Welcome To

Malnad Alloy Castings Private Limited

Est : 1983
Alloy Steel, Stainless Steel, Nickel Base
Castings Manufacturer
 MALNAD GROUP COMPANIES
Malnad Alloy Castings Pvt Ltd since 1985
:Scope:
Manufacture & Supply of Raw, Machined and Hydro tested Castings in Ferrous, Nickel and Cobalt
based alloys
Shimoga Precision Castings Pvt Ltd since 1996
:Scope:
Manufacture and Supply of Alloy Steel, Stainless Steel, Nickel Alloy Steel, Cast Iron and Cobalt
Alloy Steel Castings By Investment and Sand Casting Process
Malnad Prime Machining Technologies since 2010
:Scope:
Manufacture of Precision Machined Components
Malnad Alloy Castings Pvt Ltd (Laboratory Division)
since 2018
NABL Accredited Mechanical and Chemical Testing Lab
)
We are located in…
 Management Contacts

Y. V. Madhukar Jois, Managing Director

+91 990 017 7820
jois@malnad.co.in

Prateek M Jois, Executive Director

+91 966 315 5553
pj@malnad.co.in

Land Lines - (08182) 46141,246142,246143

4
Organisation Chart
 Vision & Mission
The Vision of our company is to

“Become global leader for the supply of finished cast components

in wide range of materials with highly committed and socially
responsible employees”
Our Mission is to
*To meet the casting requirements of the country using latest state
of the art-technology in wide range of materials at competitive
cost.
*Provide stable employment and develop highly skilled technical
manpower and develop wide vendor base.
*Adopt environmentally sound and safe technology and create
awareness on energy conservation.
*Serve the community around through welfare schemes.
 Our Progress…
❑ 1985 – Started with 175 KW furnace & 30 MT/Month capacity.
❑ 1991 – Addition of 250KW furnace & Capacity Enhanced to 100 T/Month.
❑ 1993 – Well known foundry status from IBR .
❑ 1995 – Implemented QMS & Certified for ISO 9001.
❑ 1996 – Implemented integrated ERP system.
❑ 1998 – Certified by AD 2000 MarkBlatt.
❑ 1999 – Enhanced Furnace capacity from 250 to 350 KW & 150T/Month capacity.
❑ 2000 – Qualified for PED Certificate.
❑ 2004 – Direct Export Business Started.
❑ 2006 –Enhanced Furnace Capacity from 350 to 450 KW increasing production to
275T/Month .
❑ 2006 – Added Machine shop.
❑ 2007 – Started LEAN activities.
❑ 2009 – Approval by BV Marine Division.
❑ 2012 – Added testing facilities like PMI, Height Master & Surface tester.
❑ 2012 – Separated processing of stainless steel and carbon steel in different areas.
❑ 2013 – Added 750KW Furnace increasing production to 625T/month
 Our Progress…
❑ 2013 – MAGMA Simulation Software installed
❑ 2014 – Lloyds Foundry Approval.
❑ 2015 – Certified EMS-OHSAS; Highest sales; DNV Foundry Approval
❑ 2015 – New building 31360 sq foot for processing of above 500kg castings
❑ 2015 – Mould Carousel 8 Station semi automatic system
❑ 2016 – Fork Lift for Pattern Movement
❑ 2016 – NORSOK Certification for 4A, 5A and 6A Grades
❑ 2016 – Upgraded ISO 9001-2008 to 2015 Version
❑ 2016 – Solar Roof Top Cells 100 KW Capacity Installed
❑ 2016 – 25MT Shake Out Machine With Material Handing EOT Crane 25 /10 MT
❑ 2016 – Mechanized HT Quenching System to facilitate quenching within 50 sec.
❑ 2016 – IBR Well Known Foundry status & certified for Carbon & Alloy Steel up to
2400 Kg single piece.
❑ 2017 – Installed 3MT Capacity Table type Shot Blasting Machine.
❑ 2017 – ISO 14001-2004 upgraded to 2015 Version.
❑ 2018 – Thermal Reclaimation plant
❑ 2018- NABL approved Mechanical & Chemical Lab
❑ 2018- Automatic Scrap Baling Machine
 Our Strength
❖ State of Art Omega Semi Automatic Mold Carousal for consistent mold
quality for small & medium casting production with 120 molds/shift
capacity.
❖ Mechanized Quenching system for Heat treatment Process.
❖ 10 WPS-PQR Certified Operators for various grades witnessed by TUV,
Lloyds & DNV.
❖ Qualified weld inspector is available
❖ 10 Qualified Welders for handling the welding activities of various grades
❖ More than 15,000 Patterns with 6000 patterns live!. Traceability through
ERP maintained location system and Product code.
❖ Exclusive storage arrangement for preservation of patterns.

