CALDERYS INDIA EXPERTISE IN FOUNDRY
Calderys India has been serving Indian Foundry industry in various roles. We have been closely associated with the continuous growth of Indian Foundry industry for more than 25 years. We have played the role of a dependable solution partner with them by working together towards their performance improvement while proposing most suitable services and solutions. Since decades, Calderys India has been catering to their requirements of monolithic refractory and precast shapes. Applications of our refractory have improved equipment performance, thus improving plant productivity.
We have also worked with all leading global OEMs catering to foundry industries both in ferrous and non ferrous segment. Couple of decades back when a leading OEM decided to set up their operation in India, they were looking for international quality refractory and services. We were chosen as their preferred partner to develop and supply suitable low cement castables and pre cast shapes. These solutions surpassed their expectations in performance. Today with ever growing Foundry market in India, more OEMs have stepped into this segment and we have played similar role in all OEMs catering to this segment. Our leading brands like WHYTHEAT, FIRECRETE, ACCMON, AC Bricks, AC INS Bricks have became synonymous with Foundries all over the country, thanks to our strong and committed channel partners throughout the length and breadth of India.
Subsequent to merger with Calderys, we got complete access to their well established product range and global expertise. Calderys being the undisputed world leader in refractory solutions in both ferrous and non-ferrous foundry segments, already accumulated over 100 years of successful experience which resulted in long term partnership with customers worldwide. Calderys strength lies in combining products, concepts, knowledge and experiences to arrive at the most acceptable refractory solutions in all segments in foundry industry. This includes conceptualization of refractory layout followed by thermal profiles, design and drawing, installation and refractory commissioning services.
At Calderys India, we see Indian foundry market growing and demanding high performance products. In view of this, we are concentrating on combining the strengths of both Ace and Calderys offerings to derive the best solution for the local market. Our in-house R&D is continuously exploring the possibilities of local manufacturing of global products with the support of most advanced technology. Calderys India are progressing with its range of silica and alumina DVM products based on Calderys established expertise and local source of raw materials to give an optimized solution for the foundry end-user.
We offer full range of solutions for all the cupola zones such as the siphon box, well area, melting zone, stack, and gas offtakes. Concepts include precast wear parts, special coated and protected raw materials, special bonded ramming mixes, as well as more traditional concepts. We have developed specific products for cupola siphon box, such as the new CALDE™ CAST G 7 P or ACCMON FF SC B. Also, our CALDE™ GUN G C 65S25 is dedicated to the lining and repair of the cupola hearth or melting zone by gunning. Customers working in close partnership with us, and using our latest advanced products, have often seen their specific refractory consumption reduce to below 0.5kg/ton of metal processed.
Our recommended products:
- CALDE™ CAST G 7 P and ACCMON FF SC B
- CALDE™ CAST G UC 65S25 and ACCMON FD SC C
Coreless Induction Furnace:
The Coreless Induction Furnace is considered by many to be the most versatile melting unit available for the foundry industry. The demands placed on the refractory lining vary and are often very complex, bringing very different sets of circumstances that can affect the performance of the refractory lining, including:
- High Thermal Shock
- Lining Wear (corrosion and erosion)
- Metal Static Pressures
- Mechanical Stress
- Gas Penetration
- Slag Build Up
In the CIF segment, we have more then 50 years of successful partnerships in the foundry industry worldwide. We offer a full set of monolithic linings covering all refractories for the complete furnace (hot face lining, cast blocks, coil grouts, covers, spouts, mica slip planes, etc). We offer a unique naturally formed micro-crystalline silica-based Dry Vibratable Mix from our own 100% controlled Swedish quarry in Åmål. This raw material uniquely gives slow in line crystal transformation, in turn giving excellent thermal stability, uniform hardness and high refractoriness and has long been considered to be the benchmark lining for CIF. All products manufactured with the Åmål material are sold under the name the SILICA MIX brand name.
Our recommended products for Coreless Induction Furnaces – IRON:-
- SILICA MIX 5 / SILICA MIX 7
- SILICA MIX Q / SILICA MIX Z
Our recommended products for Coreless Induction Furnaces – STEEL:-
- CALDE™ MIX SC 84 M16 / CALDE™ MIX SC 84 M18
- CALDE™ MIX SC 85 M17 or ACCMIX FF SF 17
Our recommended products for Coreless Induction Furnaces – COPPER:-
- SILICA MIX B CU 7 / SILICA MIX MS / SILICA MIX I/CU
- CALDE™ BC 85 S
Additional associated materials for CIF:
- For Top cap: WHYTHEAT FD I
- For the cover: WHYTHEAT FD F
- For the Coil grout: COILCOAT FD I
- For the spout: ACCPLAST FF H and ACCMON FD AR I
- For the upper and lower support rings:
- ULTRAMON FF H
- For safety lining: FLOWMON FF ZR B
- For insulation: MICA 140 G
Channel Holding and Pouring:
We have extensive experience in this field for both iron and copper based applications. The need for higher productivity and lower costs whilst seeing conditions such as available scrap qualities has placed increasing demands on the refractory lining. Due to the various elements causing different forms of stress (erosion, corrosion, slag buildup and overheating) on the refractory lining, we have created new materials and designs to offer optimized solutions to our customers.
