1. Aluminium Die Casting

2. ESMO GROUP - Established in 1974. Following companies make the group
ESMO TRADING CORPORATION
ESMO INDUSTRIES
UKAY PULVERISING INDUSTRY
SUVARNA ROADLINES
GLOBIZ SOLUTIONS & SERVICES
NEXUS LOGISTICS
SUVARNA ALLOYS PVT LTD

3. Business sectors -
ESMO GROUP COMPANIES ARE PRESENTLY WORKING IN FOLLOWING BUSINESS AREAS –
MINING
TRANSPORTATION
WAREHOUSING
INFORMATION TECHNOLOGY
MANUFACTURING & ENGINEERING

4. VISION STATEMENT
Our organization is formed on the grounds of being world class in the field of Die Casting. It is our vision to make SAPL a name that stands for – Reliability – In what we deliver. Quality – In process, infrastructure, raw material and man power. Strive – In what we can achieve next. Being at fore front of advanced technologies.

5. CORPORATE POLICY In all things we think, say or do - we will maintain
Integrity – In truly giving our sincere effort, complete honest involvement and best possible delivery to associates inside and outside our organization.
Faith – That every individual in this organization truly believes in the value system of the organization, its aims, goals and efforts. Collectively we have faith in achieving goals which will make tomorrow a better place for employees, associates, customers and largely our society that we live in.
Optimism – Our organization is committed towards making a better tomorrow for all concerned. It is with this optimism that every individual shall approach every new day and a new challenge as an opportunity.

6. Customer value system -
At ESMO GROUP this is single most important thing that matters -
Every Customer that walks into our doors is an important person.
He is not dependant on us, but we are.
He does not bring hindrances in our work, but it is our goal that he comes to us.
He is not a stranger but part of our duty and responsibility to be answerable to him.
By servicing out customer, it is not that we are doing any favors to him, on the contrary it is because of whom we get can opportunity to excel.
- Mahatma Gandhi!

7. INFRASTRUCTURE – HPDC - GDC
Casting capacity / capability –
Any HPDC castings from 60 grams upto 4 kgs.
In terms of Locking force, from 150 Tons to 850 Tons.
State of the Art Infrastructure –
Melting – Crucible less gas fired furnace. (500kgs/hr) Fuel – Bio-Gas for HPDC
Melting – Electric Crucible type furnace for GDC
Melt Treatment - Nitrogen Degassing Machine.
Die Casting –HPDC - Buhler Ecoline – Multi step HPDC. 3 machines (Locking force – 250T, 340T and 660T)
cfm)
SAPL – Machinery & Capacity

8. INFRASTRUCTURE – HPDC - GDC
DIE CASTING – GDC – Hydraulic tilting type Gravity Die Casting machines.
Compressor – Atlas Copco GE series screw type. (200
Holding Furnace – Crucible Less, low energy consuming top heating electric furnace. (500kgs/hr)
Cooling Tower – Inductokool IK-10 & IK-40. Seperate cooling circuits for die and machine.
SAPL – Machinery & Capacity

9. INFRASTRUCTURE - QUALITY
Material Handling – EOT Crane 10T & 2T double girder, Trolley mounted Transfer Ladle.
Quality Assurance –
Alloy testing – Spectrometer with 32 element detection.
Melt testing – Density Index Tester. Hydrogen Content Test.
Component testing – Gauges, Tools and CMM.
Compression Test – Universal Testing Machine.
SAPL – Machinery & Capacity

10. INFRASTRUCTURE - QUALITY
X-Ray image analysis. (Proposed)
Thermal image analysis. (Proposed)
ISO certified.
Fettling – At HPDC cell fettling and manual inspection with go-no go gauges.
Shot Blasting – Hanger Type Shot Blasting machine for surface finish requirement.
Machining- Ace Micromatic VMCs and CNCs with tooling capability.

11. Features of Buhler machines:- Proven 3 Platen toggle system.
INFRASTRUCTURE
BBUHLER ECOLINE
Features of Buhler machines:-
Proven 3 Platen toggle system.
High shot speed up to 8.5 m/s filling velocity with metal.
Shot profiles set manually or by multistep remote control
Multistep Technology for more flexibility
Auto Ladle, auto sprayer and auto extractor.
SAPL – Fully Automatic Cell

12. Quality Lab Equipment Degasing Unit Density Index Tester Spectrometer
Foundry degasing unit is installed for molten metal treatment. By purging high purity inert gas we improve molten metal and casting quality.
Density Index Tester
Density Index Unit is also a part of SAPL Facility. This is very important Test which provide Gas content into molten metal.
Spectrometer
The metal analyser is used for material testing in foundries. It determines all of the elements in the metal, trace analysis of carbon, phosphorous, sulfur & nitrogen.
SAPL – Quality Assurance

13. Present Customers Light Commercial Vehicals
Engine Parts – Covers, Housings.
Genset Manufacturing
Engine Parts – Plates, Support components
Automotive
Safety components.
SAPL – What makes us different ?

14. Capacity Planning
We are now procuring 2 fully automatic die casting cells.
530 T Buhler Ecoline or equivalent with automatic ladle, sprayer and extractor.
840 T Buhler Ecoline or equivalent with automatic ladle, sprayer and extractor.
With existing 250T, 340 T and 660 T and addition of 3 new machines, we will be having all sizes and rangers of machine to cater from component as small as 30 grams (few mm in dimension) to 5 kgs (600 x 600 mm dimension)
SAPL – What makes us different ?

15. Capacity Planning
PRODUCTION CAPACITY –
Present = shots per month with 3 machines.
Additional capacity = sh0ts per month.
Quality & Testing –
Present = Spectrometer, Density Index tester, Rotary Degassing Machine.
Additions = Radiography at ASTM E 505 resolution, Hardness tester, Universal Testing Machine, Pneumatic leakage testing machine, Hydraulic Leakage testing machine.
Post treatment –
Present = Fettling, Shot Blasting.
Additions = Heat Treatment, Vaccum Impregnation.

16. PLANT LAYOUT SAPL – Efficient Movement! RM Store Melting Shop
Al Die Cast
Quality Lab
Machine Shop
Dispatch Gate
Die
Maint.
Melt Shop– 3,000 sq ft.
Al Die Casting – 10,000 sq ft.
Machine Shop– 7,500 sq ft.
Total Land Area – 1,40,000 sq ft.
Total Plant Area – 20,500 sq ft.
SAPL – Efficient Movement!

18. Contact Business Development: Office Address: Sachin Badgujar
Rahul Suvarna
Director – Operations
255/1, Highway Park,
Old PB Road, Tararani Chowk,
Kolhapur –
Phone:
Business Development:
Sachin Badgujar
Business Development Incharge.
Phone:
PLANT ADDRESS
Plot C-8, Kagal Five Star MIDC,
Kolhapur.
Office:

19. We Look Forward!