❖ 50 to 60 New Products being developed every month.

❖ More than 2500 fully machined cast components exported / month.

OUR SALES

100 90 86.5 94.5

90 75 84
80 76.52
65.39 69.03
70 63.6
60
50
40
30
20
10
0
2011 2012 2013 2014 2015 2016 2017 2018 2019
Sales in Cr.INR
 Certificates & Awards

❖ ISO 9001:2015

❖ ISO 14001:2015

❖ OHSAS 18001:2007

❖ Well Known Foundry Status IBR

Since 1983

❖ PED

❖ AD MERKBLATT

❖ Lloyds, Bureau Veritas & DNV

Foundry Approval

❖ NORSOK Process Approval for

4A, 5A & 6A

❖ Export Excellence Award By Govt.

Of Karnataka

❖ Export Excellence Award By IIF

 Product Mix
Clas s 150
Ball Valve 2” to 30”
to 1500
Valve components Clas s 150
Globe Valve 0.5” to 12”
Pump components to 900

Hydraulic Components Gate Valve 0.5” to 12”

Clas s 150
to 900
General Engineering Check Clas s 150
0.5” to 12”
Turbine component Valve to 900

Defence Components Control

0.5” to 16”
Clas s 150
Valve to 2500

5% 5% 5% Butterfly
2” to 40”
Clas s 150
Valve to 1500

5% Diaphragm
2” to 12”
Clas s 150
Valve to 300

10% Pis ton

2” to 8”
Clas s 150
Valve to 300
70% Double clas s 150
2” to 24”
dis c to 300

Check clas s 150

2 " to 12 "
Valve to 300
Customer Base

China
Major Customers
 Foundry Capacity
❖ Total Capacity - 625 MT/Month. Utilized Capacity - 450 MT/Month
(in view of recession in market).
❖ Maximum Single Piece Weight We Can Produce is 2400 Kgs.
 2/14/2020

2400 Kg Butterfly Valve

2700 Kg Casting Exported

from Malnad

16
 Typical Lead Time

SECTION TIME REQUIRED

Pattern Development 3 weeks

Sample Castings (Including Radiography 45 Working Days (From the date of receipt Pattern
Test) ready for molding)

Sample Machining 3-4 Weeks (From Receipt Of Castings)

Production Castings 45 Working Days

Production Machining 75 Working Days

All the above lead time depends on the size & complexity of the castings.
 Material Of Construction
❖ Carbon Steel
ASTM Grades WCB,WCC,LCB,LCC,
❖ Alloy Steel
C5,C12,C12A,WC6,WC9,
❖ Martensitic Steel
CA-6NM,CA-15,CA-40,SS410, SS430
❖ Stainless Steel and Duplex Steel.
CF8, CF-8C, CF8M,CD4MCU,CD4MCUN, Grade 4A, 5A, & 6A, CN7M,CF-
3,CF-3M, CG8m, PRECIPITATION.HARDENING:17.4PH
❖ Nickel Base Alloys
CW12MW, CW2M,CW6M,CW6MC,CU5MCuC,N7M,N-12MV, Monel

All the above grades corresponding to DIN, Ghost and Indian

Standards can also be manufactured
 Pattern Methoding And Mounting

Magma Simulation Pattern Mounting

 Manufacturing - Molding

NO BAKE SYSTEM
Continuous Mixer 12MT/Hour 1no
Continuous Mixer 6MT/Hour 2nos
Continuous Mixer 1.5MT/Hour 2nos
Batch Mixer 150Kgs 2nos
Mechanical Sand Reclamation 4MT/Hour & 8MT/Hour 1no each
Thermal Sand Reclamation 1 MT/Hour 1no
 Manufacturing - Molding
Core Making Mold Coating

