1. Foundry & Machining Services
Make measurable
progress in reasonable time
Foundry & Machining Services

2. Our Mission
• To be a progressive unit that is constantly changing, upgrading and improving its systems and technology so as to encourage our employees to realize their full potential and participate in our goals.
• To assist all individuals or organizations associated with us in their individual quests towards excellence through training and partnerships, so as to build a solid foundation for our growth.
• To aggressively grow business, by entering new global markets.
• To achieve customer satisfaction by exceeding expectations with respect to product quality, response time and by being price competitive. We understand that our growth is directly linked to the growth of our customer.

3. Our Vision
Our Endeavor – to grow to be a World Class One Stop Shop Organization that provides the complete supply chain, service beyond expectations – whether as a Product to the customer, a relationship with the supplier, satisfaction to our employees and contribution to society.

4. Objectives To upgrade and improve our quality systems.
To continually improve processes through Small
Group Activities, Kaizens and Suggestion
schemes.
To satisfy customer expectations by delivering on
time products that conforms to the requirements consistently.

5. Company Profile
Excel Wirecut Inc. is a Bangalore, India based company, offers complete solutions for Ferrous and Non ferrous castings & machining requirements.   We are an ISO Company dedicated to the manufacturing of castings, Precision Machined Components, This includes product design, development of prototype and large volume production for Valve Industries. Automobile Industries and Defence sector with state-of-art Ferrous and Non ferrous Foundry & Machine Shop with skilled dedicated staff, backed by significant experience.
Excel Wirecut Inc. have a commitment to Quality, Efficiency and Reliability that has stood the test of time. Our reputation is built on nearly 20 years experience, cutting-edge technology and business values based on a philosophy of continuous improvement. Our Customers rely on our proven capabilities to manufacture a wide variety of parts, including those with high degrees of complexity and extremely tight tolerances. We are committed to continuously improving our processes and dedicated to Customer satisfaction .

6. Geographical Location
Postal Address
Foundry Division Components Mfg Division
Regd.Office/Works
Plot No.87F,Road No-2,1st Phase,Jigani Industrial,Area,Anekal Taluk,Bangalore
No.5/6, Pete Channappa
Industrial Estate, Magadi Road, Kamakshipalya, -Bangalore
Ph ,
Mob:
Nearest Airport : Bangalore International Airport.
Port : Chennai Port.

7. Company Profile
Excel Wirecut Inc. have a commitment to Quality, Efficiency and Reliability that has stood the test of time. Our reputation is built on nearly 20 years experience, cutting-edge technology and business values based on a philosophy of continuous improvement. Our Customers rely on our proven capabilities to manufacture a wide variety of parts, including those with high degrees of complexity and extremely tight tolerances. We are committed to continuously improving our processes and dedicated to Customer satisfaction.

8. Company Profile
Excel Wirecut Inc is promoted by Mr. Sanjay Kulkarni, Sanjay kulkarni is a Engineer with post graduation in Tool design, having over two decades of vast experience in various machining techniques and specialized expertise in development of ferrous and non-ferrous castings.
Our technical talent pool consists of a qualified, efficient and capable group of Managers and Engineers as well as our operators who have been employed with us from inception. They have been trained in-house and are our most valuable asset. Each employee undergoes about six hours of training per year. They form a spirited group of individuals who believe in working as a Team for the growth the company.
We are an ISO 9001:2008 certified company .
Our operations are well supported by ORACLE based ERP systems

9. Machining Facility @
Excel Wirecut Inc.

10. State of the Art of CNC Machining Facilities
Sl No
Machine Description
Qty
Size
Make 1
Horizontal Boring Machine 01
1000X1500
Tos 2
CNC Horizontal Machining Center 02
500x500
HASS MIKRON
Vertical Machining Center
1200x600x630
Hartford 3
Vertical Machining Center with 4th Axis
1200x800x650
Starway 4
Vertical Turret Lathe
1500 x 1000
Stanko 5
CNC Turning Center
500x 1000
Gieldmiester 6
300x1000 7
600X800
Pride Machine 8
500 x 1500
Askar Micron 9
475 x 675
Askar Micron /HMT 10
250 x 500 12
Band saw cutting  
Dia 500
Laxman

11. Conventional Machining Facilities
Sl No
Machine Description
Qty
Size
Make 1
Lathe 02
1200X2000
KIRLOSKAR 2
500x1500
RADIAL DRILLING MACHINE 01
DIA 80.00
WEBO 3
DIA 50.00
EIFCO 4
SIDDAPUR 5
PILLAR DRILLING MACHINE
DIA 35.00 6
SURFACE GRINDING
300x1000
MAGERALEY 7
BAND SAW CUTTING
DIA 500
LAXMAN

