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Melting


Sky Technocast has installed latest technology C.I. & Ductile Iron melting plant of 200 MT per month melt by 450 KW panel, 500 Kgs × 1 Crucible VIP tri-track medium frequency furnace from ORITECH SOLUTION with a melting capacity of 500 KG per hour.

This furnace is equipped with hydraulic tilting arrangements, water cool leads and standard set of bus bar & fume capture hoods for collecting smokes, dust & airborne pollutants during all phases of furnace operation, remote display crane weighing, pyrometers for controlling temperature.

In addition we have carbon and silicon analyzer with charge calculation.

Core Shop


  • 1. Cold Box Core Shooter
  • 2. Shell Core Shooter
  • 3. Manual Core Making (Oil Core )
  • 4. Core Oven- Electric (Make : Self )
  • 5. Sand Mixer(100 kg) (Make :Self)

Horizontal Parting, Cold Core Box Machine having 15 Litres capacity SUSHA make (Size: 450mm x 450mm x 200mm).


Sand Plant


Sky TechnoCast has installed a 4 ton per hour capacity sand plant from RHINO MACHNIES PVT LTD. We have selected Belloi & Romagnoli for sand mixture and RTC – Online Sand Controller, with PLC interfaced load cell for return sand, new sand and additives like Bentonite, Coal Dust etc. with online moisture and sand testing facility. Also the homogeneity in mixing of Raw Material which also drastically reduces consumption of Bentonite, cold dust etc. Which also affect the quality of casting finish due to less generation of dead clay in sand.

It has fantastic advantages like :-


  • 1. Min. Casting defects like blow holes, porosity and mould breakage etc. Due to highest quality consistency of  ready sand.
  • 2. High amount of raw material saving due to best design and proven  performance of sand mixer.
  • 3. Homogeneous quality in all batches. Inbuilt properties of input return sand is retained with min. losses.
  • 4. Exact feeding of input raw material due to feeders with electronically  controlled load cells coordinated with online sand inspection facilities synchronized with main computer.

This sand plant will encompass components like :-

  • 1. Intensive Mixer.
  • 2. RTC – Online Sand Controller
  • 3. Sand Cooler
  • 4. Automatic additive dosing systems
  • 5. Centralized PLC based controls

RTM 400(Process)


Loading : Period during which the mixer is filled with sand. During this period, the motor speeds increase from nominal speed to the necessary speed for lump breaking.

Dry Mixing : The sequence is designed to eliminate as many sand balls as possible from the sand and efficiently mix the additives. The tool speeds are increased significantly to achieve this.

Wet Mixing : This is the most important process phase. After adding the necessary water, tool speeds automatically self adjust as the sand properties are achieved resulting in optimized power input and '0' temperature increase.


Aeration : At the end of the preparation sequence and after the sand reaches its nominal characteristics, the speed ratio can be judiciously chosen to give well-aerated sand, extremely silky in touch and ideal for moulding fine parts.

Emptying : Sand is emptied from the mixer and the two motors return to their normal speed.

RTC 103.6


  • 1. Brings sand to right temper for good workability.
  • 2. Maximum green strength and optimum characteristics of all sand parameters.
  • 3. Direct access to the whole system at the click of a mouse .
  • 4. Real time flow chart of RTC.
  • 5. Historical records recovery .
  • 6. Statistical display of data.
  • 7. Maintenance operator comments and records storage.
  • 8. Direct access to system calibration
  • 9. Consistently raises the quality of moulding sand.
  • 10. Reduces the consumption of additives.
  • 11. Brings down your casting rejection levels
  • 12. Collect, at any time, information on sand parameters.

Tools, Pattern Design & Development


Sky Technocast has in-house pattern design and manufacturing facilities, equipped with JYOTI VMC Machine(Size :- 500 X 500 X 800) & Designing / Programming Software for quick development of new castings. 

Simulation Software(Delcam) facility for methoding provides mechanism to avoid shrinkages and to make Sound castings.

Moulding


Sky Techno cast drives the moulding machine technology from French. We have high pressure vertical parted fully automatic moulding machine from Rhino Machines Pvt. Ltd.(India). This moulding line is having capacity of 40 moulds per hour with cake size 600 × 500 x 140~200 and is based on latest pre-fill, shoot & squeeze technology, where the moulding process will be extremely uniform which will finally result into highly consistent production by means of component weight, piece variation, mould variation, wall thickness, mould drawal with min. draft angle on pattern etc. This Machine was developed for higher quality moulds & increased productivity

Advantages of this Moulding Systems are as under briefly


  • 1. Pre-fill, shoot and squeeze technology makes sure that mould quality are perfect, uniformly & minimal variation even in deep cavity moulds.
  • 2. No mould swelling which also directly affects the final weight of casting
  • 3. Extra ordinary surface finish of casting , Min. machining allowance, reduces machining process time, cost and minimizes scrap generation.
  • 4. Minimum man power required
  • 5. Overall cost reduction in operation cost.

Fettling & Shot-Blasting


After shakeout casting will process in shot blasting machine and for grinding to remove scales and achieve clean & uniform surface textures.

  • 1. Hanger type shot blasting machine.
  • 2. Tumble Type Shot Blasting Machine.
  • 3. Heavy duty swing frame grinders
  • 4. Pedestal grinders
  • 5. Portable pneumatic grinders
  • 6. Wedge breaker for runner/riser cutting

Product Testing Facilities


Some of the world-class testing and quality assurance equipment installed with :-
1. Foundry Devision

METALLURGICAL TESTING
  • 1. Image analyzer for metal phase analysis.
  • 2. Brinell Hardness Tester.
  • 3. Universal Testing Machine (UTM) for standard test bar.
  • 4. Sand Testing Equipments
CHEMICAL TESTING
  • 1. Spectrometer
  • 2. C.E Meter Analysis
  • 3. Portable Pyrometer

Machine Shop Facilities


Machinery Type Make No. of Unit
CNC Turning Center Marshall 2 Unit
Lathe Machine Various 50 Unit
Drill Machines Various 15 Unit

Measuring Equipments


  • 1. CMM (Co-ordinate Measuring Machine) Carl Ziess ( 700 × 1000 × 600 mm).
  • 2. Surface Roughness Tester.
  • 3. 2D Primos & Height Master (600 mm)
  • 4. Marfos Gauges for Bearing Bore Checking (Range: 60 to 120 mm)
  • 5. Linear Measuring like Micro Meters, Vernier & Bore Gauges.

Quality Policy

We at Sky Techno CAST  are  committed to build & sustaion consistent quality to meet & exceed customer requirements,expectation and satisfaction.

To achieve this team STPL is committed to :

  • 1. Systematic approach of management and employee Continuous improvement in each function
  • 2. Training and implementation of new methodology for productivity and quality improvement Consistent upgradation and growth of appropriate technology
  • 3. 100% involvement of every employee