.
 Manufacturing - Melting

Medium Frequency
Induction Furnaces
750 KW 3000 Kg & 2000 Kg
Crucible
450 KW 1500 Kg & 1000 Kg
Crucible
175 KW 300 Kg & 150 Kg
Crucible
One Crucible is standby in all the above cases.
 Manufacturing – Post Pouring
➢ Shot Blasting Machine
1MT hook type - 1 No
5MT hook type - 1 No
➢ Shot blasting machine
Table type 1 MT - 2 Nos.
Table type 3 MT - 1 No
➢ Aluminum grit blasting
Machine 750 Kg - 2 Nos.
Room Blast - 2 Nos.
➢ Pedestal grinding
Machine 3HP - 1 No
➢ Swing frame
Grinding Hp - 4 Nos.
➢ Flexible shaft with variable
Speed 2.5 HP - 25 Nos.
➢ Subcontracting Facilities:
3 Groups within the campus with
capacity 20 & 80 MT/Month.
6 Subcontractors outside with
total capacity 350 MT/Month
 Manufacturing – Heat Treatment
Mechanised Quenching
3 & 7.5 Ton Furnaces
System

Furnace Name Capacity (KW) Tonnage capacity

All 6 furnaces are Electric PLC Controlled
HTA 100 2.5 Tones
2 Water Quenching facilities with 60000 &
HTB 60 2 tones
75000 liters with cooling system.
HTC 100 3 tones
All furnaces are validated as per API 6A ;
HTD 100 4 tones
THE 40 1 tone
NORSOK in the presence of external
HTF 150 7 .5 tones agency
Malnad Alloy Castings Pvt Ltd ( Laboratory Division)
NABL ACCREDITATION FOR CHEMICAL AND MECHANICAL LAB
Chemical Tests Mechanical Tests
 Optical Emission Spectrometer  Tensile strength
 Intergranular Corrosion test  Yield Strength
 0.2% Proof Strength
 Pitting Corrosion test
 % Elongation
 % Reduction in Area
 Brinell Hardness (HBW 10/3000)
 Bend Test (Root; face; side )
 Impact Test (Charpy “V”)
 Inclusion Rating
 Micro Examination Graphite Flakes/ Nodules
Type and Size, Distribution Characteristics and
Matrix Analysis
 Determination of Volume Fraction of Phase
 Testing Facilities (NABL Lab)
Spectro Analyzer with Three Base Metal - Iron, Nickel and Cobalt with 25
elements including Nitrogen And Oxygen.
Group of products, Specification, standard
materials or items (method) or technique
tested used
NABL SCOPE

Ferrous / Low Alloy ASTM E415:2015 /

Steel IS 8811:1998 (Ra 2012)

Ferrous / Duplex , ASTM E1086:2014 /IS

Super Duplex , 9879:1998 (Ra 2009) /
Stainless Steel MACLD/VAL/Fe/2017

Nickel & Nickel alloys

ASTM E 3047:2016
MACLD/VAL/Ni/2017
Testing Facilities (NABL LAB)
Group of products, Measurement
Specific tests or types of Specification, standard Range of testing/ Limit
materials or items Uncertainty (± )
tests performed (method) or technique used of detection (%)
tested (%)

Intergranular-
Duplex Stainless
Corrosion Test – ASTM A923: 2014 Qualitative NA
Steel
Method A

4 mils/year @ 27
IGC Practice B upto 100 mils/year
Stainless Steel mils/year
ASTM A 262-2015
Wrought / Cast
Products Bend Test (Visual)
IGC Practice E NA
Qualitative
ASTM G 28 – 2002
Wrought Nickel
0.0001 – 10.0 0.0006 mm/month @
Rich Chromium . IGC Method A
(Ra 2015) mm/month 0.0021 mm/month
Bearing Alloys

Pitting corrosion Test 0.17 g/m2 @ 0.60

Stainless Steels ASTM G 48 – 2011 0.1 – 4.0 g/m2
– Method A g/m2
Testing Facilities (NABL Lab)
Group of
Specification, Range of Measurement
products, Specific tests or types
standard (method) testing/ Limit Uncertainty
materials or of tests performed
or technique used of detection ( )
items tested

