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Face-to-Face

- Kiran Jaykumar PatilChairman and Managing Director

Ghatge Patil Industries Limited

iran Jaykumar Patil, is a well Krenowned name with a rich and diverse experience of 40 years in the field of Engineering. He has completed his academics in B.E. (Mech), Regional Engineering College Surathkal Now: National Institute of Technology, Surathkal and M.B.A. (USA).

He is the Chairman and Managing Director Ghatge Patil Industries Limited, TS 16949, ISO 9001, API, DB accredited company having an annual turnover of over $86 Million, employing more than 1200 union of minds providing technological solutions to its customers. The Foundry Division has a sophisticated Foundry with Fully Automatic High Pressure Moulding Line with Automatic Core Shooting Units, Automatic Press Pour manufacturing Grey & S.G. Iron Castings specialized in thin walled high precision transmission castings.

The Product division has state of the art Machine shop with battery of Horizontal Machining centers, Vertical

Machining centers and general purpose machines manufacturing Valves such as Gate Vales, Double Block & Bleed (DBB) Plug valves, Check Valves for the oil and gas industry, Power Transmission products like Marine Gearboxes, Fluid Couplings, Clutches and Power Take Offs to major suppliers of Mechanical and Hydraulic aggregates to leading earthmoving equipment manufacturers in India.

The company exports its products to various countries like USA, Europe, South America, Africa, Middle East and Far East.

The company has set up new state of the art mega foundry project catering to its increased demands of domestic and international cliental and is looking forward towards becoming leaders in global technology.

Other Associations

Ÿ Indus FerroTech Limited

Director 2007 – Present

Ÿ The Ratnakar Bank Limited

Director 2008 – 2015

Ÿ Confederation of Indian Industry

Past Regional Chairman

Ÿ Indian Institute of Foundrymen

Past Regional Chairman

Ÿ Maharashtra State Board of Technical Education Director Advisor 2006 - Present

Speaking to Metalworld, he talks about the present and future status of the foundry industry.

Excerpts.

How is the foundry Industry performing presently?

The Foundry Industry is experiencing sudden surge in demand after a slow down since 2015. With the introduction of GST there was a turmoil since the GST levels set in by the government created a lot of controversy which took time to

Foundry Industry is ExperiencingSurge in Demand

Face-to-Face

With the introduction of GST there was a

turmoil since the GST levels set in by the

government created a lot of controversy which

took time to settle.

settle. The tractor industry in particulars is showing a healthy recovery, with good rainfall, the trend is expected to continue. The commercial vehicle sector is also showing signs of recovery as there is an increase of spending's on infrastructure. The Chinese government is imposing stricter pollution control norms, the Indian foundry industry stands to benefit as import of castings from China may be affected. However for Indian foundries, prices of Ferro Alloys, Ferro Silicon and Coal ( currently sourced from china)are already showing an upward trend which will lead to increase in pricing pressure on Indian foundries.

In your opinion what are the problems which needs to be tackled to give a boost to the foundry business?

a. High Energy Cost

b. Inter State Open Access where energy is available at a cheaper price but is discouraged by many states

c. Poor availability of CNG pipe line network.

d. Industry should be encouraged to melt metal in Foundries during night with substantial low cost power. This should allow Foundries to melt and hold the metal in holding furnaces to be used in day shift as is done in Europe. Special financial assistance for such large holding Furnaces would be a viable option for the industry.

e. Legislation of implementing policy

of scrapping old commercial vehicles would lead to sustained growth of the industry. This needs to be speeded up thus will lead to substantial growth of the Industry and will curtail pollution in a larger scale.

f. Special emphasis on training to acquire skill and knowledge related to the Modern Foundry practices under the scheme of Skill India.

g. Labour laws to be modified to suit today's Industry Needs.

h. Sand mining to be monitored and regulated.

I. Pollution control norms and regulations for SME to be made applicable across the Foundry Industry.

j. MGNREGA is deterrent to the

industry, thus forcing the industry to invest in automation as the way forward.

