At U K Metals, our strength lies in our world-class manufacturing infrastructure, advanced machinery, and rigorous quality control systems. We are equipped to meet complex casting requirements with unmatched dimensional precision, material integrity, and timely delivery, making us a trusted name across industries. Our modern foundry, spread across 34,000 sq. ft. with a 4,500 sq. ft. built-up area, is designed for high-volume and high-accuracy production. We manufacture castings ranging from 0.5 Kg to 250 Kg, using advanced molding, melting, and machining processes to cater to a variety of industrial applications.
Our melting shop is equipped with advanced dual induction furnace systems designed for consistent, efficient, and high-quality metal melting operations. We utilize both Plasma Induction and Inductotherm Furnaces to ensure flexibility and uninterrupted melting cycles, essential for producing premium Grey and Ductile Iron castings.
The Plasma Induction Furnace features two pots with capacities of 500 Kg and 300 Kg, powered by a 350 KW panel. This setup allows a melting rate of approximately 500 Kg in just 45 minutes, ensuring rapid turnaround and high thermal efficiency. The Inductotherm Furnace also includes 500 Kg and 300 Kg pots but operates with a 250 KW panel, delivering a melting rate of 500 Kg per hour.
This dual-furnace arrangement enables us to maintain a continuous melting cycle, reduce downtime, and optimize production efficiency. The system is ideal for managing varied batch sizes while maintaining strict control over metallurgical properties, making it suitable for precision casting requirements in both Grey and Ductile Iron categories.
Our moulding facilities are equipped with advanced Jolt & Squeeze green sand molding technology, ensuring consistent mold compaction, superior surface finish, and dimensional accuracy for high-quality castings. We operate two fully functional molding lines to cater to diverse production needs.
The ARPA 300 molding line features a box size of 500 × 500 × 150 × 200 mm and can produce up to 30 molds per hour, handling casting weights ranging from 20 to 50 Kg. The ARPA 450 molding line supports a larger box size of 600 × 550 × 200 × 200 mm with a production capacity of 20 molds per hour, ideal for medium-weight castings between 25 and 60 Kg.
In addition to machine moulding, we also offer Hand Moulding using the traditional Green Sand Process for specialized or low-volume castings. For more complex geometries and large-size components, we are equipped with No-Bake and Shell Moulding capabilities. Our facilities can accommodate castings up to 2 meters in length, ensuring flexibility for large-scale industrial applications.
A key feature of our moulding setup is the Continuous No-Bake Mixer, with a capacity of 6 metric tons per hour, allowing consistent sand preparation and efficient production flow. This combination of molding techniques allows us to deliver high-quality, dimensionally precise castings for various industrial sectors while ensuring optimal productivity and material performance.
Our state-of-the-art in-house core shop is designed to produce highly accurate and dimensionally consistent cores, essential for achieving complex internal geometries in castings. By leveraging advanced core-making technologies, we ensure precision, efficiency, and reliability across all casting applications.
We utilize a No-Bake Sand Mixer to prepare high-quality core sand with excellent strength and workability, suitable for large or intricate cores. Our Cold Box Core Shooter allows the rapid production of strong and dimensionally stable cores, ideal for complex and high-volume casting requirements. Additionally, we employ Shell Core Making Machines that produce smooth, high-strength cores with excellent surface finish, contributing to improved casting quality and reduced machining needs.
These integrated core shop capabilities support the production of both Grey and Ductile Iron castings, enabling us to meet diverse customer specifications with superior accuracy and consistency. Our commitment to advanced core-making technology ensures optimal performance in every casting, making us a trusted partner in precision metal casting solutions.
Our Fettling Shop is fully equipped with advanced finishing equipment to ensure every casting meets the highest standards of surface quality and dimensional accuracy. This critical stage of the casting process is handled by skilled technicians using modern tools and techniques to remove excess material, smooth surfaces, and prepare components for final inspection or machining.