100 – 1500
9 N/mm2
Tensile strength N/mm2 (or)
@ 554 N/mm2
MPa
ASTM A370-2017
Ferrous ASTM E8/8M-
100 – 1500
9 N/mm2
Yield Strength N/mm2 (or)
2016 @ 324 N/mm2
& Non IS 1608-2005 (Ra
MPa

Ferrous 2011)
ISO-6892 Part 1-
100 – 1500
7 N/mm2
0.2% Proof Strength N/mm2 (or)
@ 448 N/mm2
Metals 2016 MPa
ASME Sec IX –
Includin % Elongation 2017 1 – 80 % 2.1 % @ 35 %

g Weld
% Reduction in Area 1 – 80 % 1.4 % @ 67 %
Metals
Mandrel
diameter 12
Bend Test ASTM A370-2017 NA
mm – 50 mm
Qualitative
Testing Facilities (NABL LAB)

Group of
Specification, standard Measurement
products, Specific tests or types of tests Range of testing/
(method) or technique Uncertainty
materials or performed Limit of detection
used ( )
items tested

Ferrous & Non 4 HBW @ 154

ASTM E10-2017
Ferrous Metals Brinell Hardness (HBW HBW &
IS 1500 Part 1- 2013/ 100 – 400 (HBW)
Including Weld 10/3000) 7 HBW @ 202
ISO – 6506:1-2005
Metals HBW
Testing Facilities (NABL LAB)

Calibrated using NIST USA samples

Specific
Specification,
Group of products, tests or Range of Measurement
standard
materials or items types of testing/ Limit of Uncertainty
(method) or
tested tests detection (± )
technique used
performed

Ferrous & Non

Ferrous Metals 4 – 300
Impact ASTM E23 – 6 Joules @ 84
(Including Weld Joules (Room
Test 2016 Joules
Metals & All temperature
(Charpy ASME Sec IX - (-46°C)
Weld Metals to minus
“V”) 2017
Like Plates, 196°C)
Rods, Pipes Etc)
Testing Facilities (NABL LAB)
Specification,
Group of Range of
Specific tests or standard
products, testing/
types of tests (method) or
materials or Limit of
performed technique
items tested detection
used
ASTM E3: 2011
(RA 2017)
a. Micro
Metals And ASTM E407-07
Structural 50 x to 1500 x
Alloys (Ferrous (RA 2015)
Characterizatio (Qualitative)
& Non-Ferrous) ASM Metals
n Hand Book
Vol. 9: 2004
Steel & Stainless
a. Inclusion ASTM E45: 100 x
Steels
Rating 2013 (Qualitative)

a. Micro
Examination
Graphite 50x,100x,200
Flakes/ ASM Metals
x, 250x,
Grey Cast Iron Hand Book
Nodules Type 400x,500x,
and S.G. Iron Vol. 9: 2004
and Size, 800x,
Products ASTM A247:
Distribution 1000x, 1500x
2016
Characteristics (Qualitative)
and Matrix
Analysis
 NDT Testing Facilities

➢Magnetic Particle Inspection

➢Ultrasonic Test
➢Die Penetrate Test,
➢RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters.
➢5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard.
Quality/Testing Facilities

0.50” Flow Bore Casting

 Other Testing Instruments :-

❖ Ultrasonic Thickness Gauge

❖ PMI

❖ Digital Poldie Hardness Tester

❖ Ferrito Scope

❖ Radio Active Contamination Detector

❖ Digital pH Meter

❖ Digital Lux meter; Sound meter; Tachometer

❖ Casting Comparator From Steel International France

❖ Infrared Temperature measuring instruments 500 °C & 1600 °C

 Manufacturing – Machine Shop
In House Machine Shop equipments & Facilities

❖ Vertical Machining Centre.

❖ CNC Turning Centre.

