Quality Control___________________________________________

In our foundry, we prioritize three key aspects to maintain quality: raw material quality and testing, process control, and workmanship. We have skilled workers for molding and core fitting, and we also have pattern makers available to assist molders with core fitting and other tasks if needed. We also give training to our team regularly.

To ensure raw material quality and casting quality, we work closely with Metafore Synthesis, an associated company where our company director is a partner. We test all major incoming materials and exercise strict control over each batch of incoming raw materials and outgoing products.

For melt quality control, particularly in cupola operations, both input side control and operational control are crucial. We meticulously test and weigh all major incoming materials during the charging process to maintain proper metallurgy. Additionally, we have our own Blast master to measures and controls air flow and pressure in the cupola, which helps us maintain consistent chemistry and temperature. We rely on tools such as pyrometers, CE meters, and chill tests for online melt quality checking. If any corrections are necessary, we take appropriate actions.

Regular testing of our molding sand is an essential part of our quality control process. We also calibrate our mixers at least once in a shift to ensure proper chemical addition. During the molding process, we monitor the quality by checking sand moisture and evaluating mold hardness using a scratch hardness tester. Furthermore, after core fitting and mold closing, we inspect the molds with a boroscope camera to verify that there are no issues.

By implementing these measures, we, as a team, are dedicated to maintaining the highest standards of quality in our foundry operations.

For heavy casting we have facility for Poldi hardness testing.

We also have facility for die penitration test.

We do chemical (wet analysis) & also do tensile testing & micro. Metafore Synthesis has following facilities.

1. Metallurgical Microscope with photographic attachments for microstructure analysis.
2. Wet analysis for following elements in Ferrous Alloys - Carbon, Sulphur, Silicon, Phosphorus, Manganese, Chromium, Tin, Copper, Nickel, Vanadium, Molybdenum, Lead.
3. Ferro Alloys analysis for - Ferromanganese, Ferrosilicon, Ferrochromium, Ferrophosphorous, Ferromolybdenum, Ferrosulpher (Iron Sulphide), Ferrosilicon Mg (Si,Mg).
4. Raw material testing for coke and coal dust - Ash, Volatile Matter, Sulphur, Phosphorus.
5. Limestone testing for - Loss On Ignition, Si02, CaO
6. Bentonite testing for - pH, Swelling capacity, Gel time, M.B. Test of Bentonite, Base Sand-Clay content (A.F.S. Clay), Base Sand-Acid Demand Value, Silica content in Base Sand.
7. System Sand testing for - Volatile Matter, Loss On Ignition, Total Clay, Active Clay, Dead Clay, A.F.S. NO., Moisture
8. Non Ferrous Alloys-Gunmetals, Brasses, Bronzes etc. testing for - Copper, Lead, Tin, Phosphorus, Zinc (by difference).
9. Tensile Testing.

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Bhavani Iron Industries Pvt. Ltd., 1325/1-B Shivaji Udyamnagar, Kolhapur 416008, India