12. Fabrication Facilities
Sl No
Machine Description
Qty
Size
Make 1
TIG WELDING 01
350 AMPS AC/DC
ESSAB 2
MIG WELDING
350 AMPS
CALTON
ARC WELDING
400 AMPS
JOHNSON 3
PORTABLE ARC WELDING
150 AMPS

13. HORIZONTAL MACHINING CENTER
Traverse
X-axis – 500 mm
Y-axis – 500 mm
Z-axis – 500 mm
Pallet size-500mm
Spindle Speed RPM
Cutting feed rate
– 20000mm/min
Rigid Tapping
Fanuc OM Controls
With LM Guideways
HORIZONTAL MACHINING CENTER

14. Vertical Turret Lathe Make – Sedin, Russia Traverse
Turning Diameter 1500 MM
Turning Height 1000 MM
With Auto Turret & 3 Axis DRO

15. Hartford Machining Center
CNC MACHINING CENTER
Hartford Machining Center
High Speed Vertical
Machining Center
Traverse
X-axis – 1200 mm
Y-axis – 600 mm
Z-axis – 630 mm
Spindle Speed RPM
Cutting feed rate
– 20000mm/min
Rigid Tapping
Fanuc OM Controls
With LM Guideways

16. Model – Spinner 22 and Flat Bed
CNC Turning Centre
Make : Askar Microns
Model – Spinner 22 and Flat Bed
Turning Dia – 475 mm
Between Centre – 625 mm
12 Station Turret

17. WEBO Radial Drilling Machine
MAKE : WEBO (GERMANY)
Drilling : Up to 3” Inch
Double column
Rigid tapping

18. Inspection & Testing Facility
• CNC Co-ordinate Measuring Machine (CMM)
• Digital Height Master, Trimos • Surface Tester • All sizes of Micrometer and Vernier 0 – 700mm • All sizes of Cylindrical Bore Gauges range 06 – 700mm.
Plug Gauges.and Ring Gauge.
All the Instruments are periodically calibrated by NABL accredited Labs.

19. Type of Services Steel Castings of all grades
Valve Body & Actuators Parts
Mechanical Sub assemblies
Precision machined components made out of bar,plates,rods and forging.
Valve Internals like seat rings,seat retainers,bonnets,gland flanges.
Light medium Fabrication

20. OUR PRODUCTS END CAP AL-PISTON ACT-STEM AL-CYLINDER CS-CYLINDER
STEM NUT
ADAPTOR
ADAPTOR
ENDCAP
COVER PLATE
END CAP
ENDCAP
AL-CYLINDER
AL-CYLINDER
AL-CYLINDER
AL-CYLINDER

21. VALVE BODY
END PLATE
SEAT RETAINER
FLANGE GLAND

24. Certification, Awards & Recognition
Best Vendor Award from HAL
Our ISO Certificate

25. List of Major Customers
Flowserve India Controls Pvt. Ltd. Bangalore.
Flowserve US Inc. Springville,(USA)
Flowserve Controls. Cookville,(USA)
Flowserve Abahsain Flow Control co. Ltd. (Saudi Arabia)
Flowserve Pvt Ltd. (Singapore)
Tyco Flow Control Pacific Pvt Ltd.( Newzeland)
Bharat Heavy Electrical Ltd.(BHEL) Bangalore Electronics Division.(EDN)
BEML-KGF and Mysore
BUHLER India
Bharat Electronics Ltd. ( BEL) Bangalore & Navi Mumbia

26. Human Resource Management.
POLICY GOALS OF HRM IN EXCEL WIRECUT INC
Managing people as assets that are fundamental to the competitive advantage of the organization.
Aligning HRM policies with business policies
Encouraging team working and co-operation across internal organizational boundaries.
Creating a strong customer-first philosophy throughout the organization.
Empowering employees to manage their own self-development and learning. 
Managing people
Developing reward strategies designed to support a performance-driven culture.
Improving employee involvement through better internal communication.
Building greater employee commitment to the organization.
Increasing line management responsibility for HR policies.
Developing the facilitating role of managers as enablers.
Developing health and safety policies;
Conducting risk assessments which identify hazards and assess the risks attached to them;
Training in good health and safety practices

27. OUR FOUNDRY
FERROUS FOUNDRY
(SHUBHAM STEEL INDUSTRIES)

28. Ferrous Foundry Profile
SHUBHAM STEEL INDUSTRIES. is your single source supplier for alloy and stainless steel castings. Our complete in-house capabilities provide the kind of expertise and craftsmanship that are acquired through providing continuous services nearly 20 years. From raw materials through quick turnaround on delivery, Our primary focus is quality and our customers know that SHUBHAM STEEL INDUSTRIES, always strives to meet the highest quality standards possible.
This brief tour of our operational facilities explains how our castings, machining and assembly shops are designed to serve our customers and meet their needs
our foundry currently has an installed capacity of 250MT/Month