❖ Conventional Lathes

❖ Radial Drilling Machine

❖ Conventional Milling

❖ Hydro Testing Machine for 150/300/600

& 900/1500/2500 CLASS

❖Malnad hydro procedure in line with
ASME and EN standards
Thermal Reclaimation Plant
 Web Access To Customers

❖ Website address: www.malnad.co.in (59.90.137.114)

❖ Customers will be given with unique login id &

Password

❖ Data Available: Order Status, Test Certificates

(3months) Dimension Ins Report, NDT Reports &
Pattern List

38
 On Going Projects-2020-21
❖ In house Radiography facility for Iridium and Cobalt
Sources with film development And for handing 3ton
castings

Planned Projects
❖ Energy Management System
❖ Rain water harvesting

39
 EMS Measures
❖ Bio Diesel as a Replacement for Petroleum Diesel
❖ Transparent sheets in order to avoid electric lights in day time
❖ Roof Top Solar Cell with 100KW capacity
❖ Solar Lights to reduce usage of Hydro Electricity during day time
❖ CETP of capacity 25000 liters installed
❖ RO plant having capacity of 1500lts/hour capacity has been installed
❖ Vermiculture compost with canteen and paper waste
100 KW Roof top static RO plant 50+ Plants planted
solar cell installed in 1500lts/hour capacity Across The Company
hall number 7 Compound
 2/14/2020

SHIMOGA PRECISION CASTINGS PVT LTD

41
 2/14/2020

Our Progress
❖ 1996 – Start up of Production .
❖ 2001 - Started ERP
❖ 2002 – ISO 9001 Certification.
❖ 2008 – Added new building for shell activity
❖ 2009 – Started Wax formulation in house
❖ 2010 – Started Manufacturing of Ceramic cores
❖ 2013-14 – 7.8 Crore sales(INR)
❖ 2014-15 – 15 Crore sales (INR)

SHIMOGA PRECISION CASTINGS PVT LTD

42
 2/14/2020

Facility Details

❖ Total Installed Capacity - 40MT per Month.

❖ Utilized Capacity – 25 MT per Month.
❖ Single piece we can pour up to :40 Kgs
❖ Experts in-Steam Trap, Control Valve components
❖ Special grades: Stellite-6,Stellite-21,NNRD2,Monel-
M35, Ultimate Alloy, Duplex steel apart from
standard Austenitic, Martensitic Steels

SHIMOGA PRECISION CASTINGS PVT LTD

43
 2/14/2020
Various Stages Of Investment Casting

SHIMOGA PRECISION CASTINGS PVT LTD

44
 Customer Base

SHIMOGA PRECISION CASTINGS PVT LTD

2/14/2020

46
2/14/2020

47
 2/14/2020

Manufacturing Experience
Ball Valve 15MM TO 25 MM Class 150 to 300

Globe Valve 0.5” to 2 ” Class 150 to 900

Gate Valve 0.5” to 2” Class 150 to 900

Check Valve 0.5” to 2” Class 150 to 900

Control Valve 0.5” to 3” Class 150 to 2500

Butterfly Valve 2” to 4” Class 150 to 1500

Diaphragm Valve Upto 2” Class 150 to 300

Piston Valve Upto 2” Class 150 to 300

Double disc 2” to 4” Class 150 to 2500

Check Valve

SHIMOGA PRECISION CASTINGS PVT LTD

49
 2/14/2020

MALNAD PRIME MACHINING TECHNOLOGY

50
M Malnad Prime Machining Technology Private Limited, a Sister concern of Malnad
A Alloy Casting, is well equipped to machine up 10” size Valves.
C We have following CNC machines with the table size details. We can supply the
H castings in completely machined & Hydro tested condition.
I Machines Specification
Size
X Y Z
N HAAS VF2 762 406 508
VMC
I VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700
N VTL
650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
G HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740
CNC - Turning MAZAK E160C 165 - 330
9C Lathes
Conventional Lathes
F 9C Lathes
Radial Drilling Machine
A
C
I
L
I
T MALNAD PRIME MACHINING TECHNOLOGY
Y
NEW MACHINES ORDERS
 VTL-40M-To machine castings from 8” till 10”
 VTL-30M- To machine castings from 3” till 6”
 CNC LATHE-Lt30-1000M- to machine hub end castings till 6”
 Additional building space to house the above machines and to
adopt cell concept size vise for :
 Up to 2” one cell; 3” to 6” one cell
 8” to 10” one cell.
 The company is also proposing for installation of 1200 M.M
VTL to machine from 12” to 16” in phased manner during the
year 2020

MALNAD PRIME MACHINING TECHNOLOGY

 2/14/2020

Thank You

53