Advanced Manufacturing Facilities for Cast Iron & SG Iron Components

Allied Products operates a modern, well-equipped manufacturing facility dedicated to the production of high-quality Cast Iron (CI) and SG Iron (Ductile Iron) castings for domestic and international customers. Our infrastructure has been developed to support the demanding requirements of OEM manufacturers, exporters, engineering companies, industrial equipment manufacturers, and global sourcing organizations that require precision, consistency, and dependable supply.

Located in Kolhapur, Maharashtra, one of India’s most established foundry clusters, our facility benefits from a strong industrial ecosystem, skilled technical manpower, and easy access to supporting services such as pattern making, machining, inspection, and logistics. This strategic location allows us to serve customers efficiently while maintaining high standards of manufacturing control and product quality.

Our integrated manufacturing approach brings together shell moulding technology, melting and pouring systems, machining operations, inspection facilities, and material handling infrastructure under one roof. This enables us to maintain complete control over production quality, process consistency, dimensional accuracy, and delivery schedules from start to finish.

Manufacturing Infrastructure:

Our facility is designed to support every stage of the casting and machining process with the right equipment, technical systems, and process controls. The infrastructure includes:

Shell Moulding Foundry

Our shell moulding section is equipped for the production of precision castings with excellent dimensional accuracy and surface finish. This process is ideal for components that require repeatability, consistency, and reduced machining allowance.

Melting & Pouring Systems

We operate controlled melting and pouring arrangements designed to maintain metallurgical consistency and stable casting quality. These systems support the production of Cast Iron and SG Iron components with reliable mechanical properties and uniform structure.

Pattern Development Support

Our facility works with pattern development and tooling support to ensure that casting designs are translated accurately into production-ready components. This helps reduce development time and improves the consistency of repeat orders.

Fettling & Finishing Operations

After casting, components undergo fettling, cleaning, and finishing operations to remove excess material, improve appearance, and prepare parts for machining or final inspection. These operations are carried out with attention to detail to ensure a clean and professional finish.

Precision Machining Facility

Our machining section is equipped to carry out critical finishing operations on cast components. This allows us to supply parts that are ready for assembly and meet the dimensional requirements of OEM and industrial applications.

Inspection, Testing & Quality Assurance

Our integrated inspection, testing, and quality assurance systems, supported by advanced measuring instruments and efficient material handling processes, ensure every casting is thoroughly verified for dimensional accuracy, surface quality, and compliance with customer specifications before dispatch

Manufacturing strength

Box size

20” x 22” x 5” /7” (508 MMX558 MM X177 MM) 222

Casting Range

3Kg to 30Kg

Capacity

Present - 200 MT

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Our manufacturing facilities

Pattern Development Facility

Shell Moulding Facility

Melting & Pouring Facility

Cooling, Shakeout & Fettling Facility

Shot Blasting & Surface Finishing

CNC Machining Facility

Inspection, Testing & Quality Assurance

Material Handling & Storage

Packing & Dispatch

The pattern shop plays a crucial role in the foundry process by creating the moulds and cores necessary for casting metal parts. Here's a simplified overview of the process:

Welcome to the Pattern Shop Division! Our pattern shop is the heart of the foundry process, where we craft the blueprints for metal parts with precision and expertise. Let's explore the importance of the pattern shop and the materials we use:

Core making

Core making is an essential process in casting, allowing for the creation of internal cavities or complex shapes within castings. Our expertise in traditional core making methods ensures high-quality, precise cores that meet industry standards. We specialize in adapting our processes to fit the specific needs of our clients, providing fully customized core solutions.

We utilize the following traditional core making techniques:

Hot Box Core Making
Cold Box Core Making
Shell Core Making

Processes we follow:

Pattern Preparation: Core pattern designed to specifications.
Sand-Binder Mixture: Sand mixed with a binder.
Core Formation: Mixture introduced into a core box.
Curing: Thermal or chemical curing.
Ejection & Finishing: Core is removed, inspected, and finished.

Curing time

Hot Box: Fast (Thermal curing)

Cold Box: Fast (Room temperature with gaseous catalysts)

Shell: Rapid (Heat-assisted)

Equipment

Heated core boxes for Hot Box and Shell Core making.

Gas generation and injection systems for Cold Box making.

Specialized core-making machinery for all processes.

Cycle time

Hot Box & Shell: Quick due to thermal curing

Cold Box: Slightly slower, chemical curing

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Hot Box & Shell: Quick due to thermal curing

Cold Box: Slightly slower, chemical curing

Melting Facilities

Our melting facilities play a vital role in transforming solid metal into molten form, crucial for casting and shaping processes. Using high-temperature techniques, we ensure efficient melting with precise control over temperature and composition, guaranteeing high-quality production. Welcome to the Pattern Shop Division! Our pattern shop is the heart of the foundry process, where we craft the blueprints for metal parts with precision and expertise. Let's explore the importance of the pattern

Inductotherm Hybrid Furnace

The Inductotherm Hybrid Furnace combines coreless induction and channel melting technologies, offering flexibility in alloy use and efficient large-scale aluminum casting.

