneering foundry in South India. We manufacture high-precision Grey, SG and Alloy Iron castings in complex shapes. It is a part of the Kovilpatti Lakshmi Roller Flour Mills Ltd Group.

Our foundry and systems are fully compliant and internationally certified, making us the foundry of choice for our many customers. Today, Eltex Super Castings supplies clients in several industries, including Automotive, Agricultural, Textile, Food and Oil & Gas.

Our Products

Eltex Super Castings specializes in manufacturing of Grey, SG and Alloy Iron Castings – both machined and un-machined. Our products include precision metal casting components for Automobiles, Earth Movers, Agriculture Machinery, Tractors, Textile Machinery, Valves, Pumps and General Engineering.

Our manufacturing processes reduce material cost and include a high degree of precision, reducing the 'after-work' required. Certain features can be made as-cast, or simpler castings joined to form a bigger single-piece casting.

Steering box

Rotor

Mounting brackets

Steering box

Rotor

Mounting brackets

Manifolds

Crank Case

PTO Cover

Manifolds

Crank Case

PTO Cover

Textile machine parts

Pump Casing

Coffee pulper

Textile machine parts

Pump Casing

Coffee pulper

Our Capabilities

With an installed capacity of 15,000 MT per annum, our manufacturing facilities are well equipped with the latest technology.

Uniqueness

Eltex Super Castings has a state-of-the-art plant with Sinto® FBO III N Flask less High-Pressure Molding Line (HPML). Our High-Pressure Molding Process consists of mainly the FBO III N and mold transporting conveyor.

Advantages of our HPML:

Productivity

133 Sand molds per hour (29 seconds/Mold), for without core jobs
75 Sand molds per hour (45seconds/Mold) for core jobs

Flexibility

Small / Large / Multiple cores can be set within the cycle time
Single Minute Exchange of patterns within 9 minutes

Quality

Maximum mismatch of two halves of the castings does not exceed 0.2 mm
Due to pouring in a horizontal mold, defects due to ferro-static pressure issues are minimised

Cost

Molding sand consumption is minimised due to variable mold thickness between 130 to 190 mm

Metallurgical capabilities

GREY IRON - ISO 185 (ASTM A48)

Grade 150 (No20/No25)
Grade 200 (No30)
Grade 250 (No35)
Grade 300 (No40/No45)

DUCTILE IRON – ISO 1083 (ASTM A536)

Grade 400/15 , 400/18 (60-40-18)
Grade 450/10 (60-42-10 , 65-45-12)
Grade 500/7 (70-50-05)
Grade 600/3 (80-55-06 , 80-60-03)
Grade 700/2 (100-70-03)

ALLOY IRON (DUCTILE IRON)

SiMo (Silicon Moly):
For exhaust applications

SiMoCr:
Exhaust manifolds

Engineering capabilities

Intricate castings

Hydraulic pumps

Crank cases

Bed plates

Engine mounting brackets

Steering boxes

Damper pulleys

Differential cases

Spinning machine frames

Pump casings

Valve bodies

Exhaust manifolds

Pipe fittings

Our Facilities

Our main production facility is housed in 1,06,658 Sq. ft. area with separate administrative office, machine shop, pattern shop, fettling shop, laboratory, and stores.

Moulding

High Pressure Mould Line (HPML) Sinto® FBO III N - Box Size 508x660x190/190mm. Wt 4 Kgs to 36 Kgs
DISA - ARPA 300 Moulding Machines – 2 Lines & Box Size 400x520x200 / 150mm. Wt 1 Kg to 20 Kgs
DISA - ARPA 450 Moulding Machines – 1 Line & Box Size 510x560x200 / 200 mm. Wt 20 Kgs to 30 Kgs
DISA - ARPA 900 Moulding Machines – 1 Line Box Size 850x750x200 / 300 mm. Wt 30 Kgs to 100 Kgs & Box Size 1150x750x200 / 200 mm. Wt 40 Kgs to 100 Kgs
Fully Automatic Sand Plant – Green Sand Moulding
Fully Automatic Sand Mixing System with PLC
Disa® Sand Mixer with Simpson - Hartley controller, Simpson Sand Cooler & Disa® Dust Extraction System
Integrated Cooling Conveyors, Shakeouts and Shot Blasting Facilities.

