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Service Spectrum

Overview

We have a Fully Integrated Forging & Machining Unit with a large product portfolio offering to our customers ranging from 1 Kg to 500 Kgs. The Forging Unit comprises Both Closed Die Forging Hammers & Presses.

This offering is spread over a large number of applications & Industries namely Automotive, Off Road & On Road Vehicles, High Performance Applications, Industrial, Heavy Duty, Oil & Gas, Marine, Defence, Railways, etc.

We have one of the largest capacities to manufacture Crankshafts & other Forged Components in the world. Our existing units can presently machine 360,000 units of crankshaft per year & this will shortly be upgraded to reach 720,000 units per year by the second half of 2021. Our Forging unit has the capacity to produce 5000 Tons per month & another 5000 Tons per month will be added from the second half of 2021.

Fully Integrated Forging & Machining Unit - Balu Industries

Laboratory

We offer a large range of Services in our Laboratory. We additionally also use a number of well recognized 3rd Party Companies for varied services suited to each customer requirement. All 3rd Part Laboratories have global accreditation & NABL approval.

Metal Processing & Analysis

Heat Treatment

Metallography

Advanced Manufacturing

3D Printing

Material Testing

Fatigue Testing

Creep Testing

Virtual Manufacturing

Product Design

Process Simulation

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Tool Room

All the required Toolings are produced in our comprehensive In-House Tool Room. The same is key to manufacturing flexibility & adding speed to Production. We have a fully integrated Tool Room & all Jiggs, Fixtures, Coils, Forging Dies & related toolings, etc. are produced In-house. This enables shorter lead times & also enables us to have minimal breakdowns in our production lines on account of Toolings.

We have also introduced 3D Printers in our Tool Room to further add flexibility & speed up our Tooling Process. We presently have one of the shortest Tooling Lead Times in the Marketplace credited to the said infrastructure.

Our Forging & Machining units are completely integrated with our own In-House Die Making. This offers greater flexibility & shortens our lead time for New Part Development. All Die Blocks are sourced from reputed manufacturers with no compromise on quality & offers greater Die life for our production.

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Forging

Overview

We have a Fully Integrated Forging Unit with a large product portfolio offering to our customers ranging from 1 Kg to 500 Kgs. The Forging Unit comprises Both Closed Die Forging Hammers & Presses with the largest offering being a 16 T Forging Hammer. We will be shortly commissioning a state of the art completely automotive new 6300T & 8000T Forging Press Lines

This offering is spread over a large number of applications & Industries namely Automotive, Off Road & On Road Vehicles, High Performance Applications, Industrial, Heavy Duty, Oil & Gas, Marine, Defence, Railways, etc.

Material Selection

We have a Comprehensive & Dedicated Raw Material Procurement & Storage. All the Raw Material for our components are only sourced from Recognized & Approved Steel Mills.

All components are supplied with the Material Test Certificate & every material is Tested in our Laboratory to ensure it is conforming to the Standard Material Chemical Composition. We offer components in a wide variety of Raw Materials & also have the flexibility to source & use material as per customer requirement. Some of the common materials we use are Alloy Steel, Micro Alloy, Stainless Steel & Carbon Steel.

Billet Cutting

We have numerous fully automated bi-metallic Band Saws enabling it to meet forging capacity with minimum-cutting losses. The Cutting Shop has capacity to utilise 10,000 tons per month on two standard shifts with plenty of spare capacity to meet any demand at hand.

Die Making

Our Forging units are completely integrated with our own In-House Die Making. This offers greater flexibility & shortens our lead time for New Part Development.

All Die Blocks are sourced from reputed manufacturers with no compromise on quality & offers greater Die life for our production. We have a fully equipped Die-Shop which comprises three 4-axis Vertical Machining Centers along with other supporting machines.

Hammery & Press Forging

We have a comprehensively & fully Integrated Forging Hammer & Press unit. This offers the flexibility of both type & volume of production. Each of the Hammer & Press units are fully equipped with the most energy efficient induction Heaters, reduce rollers, trimming & padding presses, Heat treatment & Controlled Cooling, Twist & Bend Checking equipment.

The Hammer & Press units are regularly modernized to keep with the production needs & keeping the plant energy efficient. We boast of one of the largest Forging Equipment comprising our 16T Forging Hammer line. This is further complemented by a range of 2 Ton, 3 Ton Hammer lines followed by a 2000T Hot Forging Press Line. We are in the process of commissioning our 6300T & 8000T pressline which will be complete in 2021 & 2022 respectively.

Trimming Process

The Forging Units are fully equipped with Trimming & Padding Presses. We have a range of Trimming Presses namely 100T, 300T, 500T & 1500T capacity Trimming Presses. This further enables us to have a fully integrated Forging Unit.

