Two integrated plants
Production runs across two facilities covering the full route in-house: pattern making, moulding, melting, heat treatment, machining and inspection. No critical stage depends on an outside supplier.
Infrastructure
What we run
Two integrated plants covering the full route in-house. Heat treatment in particular stays with us rather than being subcontracted, because it is the stage that decides how a wear casting actually performs.
- Years in castings
- 40+
- Annual capacity
- 3,000 t
- Piece weight
- 5–2,000 kg
- Integrated plants
- Two
Melting shop
Induction furnaces with optical emission spectrometer control. Chemistry is read and corrected before the heat is tapped, which is what makes composition repeatable from one heat to the next.
Moulding lines
No-bake resin sand for larger and dimensionally critical castings, green sand for higher-volume runs. Piece weights from 5 kg to 2,000 kg, at roughly 3,000 tonnes a year.
Heat treatment furnaces
Computer-controlled furnaces with recorded cycles, kept in-house rather than subcontracted. Solution annealing and water quenching for manganese steel, destabilising and tempering for high chrome.
Pattern shop
Patterns built in wood, resin or metal from OEM drawings, customer drawings, a sample or a worn casting. The mounting faces of a used part do not wear, so they carry enough geometry to rebuild from.
Machining & finishing
Fettling to remove risers and gates, then machining of mounting faces, bores and locating surfaces where the drawing calls for it.
Testing facilities
Spectrometer analysis, Brinell and Rockwell hardness testing and dimensional inspection on site. Ultrasonic, magnetic particle and dye penetrant testing arranged where a specification requires it.
Location & logistics
The works sit roughly 50 km from Delhi International Airport in India’s National Capital Region, which keeps inland haulage short and container freight straightforward.
Capability
What we can pour
Individual castings from 5 kg to 2,000 kg, at roughly 3,000 tonnes a year, in the alloy families the duty calls for.
Manufacturing
How a Melco casting is made
Six stages from pattern to packed pallet.
Pattern shop
Every casting starts as a pattern. We build from OEM drawings, customer drawings, a physical sample or a worn part. The mounting faces of a used casting do not wear, so they carry enough of the original geometry to rebuild from. Patterns are made in wood, resin or metal depending on how many castings the tooling has to produce.
Moulding & casting
Moulds are produced in no-bake resin sand for larger and more dimensionally critical work, and green sand for higher-volume runs. Metal is melted in induction furnaces and the chemistry is corrected against a spectrometer reading before the heat is tapped, so composition is confirmed rather than assumed. Piece weights run from 5 kg to 2,000 kg.
Heat treatment
Heat treatment is where a wear casting gets its properties, so we keep it in-house rather than subcontracting it. Manganese steel is solution annealed and water quenched to ASTM A128. High chrome irons are destabilised and tempered to bring the matrix to martensite. Cycles are computer-controlled and recorded against the heat number.
Fettling & machining
Castings are fettled to remove risers and gates, then machined where the drawing calls for it: typically mounting faces, bores and locating surfaces. On wear parts the priority is the fit: a bar or hammer that does not seat squarely damages the machine it is fitted to.
Inspection
Each heat is checked for chemical composition, hardness and dimensional conformity against the drawing. Results are recorded against the heat number so a casting in the field can be traced back to the melt it came from.
Packing & despatch
Castings are strapped to ISPM-15 heat-treated timber pallets, edge-protected and marked with part and heat numbers. Container loading plans and test certificates travel with the shipment, which is what keeps clearance straightforward at the destination port.
Quality control
Tested before it ships
A wear casting either has the right composition and the right heat treatment, or it does not last. Both are verified in-house and recorded against the heat number, under a quality system certified to ISO 9001:2015.
Chemical analysis
Every heat is analysed on an optical emission spectrometer before tapping. If the composition is outside the grade window it is corrected in the furnace, not accepted and explained afterwards. The certified analysis is issued against the heat number.
Hardness testing
Brinell and Rockwell testing confirms that heat treatment achieved the specified hardness. For manganese steel we verify the as-supplied condition is correct for ASTM A128, because a manganese casting that is already hard has almost certainly been heat treated wrongly.
Dimensional inspection
Castings are checked against the drawing with templates, gauges and coordinate measurement where the tolerance calls for it. Mounting and locating faces get the closest attention, because those are what determine whether the part fits the machine.
Non-destructive testing
Where the application or the customer specification requires it, we arrange ultrasonic, magnetic particle and dye penetrant testing to confirm soundness below the surface. This is normally specified for larger sections and safety-critical work.
Metallurgical review
Microstructure is reviewed to confirm the heat treatment produced what it should: carbides in solution for austenitic manganese steel, a martensitic matrix for high chrome. This is the check that catches a cycle that hit the right hardness by the wrong route.
Documentation & traceability
Chemical, hardness and dimensional results are issued per heat and retained. A casting in service can be traced back to its melt, its heat treatment cycle and its inspection record.
Questions
Manufacturing and quality questions
What test certificates do you supply?
Chemical composition and hardness results are issued per heat as standard, together with a dimensional conformity report. Certificate of origin and ISPM-15 packing compliance are prepared for export consignments.
Can we appoint our own inspector?
Yes. We regularly work with SGS, Bureau Veritas and customer-nominated inspection agencies. Tell us at the order stage so inspection can be scheduled against the production plan rather than delaying despatch.
How do you verify manganese steel has been heat treated correctly?
Two checks matter. Hardness in the as-supplied condition should sit around 200–229 BHN. A manganese casting that arrives already hard has usually not been solution treated properly. We also review microstructure to confirm the carbides went into solution.
Is castings traceability maintained after despatch?
Yes. Castings are marked with the heat number and inspection records are retained against it, so a part in service can be traced back to its melt and its heat treatment cycle.