The varying chemistry of alloys and the increased demands in production volumes have influenced the development of our products and concepts. Our advanced knowledge also allows us to give the best practical advice based not only on refractories but also on operating conditions.
We provide solutions for all furnaces with a global product range composed of acid, neutral and basic products and from castables (all cement and no cement variants, self-flowing, rodding and vibration), gunning, ramming to dry vibratable mixes. To maximize the furnace performance we also focus on the installation, commissioning, and maintenance of the lining.
Our recommended products:
- CALDE™ CAST UB and ULTRAMON FF H
- CALDE™ CAST UT 94 and ACCCAST FD T 94
- CALDE™ CAST T 96 and ACCCAST FD T 97
- CALDE™ MIX SC 88 SR
- CALDE™ MIX BT 98
- CALDE™ MIX MS 86 BTI
CASTHOUSE (TRANSFER AND TREATMENT LADLES, CONVERTORS, LAUNDERS):
The importance of the correct refractory solution is often overlooked in these applications. By optimizing refractory life, unit availability, energy consumption and labor, a foundry can make great savings in their plant from areas such as down time, casting quality, and temperature controls. Depending on what is the most costly area for a given site, Calderys is able to offer a solution from plastic, ramming, castables, dry vibratables, precast monoform parts, and coatings.
Our recommended products:
- CALDE™ CAST UB / ULTRAMON FF H
- CALDE™ CAST LX 58 / ACCMON FF A F
- CALDE™ CAST NB 82 QD
- CALDE™ FLOW MA 92 / FLOWMON FF SB A
- ACCMON SF 15 AZ
Installation practices have great influence on performance of a refractory. In India Calderys India offers these services to ensure that the refractory true potential is exploited by getting desired life.
We employ dedicated skilled staff and the latest advances in refractory installation equipment. This can be applied to large, small, and turnkey projects alike depending on the requirement. Alternatively, we can support the customer's own staff by supervision, job management, equipment, and also direct training. Our aim is to ensure the best installation and dry-out of the refractory so that the customer gets maximum performance.
Once in service, the refractory may require specific maintenance products which again can be supplied depending on the customer requirements. In some cases, and depending on the situation, services may be available 24 hours per day, 7 days per week, ensuring minimum downtime for the customer—especially in times of unplanned emergencies.
Calderys India is often consulted in the development of a technical solution. Familiar with the specific processes of each type of units, we are able to engineer a refractory solution, provide project management services, and advise on the proper installation techniques for new projects. We have an excellent reputation for providing reliable solutions and thus have created many long-lasting relationships with our customers, end users, and engineering companies which have praised our products. Our strategic partnerships with the customers ensure that we develop market-oriented solutions on regular basis. Our decades of Indian experience coupled with over 100 years of experience of Calderys provides us the capability to become the integrated refractory partner and meet all your needs from solution design to implementation.
Calderys India has been serving Indian Foundry market for decades. With merger with Calderys, our focus on foundry industry has increased. Today we have a separate Foundry division which employs an expert team of Technical Sales Mangers, one each stationed in all 5 Regional offices i.e. Ahmedabad, Chennai, Delhi, Kolkata and Mumbai with the division’s head quarter being located in Nagpur. We have a large warehouse located close to Mumbai sea port to take care of the logistics and meet instant demand of continuously growing Indian clienteles for imported products. Apart from this, our extensive Distribution network is capable of supplying you any regular product at a very short notice.
Our manufacturing units in Katni and Nagpur are also preparing to produce some of the global products indigenously. Our design centre based in Nagpur has been trained to prepare refractory layout drawings at a short notice to meet the customer expectation. We have an experienced project application team to supervise refractory installation in all types of furnaces employed by Indian foundry industry. And finally, our R&D unit at Nagpur is constantly working hard to develop Indian equivalent products from Calderys range for local manufacturing, thereby making availability of these products easier and reducing the delivery lead time substantially.
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