Precision Machining

Overview

We have Two Dedicated units in our Machining Facilities namely the Rough Machining & Finish Machining Units. There correspond to 10 Precision Machining lines & 2 Prototype Manufacturing Lines enabling us to have a Total Output of 1000 crankshafts per day which will shortly be upgraded to 2000 crankshafts per day. The Dedicated Prototype lines enables us to Develop New Parts & Components with flexibility & shorter lead times. We have added a large array of components in our portfolio through a spectrum of Industries further expanding our footprint & expanding our product range.

Facing & Centering

The First Process in the Machining of a Crankshaft is the Facing & Centering Process. This acts as a base & reference for all future processes & is very critical. The Facing & Centering is the process to reduce the initial imbalance of the crankshaft thus assisting in the final balancing accuracy of the crankshaft.

We also have an additional layer in our Machining Flow where Recentering is done prior to Grinding & post Rough Machining. This ensures that the initial reference is maintained & there is no deviation found on the parts.
Milling & Turning

The CNC Rough Machining is done in our State of the Art Rough Machining Unit. There are a large number of flexible Machining Centres enabling Turning & Milling of Smaller as well as Larger Components.

We are one of the only companies in India to have 10 Heller Milling & Turning Centres installed in our units enabling us to achieve the volume capacity of 1000 pcs per day presently.

This is a mark or signature of a high quality product which has over the years become the norm of every well-known component manufacturer. This infrastructure gives us the competitive edge over our peers & also ensures that the highest standards of quality is maintained.
Drilling

All Drilling Operations are carried out in our 4 Axis & 5 Axis CNC machines. This enables higher accuracy enabling us to achieve the standards of quality desired by our patrons & partners globally with closer Tolerances, shorter lead times & higher efficiency.

The Oil Holes are produced in our 5 Axis & SPMs (Special Purpose Machines). This enables higher accuracy enabling us to achieve the standards of quality desired by our patrons & partners globally. We have Dedicated Oil Hole Drilling Machines capable of machining up to 1500 crankshaft in a single day.

All Components are machined in our CNC Machining Lines which ensures the accuracy & consistency in the production to enable us to supply precision parts with the closest tolerances, highest quality & maximum efficiency. We internally adhere to a strong policy of regular upgradation & modernisation of the technology used in our manufacturing units to ensure we always stay ahead of the curve & deliver the highest standard of quality.
Grinding

We have 32 Grinders In-House in our Finish Machining Unit. The Grinders are CNC controlled & comprises state of the art CBN grinders as well. The Grinding Unit on a 3-Shift Cycle can produce over 2000 units in a single day.

These grinders were imported from our acquisitions of the Massey Ferguson plant in Ursus, Poland & Thyssenkrupp plant in Lyon, France. Our CNC Grinding unit is unmatched & unparalleled with the latest & regularly upgraded grinders allowing machining upto 2.5 meters.

We are shortly commissioning three new CBN Wheel Grinders in our production lines which will further increase our output.
Post Grinding

We have a Dedicated Post Grinding Machining line capable of machining up to 2000 crankshaft in a single day. The line comprises a number of CNC Horizontal Machining Centres (HMCs) & Vertical Machining Centres (VMCs).

We internally adhere to a strong policy of regular upgradation & modernisation of the technology used in our manufacturing units to ensure we always stay ahead of the curve & deliver the highest standard of quality.
Dynamic Balancing

All Components are Dynamically Balanced & we have the capability to balance the crankshafts within 5 gms. We generally maintain the balancing limits as per the Customer Specification or OE requirement.

It is a very critical process in the machining & the sum of these processes optimises the running behaviour of the crankshaft in the engine and ensures that natural vibrations are as low as possible.
Splines/Serration (Deep Rolling Process)

We have multiple Special Purpose Machines (SPMs) which enable us to have higher outputs on specific production lines. This enables us to offer quicker ramp ups to our partners during sudden increase in volume demand. These machines are specifically tooled for only one type of component & we install SPM machines on long terms contracts with our partners.

A very special CNC special purpose machine is utilized for the purpose of producing the Serration/Splines on parts which may have a requirement for the same The process is called "deep rolling".
Super Finishing

One of the most crucial processes in the production is the auto lapping/superfinishing/polishing process. We have a dedicated line for the polishing process complete with state of the art Nagel CNC auto lapping machines.

All components are super finished in these machines enabling us to achieve a surface finish of upto 0.10 RA which is the standard requirement for most of our OEM partners & patrons globally.

We are shortly introducing Micro Finishing as well as Nano Finishing Machines keep in line with the latest Innovation & Technologies.
Conservation & Packaging
  • Once the Quality Control is completed, we apply Rust Preventive (any one of the below)
    • Transparent RP Oil
    • Golden RP Oil
    • Golden RP Wax

    The Part is completely submerged in the above.