What are the present trends in Foundry Industry on national and international level?

a. To make the end product more cost effective, Foundries are moving towards weight reduction of castings with the help of modern analytical software. At the same time are also working towards newer materials that offer high strength and low weight at the same time.

b. Like in Europe and USA ,there is an increase in demand for Indian foundry to move towards HPML's and auto pouring systems to meet the constant fluctuation in demand as well as to get close tolerance castings.

c. As getting skilled manpower is a major concern for the Indian Foundry Industry, High degree of automation is being put in place at the core shop / Moulding / melting and some extent Fettling. This in turn also helps the foundry to be environment friendly and attracting newer generation towards the Foundry.

d. To increase customer delight, Foundry should move towards more value addition by fully machined castings which can be supplied JIT.

How do you see the short term and long term future prospects of Foundry Industry?

Short term prospectus

Foundry industry is showing increasing demand and better utilization of existing capacity.

There is pressure on cost reduction in casting, at the same time, due to sudden

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Face-to-Face

increase in demand of casting, there will be upward pressure on raw material prices and also availability.

Availability of manpower for fettling will be a very big concern forcing automation/ CNC fettling is a must. This also can give consistent output as well as enables producing huge quantities.

Current automation level in fettling is limited as well as extremely expensive as this is a new concept for India. There is still a gap to be bridged between Foundries and Customers when it comes to CNC Fettling. This may lead to shortages of casting available for end user.

Long term prospectus

Foundry is mother industry and this means the requirement will not vanish but likely to change to Aluminum castings, 3d printed castings and might also move towards lost foam process like China. The progress of electric cars/ vehicles will have negative impact on casting requirement as number of parts required are reduced considerably.

What are your views on technological up gradation in foundry industry?

Increasing pressure on demanding cost reduction and stringent quality norms for casting, foundries across India are undergoing up gradation of facilities and technology to improve their productivity and increase in capacity. To maximize export potential, foundries are setting up world class production facilities like Image Processing technology to accept or reject moulds and core qualities with online monitoring of deviations during manufacturing process and metal solidification and moulds flow simulation have started finding or customizing applications to meet quality requirements. Incorporation of new technology has now become indispensable for the foundry industry. Most Foundries in India fall under the SME and cannot afford the high cost for

technology, advance equipments or automation. Quality Assurance teams from buyers / sellers need to come together to understand limitations of CNC fettling . This will reduce strains on casting procurement.

What is the present product profile of GPI and what are your future plans?

a. Moulding

Plant 1 - Kunkel Wagner high pressure Moulding line, 3500 MT / month casting production capacity, Moulding capacity 84 moulds per hour with air pressure, moulding line is supported with Auto Core setting / pouring unit and Sand Plant with Sand multi controller system.

Plant 2 - Savelli High pressure Moulding line with production capacity total 6500 MT / month, moulding capacity 120 mould per hour with formi press system and electro mechanical control, Auto core setting unit and sand plant with aqua test control system, Casting cooling in sand with Jacket type Cooling system (6 Hrs), Automatic vent drilling unit, De-coring with manipulator,

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State of the art Sand Plant with 150 tons/hour.

b. Melting

Plant 1 - 4 MT auto press pour unit with holding furnaces, Induction Furnaces 4 Nos (4.5 MT/hr each), George Fisher convertor for SGI Production, Duplexing of Metals with 54" Cupolas (3 Nos), Standby Electric pouring trucks with Electronic controls.

Plant 2 - 8 MT Medium frequency furnaces (4 Nos), with auto charging equipment

,h EOT crane and magnetic scrap handling, Press pour Cap 6 (pouring and holding furnaces - capacity - 6mt).

c. Core Making

Battery of Cold / Hot Box Core Shooting Machines and Bowl type sand mixer built in-house, Horizontal / Vertical and Universal Core Shooter Machines ranging from 6 Ltr to 150 Ltr capacity

d. Finishing and Fettling

CNC Fettling Robotic Facility, Shot blasting machines, Spray painting booth with electrostatic gun.

e. Machining Excellence / Testing

Battery of more than 100+ HMC' s and VMC's, VTL, Integrated with centralized coolant system, CMM, Washing Machine, Auto Bore gauging system, leakage testing facility.

Future Plans :- GPI vision is to move towards the highest level of automation at all levels in Foundry and at the same time to meet the constant fluctuation in demand and keeping in mind increasing quality expectations of our customers.

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