We utilize an 18” Twin Table Grinder for efficient grinding operations on medium to large castings, delivering high precision and consistency. Swing Frame Grinders are used for heavy-duty cleaning and shaping of complex or oversized parts, providing flexibility and speed in material removal. Our Hanger-Type Shot Blasting system ensures uniform surface cleaning and descaling, enhancing the final appearance and surface integrity of the castings.
For detailed work and finishing of intricate areas, we employ Hand Grinders and Pencil Grinders, allowing fine control and precision. An industrial-grade air compressor supports all pneumatic tools, ensuring continuous and efficient operation throughout the fettling process.
With this robust infrastructure, our fettling shop ensures that every casting is finished to exact specifications, ready for dispatch or downstream processing. This comprehensive setup supports the production of high-quality Grey and Ductile Iron castings for a wide range of industrial applications.
Our in-house machine shop is fully equipped to deliver precision machining services, offering both proof machining and full machining for a wide variety of castings. We ensure that all components meet strict dimensional tolerances and surface finish requirements as specified in customer drawings, supporting diverse applications across automotive, engineering, and industrial sectors.
Our advanced machining capabilities are powered by a range of high-performance equipment. The CNC Turning Machine (Chuck Dia 400 mm, X-450 mm, Z-350 mm) enables accurate and repeatable turning operations for cylindrical components. The VMC – BFW Chakra (X-1200 mm, Y-600 mm, Z-600 mm) allows precision milling and drilling of complex geometries with high-speed, multi-axis capability. For large and heavy-duty parts, we utilize the VTL – BFW Sudarshan (Chuck Dia 500 mm, X-650 mm, Z-700 mm), ideal for vertical turning and boring tasks.
To ensure balance and vibration-free performance in rotating parts, our facility includes a Universal Balancing Machine with both vertical and horizontal configuration. Additionally, we have three Manual Lathe Machines integrated with drilling units for custom machining and smaller production runs.
With a focus on accuracy, consistency, and quality, our machine shop enables us to deliver fully machined Grey and Ductile Iron castings ready for assembly or end-use. Our end-to-end machining solutions make us a reliable manufacturing partner for high-precision components.
Our machining facility is capable of handling a broad range of components with precision and efficiency, catering to various industrial requirements. We offer precision machining services for castings within a weight range of 3 Kg to 150 Kg, making us well-suited for both small and medium-sized components.
Our infrastructure supports machining of parts with a minimum diameter of 100 mm and a maximum diameter of up to 680 mm, allowing us to work on a wide variety of geometries and dimensions. This capacity is ideal for producing critical components used in sectors such as automotive, hydraulics, agriculture, construction, and general engineering.
With a combination of CNC turning, VMC, and VTL machines, along with experienced machinists and quality control systems, we ensure that every part meets exact dimensional tolerances, surface finish, and customer specifications. Our reliable and scalable machining capacity makes us a trusted partner for high-quality Grey and Ductile Iron castings with complete machining solutions.
At the core of our operations is a robust Quality Assurance & Testing department, committed to delivering castings that meet the highest mechanical, chemical, and dimensional standards. Every product undergoes rigorous inspection at multiple stages to ensure compliance with customer specifications and international quality benchmarks.
Our facility is equipped with a Universal Testing Machine (UTM) for evaluating tensile and compression strength, while a Spectrometer (Spectro Machine) ensures accurate chemical composition analysis of each melt. To maintain sand quality for mold integrity, we use comprehensive Sand Testing Equipment. A high-resolution Microscope is used for Microstructure Analysis, ensuring metallurgical consistency and grain refinement.
We also perform Brinell Hardness Testing (BHN) to assess material hardness and durability. For dimensional verification, we rely on advanced tools like the Coordinate Measuring Machine (CMM) and 3D Scanning technology for detailed inspection of machined parts. A Granite Surface Table (2000 mm × 1000 mm) provides a stable reference surface for high-precision measurements.
All quality control processes are conducted under the supervision of experienced engineers, supervisors, and skilled technicians, ensuring zero deviation from client expectations. Our commitment to strict quality assurance guarantees that every Grey and Ductile Iron casting we produce is reliable, consistent, and ready for high-performance applications across industries.