  • The Part is then packed in VCI Paper
  • The Part is then placed in VCI Plastic (The Plastic we use is Bio-Degradable & Environmentally Friendly)
  • We then pack the goods in Individual Boxes or Bulk Packaging depending upon the Customer Requirement
Marking

We mark goods by laser in various stages of the production. These are maintained in records with traceability for a period of 10 years. We also offer QR Codes & Bar Codes as marking options for the customer to allow a more convenient tracing for the end user

Heat Treatment

Machining Process

We have an In-house Heat Treatment facility that adds flexibility in our production Flow. All Components are tested for the Surface Hardness post the Heat Treatment process to ensure it is conforming to the requirement of the customer. We offer various Heat Treatment methods to our customers namely Induction Hardening, Fillet Hardening & Nitriding. All Induction Coils for Heat Treatment are also manufactured in our In-house Tool Room. This shortens our lead time for production & also speeds the Development Time for new parts.

In addition to the same, we also have our fully equipped In-House Metallurgical Lab for measuring Case Depth/Material Flow & Hardness We generally maintain a Hardness range of 55-62 HRC (Varies as per Customer & Part Specification) & HRC is the generic unit we use internally for measuring the Hardness.
Forging Process

We utilise box type Furnaces in the Forging Unit for Hardening of the Components. The unit is capable of loading up to 6000 Tons per month & the capacity is further expandable depending upon the demand.

There is a dedicated facility with multiple furnaces & Hardening, Tempering & Normalizing Operations are done under one roof. We generally maintain a Hardness range of 250-350 BHN (Varies as per Customer & Part Specification) & BHN is the generic unit we use internally for measuring the Hardness in the Forging Process.

Design Facilities

We have a dedicated design team comprising of thirty five very skilled designers with a capability of both 2D & 3D Modelling. We have all the required 2D & 3D Design Softwares with Simulation Modelling to enable the product design is done as per the customer specifications.

We also offer solutions to our patrons for New Product Design & Development & our comprehensive Design Team & Infrastructure enables us to offer end to end Design Solutions. Our design team also utilises 3D Printers for modelling & prototyping for any NPD Project.

A strong design team & infrastructure is imperative for the success of any engineering company & we have built a strong expertise & foundation for our Design Department. We are further expanding our design scope & regularly enhancing our capabilities.

Balu Edge & Key Tech Solutions

Quality Control

We have inculcated a culture of ‘Quality First’ throughout the organisation to ensure we can deliver to our promise & the part quality expected by our patrons & partners globally.
In-Process Inspection

A crucial part of any Machining Process is the In-Process/In-Line Inspection methodology that adds an additional & crucial layer to the Quality Control Flow. This enables us to eliminate defects if any early in the production process & increase the efficiency of the whole operation. This also ensures a stringent Quality Control flow enabling us to achieve our 0% Rejection claim & promise policy.

Our Team ensures that every part is precisely checked & we maintain traceability for a period of 10 years for every part that is dispatched from our facility.
Crack Testing, Demagnetisation & Stress Relieving

The Heat Treatment process is followed by the Crack Testing, Demagnetization & Stress Relieving process. The parts are subject to crack testing twice in the production process namely post Heat Treatment & Post Grinding. There is a practice & policy of 100% Crack testing on all components manufactured by our company.

Stress Relieving is the final process prior to shipping the parts to our Finish Machining Unit. It is a very critical process to ensure that the parts do not stay brittle post Heat Treatment & prior to the Grinding Process.
Metallurgical Lab

We have a fully equipped In-House Metallurgical Laboratory for measuring Case Depth/Material Flow & Hardness (In HRC). We generally maintain a Hardness range of 55-62 HRC (Varies as per Customer & Part Specification) & Case Depth of up to 4.5 mm.

Our Metallurgical Laboratory is fully equipped with Hardness Testers & Metallurgical Microscopes. We have a key emphasis on the Laboratory & the same is regularly upgraded with latest instruments & equipment. We supply cut pieces with every batch to our customers. This ensures the Hardness is consistent & is conforming to the Customer requirement.

Metallurgical testing includes microhardness testing and microscopic and macroscopic examinations to evaluate surface and internal features, defects and material characteristics. Samples for all metallurgical testing are prepared at our laboratory. All inward Raw material is tested & also per lot one unit is cut to check the pattern of the hardness & material flow.
Fatigue/Durability Testing

It determines the convenience of metal material’s mechanical feature. We use both In-house & outsourced equipment to conduct fatigue tests as per customer requirement. The equipment used to carry out the fatigue test is a pulsator & an electrodynamic shaker.

Services

Assembly Services

All Assembly related production is also done under one roof. We offer a range of Assembly services to our customers such as Gear Production & Assembly, Balance Weight Production & Assembly, etc.

We do not only manufacture & supply crankshafts, we supply ready-to-install crankshafts for manufacturers. Our key motive is to ensure all services related to components are done at our end with a complete end to end solution.