29. Ferrous Foundry Profile
Our foundry is equipped with 1.5MT medium frequency Induction furnace connected to a power pack of 750KW. With this the foundry can produce quality castings weighing from 10 Kgs to 850 Kgs single piece.
Our foundry has adopted No-Bake process for moulding and core making which results in superior surface finish ,internal soundness and reliability.
Our Foundry has 125 KW, 3MT ,Themal tech make electrically heated bogie hearth type heat treatment furnace with automatic temperature controller, graphic recorder and thyristor controls for a predetermined Heat treatment cycle with controlled heating.
Our Foundry has a good quality set up, Melt chemistry is controlled by Direct reading Spectrometer , from M/s Spectro Analytical Instruments, Kleeve, Germany. All heats are numbered and test certificates are provided for each heat. 100% visual inspections are carried out on all castings and dimensional inspections are carried out on sample castings. NDT tests like Radiography , Magnetic Particle testing are done on first sample castings and thereafter as required by customers.

30. Ferrous Foundry Profile
The Pattern Shop is staffed by dedicated craftsmen with decades of experience. They utilize state-of the art machine tools and superior hand-tool knowledge to build and repair patterns, from the simplest to the most complex. Our foundry division uses a continuous, flow molding line which begins with the molding process of making required cores. Our molding floor uses No Bake Sand, Green Sand, Chromite Sand, and Pep Set resin binder technology.
Our in-house heat-treat facilities include a 3 MT capacity furnace. It is suitable for annealing, normalizing and tempering any of our alloy steel. The furnace is computer-controlled and maintained and calibrated by our trained technicians to ensure all procedures are consistent. 

31. Foundry Facilities Sl No. Description Capacity Make Qty 1
Induction Furnace 750 KW with 2 Crucibles
1.5MT
Megatherm Ltd.,
1No. 2
Laddles
2MT
3Nos 3
Skip Hoist for scrap charging 4
Sand Mixer
500 Kgs 5
Shot Blasting machine, Table type
1.5 MT
Patel Furnace & Forgings 6
Semi portal crane
3 MT
4 Nos 7
Trolleys
10 MT
6 Nos 8
Trolleys motorized
8 MT
2 Nos 9
Welding Rectifier
1 No. 10
Heat treatment furnace thyristor controlled with Graph
Thermal tech 11
Flexible grinding machine 12
Electronic Weighing Bridge
50MT

32. Foundry.

33. Foundry Testing Equipments
Sl.No.
Description
Make
Qty 1
Direct reading spectrometer for chemical analysis of Iron Base, Nickel base material with Nitrogen analysis
Spectro Analytical Instruments, Kleeve, Germany
1 No. 2
Semi automatic Carbon Sulphur operates
Supertech Scientific & Metallurgical services
1No. 3
Brinell & Rockwell hardness tester
Mechatronic control systems
1No 4
Computerised Digital Universal testing Machine- 40MT with electronic extensometer 5
Poldi Hardness Tester 6
Sand sieve test mesh
Versatile Equipments Pvt.Ltd., 7
Sand testing Machine 8
Scratch Hardness Tester 9
Digital Immersion Pyrometer 10
Radiography
Sub contract 11
Magnetic Particle Testing Machine
Magnaflux 12
Dye Penetrate testing facility
Available

34. OUR ASSOCIATION WITH NON FERROUS FOUNDRY FORGING
Steel and Duplex Steel Traders

35. Non Ferrous Foundry Profile
Castfab Engineering India (P) Ltd was established in the year 2000.
An ISO 9001:2008 certified Company, manufacturing
quality aluminum castings.
Located in Coimbatore, South India, a city popularly referred to as the ‘Manchester of South India’.
One of the fastest growing cities in India, Coimbatore, is well connected by rail, road and air to the other major cities in India, as well as abroad. Major ports are also at a few hours drive from the city.

37. Mission
To be in the fore - front of technological innovations in our chosen field and grow into the most preferred choice in the engineering industry, specializing in aluminum castings, supply of machined components.

38. Facilities
Our production unit is equipped with the latest machinery, which enables world - class quality.
Having full –fledged manufacturing facility comprising of Aluminum Gravity die casting.( Permanent Mould castings)

39. Quality Policy We are committed to satisfy our customers through
Supply of quality products
Always adhering to prompt delivery schedules
Effective and optimum utilization of resources
Integrity in our operation
Continual improvement of processes and systems

40. Aluminum alloys Grades
Aluminum Alloy castings are manufactured as per various chemical compositions and Industrial Standards . Castfab manufactures castings, single piece weighing from 0.5 Kg to 25kg ,as per the following specifications:
Based on the casting configuration, select alloys suitable for specific use could be developed as per the customer requirements.