Melting

Medium Frequency - Electrical Induction Furnace –2.0 T (Dual Track) – 2 units (each 1500 KW)
Medium Frequency - Electrical Induction Furnace – 1.0 T (750KW / hr) – 1 unit
Sandwich SG Iron Treatment Process
Monorail Pouring system

Core making

Cold Box Core Shooter - 5 Liter capacity - 3 units
Cold Box Core Shooter - 10 Liter capacity – 1 units
Shell Core Shooter - 5 Liter capacity - 5 units
Shell Core Oven – 2 units
Baking Oven – 2m x 2m – 1 unit
Baking Oven – 2m x 4m – 1 unit

Quality - metallurgical labs

We use Ultimate Tensile Test, Transverse Shear Stress, Micro Structure of Casting, Hardness Testing and Chemical Testing approach to design critical components.

Direct Reading Spectrometer –25 Channels
Microscope with Image Analyzer CARL ZEISS
Brinell & Rockwell Hardness Testers
Universal Testing Machine – 40MT Capacity
Non Destructing Testing – Ultrasonic, Magnetic Particle, Die Penetrant test

Radio Activity Contamination Check Equipment (RAD Check)
In-house Wet Analysis / Raw Material / Moulding Sand testing
Leak Testing – for specific component
Endoscopy from IT concept

Pattern shop/ development

Comprehensive Pattern Repair & Maintenance
Cutting Machine
Radial Drilling Machine
Swivel Index
Surface Tables
Radiography Viewer
Height Gauges, Calipers etc

Software systems

Solid Works – 3D software
AUTO CAD - 2D
ERP:
Enterprise resource, process & financial planning system
Right Quote:
Software for new product selection
RAMP:
Software system for performance analysis

Finishing

Shot Blasting Machines – 4 units
Hanger type
(1200x1200x1500mm Chamber Size) - 2 units
Tumble Blast Machine – 1 unit
Nozzle Blast Machine - 1 unit
Hydraulic Press - Runner/Riser Breaker
Swing Frame Grinders
Pedestal Grinders
Pneumatic Grinders
Electrical Grinders
Sanders etc

Integrated Machining Facility

VMC - Model MCV450 – twin pallet – 3 units
CNC – lathe – 1 unit
Conventional lathe – 8 units
Vertical milling machine – 2 units
Radial Drilling Machine – 2 units
Drilling Machines – 3 units

Other facilities

VMC - Model MCV450 – twin pallet – 3 units
CNC – lathe – 1 unit
Conventional lathe – 8 units
Vertical milling machine – 2 units
Radial Drilling Machine – 2 units
Drilling Machines – 3 units
High Pressure Mould Line (HPML) SINTO FBO III N - Box Size 508/660

Powder Coating - with Auto Conveyor and 7 Tank
Fork Lift (3 MT)
BINs - Material Handling
Weigh Bridge - 20 MT
Compressors - 4 units (190, 380, 525 & 760 CFM)
Diesel Generators – 1 unit (500 KVA)

Outsourced facilties

Pattern & Tooling Machining
Casting Simulation / Mould Flow Simulation
Heat Treatment
Radiography
E-Coating
Machining

2008

Best Performance Award from Brakes India Ltd.

2009

Certificate of Merit Award from Indian Institute of Foundry Men
Best Supplier Award from Elgi Equipments Ltd.

2010

Coveted ISO 9001:2008 Certification (Awarded by TUV SUD)
Coveted ISO/TS 16949:2009 Certification (Awarded by TUV SUD)

2011

Retained Best Supplier Award from Rane TRW

2012

Awarded the prestigious SQ MARK Certification from Hyundai Corporation, India
Excellent Support and Performance Award from Rane TRW

2012

Coveted Certificate ISO 27001 for Information Security
(Awarded by TUV SUD South Asia Pvt. Ltd.)

2014

Best Performance Award from Brakes India Ltd.

2015

Best Support For New Product Development Award from Rane TRW

2017

Coveted ISO 14001:2004 Certification of Environmental Management System (Awarded by TUV SUD)
Coveted ISO 18001:2007 Certification of Occupational Health & Safety Management System (Awarded by TUV SUD)