Furnace Name: Inductotherm Hybrid Furnace
Furnace Type: Induction and Electric Arc Combination
Furnace Size: Configurable from 5 to 25 tons
Melting Capacity: Up to 25 tons per hour
Power: Ranges from 250 kW to 6,000 kW
Duration for Melting: 30 minutes to 2 hours
Casting Range: Suitable for various casting processes
Materials Used: Steel, aluminum, copper, and alloys
Spare Capacity: Typically 60% of total capacity
Used Capacity: Up to 80% for effective operations
Temperature Range: Up to 1,600°C

Inductotherm Dura-Line Furnace

Dura-Line® induction melting furnaces are designed for rugged use, offering high-power density in a midsize package. Built with heavy cast refractory, stainless steel reinforcement, and copper power coils, they ensure durability and efficiency. These furnaces feature hydraulic or hoist tilting, single-trunnion action, and "nose-tilt" pouring. Ideal for efficient melting with budget-friendly options, they provide a wide range of capacities while ensuring structural integrity and easy maintenance.

01. Furnace Name: Inductotherm Dura-Line® Furnace
02. Furnace Type: Coreless Induction Furnace
03. Furnace Size: Available in various configurations to suit different operational needs
04. Melting Capacity: Up to 25 tons per furnace (depending on model)
05. Power: From 250 kW to 12,000 kW
06. Duration for Melting: 45 minutes to 3 hours, depen

Tenova Consteel® Electric Arc Furnace (EAF)

The Tenova Consteel® EAF is engineered for high efficiency and reliability, boasting a melting capacity of 30 to 420 tons per hour. Operating at power levels of 10 MW to 180 MW, it achieves temperatures up to 1,800°C. The melting duration typically ranges from 45 to 90 minutes, with an operational capacity utilization of 85-90%. This furnace is versatile, processing various materials such as scrap metal and pig iron, making it an ideal choice for modern melt shops.

DISA Flex Moulding Machine
ARPA Moulding line

Casting Materials:

Compatible with iron, steel, and aluminum alloys.

Casting Range:

Weight Capacity: 0.5 kg to 50 kg per casting.
Size: Molds can be customized up to a maximum dimension of 1,200 mm × 1,000 mm.
Moulds Per Hour: Capable of producing up to 1,200 molds per hour.
Annual Volume: Designed for an annual production capacity of over 100,000 molds.

Additional Features:

Modular design for enhanced customization.
Advanced automation

Casting Materials:

Compatible with iron, steel, and aluminum alloys.

Casting Range:

Weight Capacity: 0.5 kg to 50 kg per casting.
Size: Molds can be customized up to a maximum dimension of 1,200 mm × 1,000 mm.
Moulds Per Hour: Capable of producing up to 1,200 molds per hour.
Annual Volume: Designed for an annual production capacity of over 100,000 molds.

The DISAMIX is a next-generation bentonite-bonded

The DISAMIX is a next-generation bentonite-bonded foundry sand mixer engineered for high-speed, energy-efficient performance in green sand foundries. Designed to meet modern foundry needs, the DISAMIX

Specifications:

Model: S100

Capacity: 100t/h

Parameter: S100

Mixer Capacity: 100t/h

Batch Capacity: 3000 kg

Installed Power: 160 kW

Water Consumption: 20 l/min

Mixer Height: 2970 mm

Net Weight: 17 Tonnes

Water Reservoir

Fast and precise pre-water dosing

Intensive Mixing

fast and complete mixing with short cycle times.

Industry 4.0 Ready

advanced data-driven process control, real-time production monitoring

Sand Multi Controller (SMC)

Automates sand moisture control and ensures consistent quality

Fettling Shop

Fettling is the crucial process of cleaning and finishing castings to remove excess material and ensure compliance with specifications. Common equipment in a fettling shop includes shot blasting machines that use high-velocity abrasives for thorough cleaning, grinding machines for refining surface finishes and dimensions, robotic fettling systems that automate grinding and polishing tasks for improved productivity, and vibratory finishing machines that effectively polish and deburr castings.

These machines play a vital role in maintaining quality control in foundries, enhancing the overall efficiency of the production process.

These machines play a vital role in maintaining quality control in foundries, enhancing the overall efficiency of the production process.These machines play a vital role in maintaining quality control in foundries, enhancing the overall efficiency of the production process.These machines play a vital role in maintaining quality control in fou

Surface Coating Spray

Spray coating is a widely used technique for applying a uniform layer of coating material to various substrates using a spray gun. This method accommodates multiple coating types, including paints, varnishes, and protective finishes.