The Shanthi Gears foundry division in Kannampalayam, Coimbatore, India has moved a long way in the last 40 years from it's inception days. When it was built in 1969, and it is still one of the best foundries in the the country, surpassing all indian norms on emission control. This is expectable from Shanthi Gears have done some basic work in ensuring green atmosphere.

The Infrastructure and Manufacturing Facilities

• Manufacturing of graded casting in Grey cast iron and SG iron suitable to all industrial applications to world class standards, weight vary from Few Grams to 2000 Kg.
• For maintaining of green atmosphere, we have Venturi wet scrubber system in melting and Dust Extraction system in moulding
• Steel fabrication up to 10 Ton single piece, equipped with CNC gas cutting machine and Stress relieving furnace

Fabrication shop

• Fabrication Facility Single piece 10 Tonnes
• CNC Flame cutting Machine – max 250 mm thick
• Welding with ARC / MIG / TIG
• Stress Relieving Muffle furnace
• Computer controlled Heat treatment plant

Pattern Shop

• Pattern manufacturing routed through CNC
• More than 15000 numbers of patterns are in use

Moulding

Process :
Green sand Machine Mould and No-Bake and CO2 Hand Mould

Moulding Machines :
1. DISA 300 of Box size 520 X 400 X 120
2. DISA 450 of Box size 700 X 510 X 200
3. DISA 900 of Box size 1200 X 910 X 450

	Technical Specification	APRA 900
	Jolt Capacity (Kg)	900
	Static Squeeze Force (Kgf)	16000
	Dynamic Squeeze Force (Kgf)	40000
	Pattern Draw (mm)	340

Sand Plant : Fully Automatic DISA Mixer 20T/Hr

Core Process : Cold Box core shooter ,CO2, Airset and Baked core

	Technical Specification	TM 160 -45
Dimensions in mm
	Diameter	1650
	Blender width approx.	600
	Height of mixer	1990
	Height of measuring vessel	1400
	Int. width of meas. vessel	860
	Center dist. mixer/vessel	250
	Depth of drive approx.	1827
	Width of drive approx.	1093
	Width of unloading door	1330
Batch Specifications
	Batch Volume (max.)	500 kg
	Cycle time	100 s
	Batches/hour	36
	Mixing rate *	20 m3/h
	Vessel cap. used + new sand	0.7 m3
	Cap. weigh. hopper bent + coal	0.1 m3

Melting

• We have facility of medium frequency induction furnaces for manufacturing up to 5000 Tons of castings per annum.
• The range of casting Weight from Few Grams to 2000Kg

Quality

Shanthi Gears having the following facilities to maintain quality system.

	Technical Specification
	Number of elements analyzed	28
	Base	Ferrous, Copper & Aluminium

• Raw materials and liquid metal chemistry will be controlled by Spectro with 28 Elements Analyzer
• Computerized Universal Testing Machine, Impact testing Machine and Optical Brinell Hardness Tester for checking mechanical properties of castings
• V- Smart Analyzer for checking Mechanical properties of ferrous liquid Metal
• Metallurgical Microscope with Image analyzer
• Digital Pyrometer for temperature control
• Modern Sand lab for controlling moulding process
• Soundness of raw materials and castings are checked by Ultrasonic Flaw Detector and external source of Radiography facility

Fettling

• Well equipped fettling department for removal of sand and external parts of castings by DISA Shot Blasting machines and various types of grinding machines
• Electrically operated Stress Relieving furnace of max weight 5000Kg

	Technical Specification	VP14 - 238
	Impeller wheels	2 X 380 mm dia
	Power of Wheels	2 X 15 kW
	Maximum length of parts	1250 mm
	Exhaust air M3/min	125
	Throughput Tonnes/hour	1 - 3
	Shot flow per minute	2 X 240 Kg
	Load carrying capacity	500 Kg
	Diameter of turning circle	1000 mm

Non Ferrous

	Process	Centrifugal, Gravity die casting and Sand mould casting
	Capacity	250 Ton/ Year
	Casting Weight	10Kg – 500Kg Max
	Furnace	150 Kg Medium Frequency Induction Furnace, 300 Kg Diesel Fired Crucible Furnace, 40 Kg Diesel Fired Pit Furnace
	Grades	Phosphor Bronze, Aluminium Bronze, Leaded Bronze and Aluminium

Forging

• Capacity 80 Ton per Month
• Open type Forging of Gears and Shafts
• Plain forgings, Ring forgings and Step forgings
• Hammer Capacity Max 500Kg
• Forging size 600mm in Dia , 2 meter in Length and 200 mm in Thick
• Pit type Normalizing furnace of capacity 2 Ton, Size Dia1200 X 2200 mm

The results are very rewarding, many companies in the world are tied up with Shanthi Gears for design and development of castings and gears.