41. LIST OF MACHINERIES @ Foundry
S No
Machine Name
Machine Code
Make
SPEC
Location *
Furnace A A
Wesman
300 Kg/Melt-2Nos
Foundry
Furnace B B
SKR
150 Kg/Melt-2 Nos
-Foundry
Hydraulic Stand 1
Own -
Band saw Cutting M/c 2
Air Compressor 3
Elgi
3 HP, Reciprocating Double Cylinder
Belt Sandring M/C 4
Fettling
Core Oven M/c 5
Agni
Core Section
Muller M/c 6
Sakthi
Drilling M/c 7
CKP
Up to 20 mm
Light Duty Hand Press 8
1 Ton
Machine Shop
Center Lathe 9
Shree Industries
9” Center Height
M1 DRO Milling M/c 10
ESTEEM
Hydraulic Stacker 11
1000 mm X500 mm
Generator 12
Kirloskar
62.5 KVA
Out Side
Bench Grinder 13
Stark
0.55 HP

42. GRAVITY DIE CASTING TOOLS

43. MELTING FURNACE

44. LIST OF PLANT & EQUIPMENT
BHANDARI PRECISION FORGINGS PVT LTD
LIST OF PLANT & EQUIPMENT
SL. NO MACHINE NAME QUANTITY
Ton Clear Space Pneumatic Power Hammer 01 No.
02 1 Ton Clear Space Pneumatic Power Hammer 02 Nos.
Ton Oil Fired Furnace Batch Type 02 Nos.
/2 Ton Clear Space Pneumatic Power Hammer 01 No.
Ton Oil Fired Furnace Batch Type 01 No.
Ton Jib Crane No.
Ton Jib Crane No.
KVA Power Generator 01 No.
09. Ring Rolling Machine - Dia 1500 mm No.
- Dia 300 mm 01 No.

45. IN HOUSE METALLURGICAL QUALITY CONTROL FACILITIES
1. Ultrasonic Flaw Detector
2. Magnetic Particle Tester
3. Dye Penetrant Tester.
4. Chemical Laboratory
5. Universal Testing Machine KN Capacity
6. Vickers Hardness Tester
7. Rockwell Hardness Tester
8. Brinnel Hardness Tester
9. Impact Testing Machine.
10. Erichsen Testing Machine.

46. APEX METAL INDIA,BHANSALI INOX
Traders for supply steel and Duplex steel rod and tubes
All the above suppliers provide CMTR /Mill test report

47. Anodizing for aluminum parts
LIFE LINE COATERS
Lifeline Coaters is ISO 9001;2008 certified partnership concern established in the year 2000, specialized in various finish coatings of small to heavy jobs with the following facility
Powder coating
Hot zinc Phosphating
Anodizing for aluminum parts
Chrome free clear chromate for aluminum parts
Spray painting

48. ISO 9001-2008 CERTIFIED COMPANY

49. It is a 9 stage line with a three ton overhead monorail
POWDER COATING:
We have four exclusive Mitsuba make powder coating guns with individual Boths for different colors – Grey, white, and other customer specific colors
There are two curing ovens suitable to handle very small to big jobs. The sizes are given for your reference
8 x 6 x 6 Feet – 2 nos
4 x 5 x 5 Feet – 2 nos
HOT ZINC PHOSPHATING
It is a 9 stage line with a three ton overhead monorail
All heating source is done by Thermax make thermic fluid Boiler
Tanks are suitable to handle big jobs of size 1.5 x 1.2x 1.2m

50. Tappets motor blocks and similar bearing surfaces
MANGANESE PHOSPHATING
This is the corrosion resistant coating consists of iron and manganese phosphates and reduce wear on such articles like pistons, piston rings, liners, cam shaft
Tappets motor blocks and similar bearing surfaces
We have six stage facilities to carryout this phosphating
Tanks are suitable to carryout jobs of size 0.5 x 0.5 x 0.5m
ANODIZING FACILITY
We have fully established clear anodizing line for aluminum components

51. We have the following facilities in our QA laboratory.
Bath Analysis facility for Phosphating.
Adhesion testing.
Thickness testing
CAPACITY
At present we are running one shift from 8.30 am to
5 pm, with overtime if required.
SKILLED PEOPLE
Experienced and skilled people are managing the unit. There are totally15 employees of which, two engineers, one supervisor, two skilled operators, one QA person and remaining helpers

52. THANK YOU