India’s foundry sector is experiencing a massive boom driven by the nation’s rapid urbanization and industrialization amplifying the utilization of metals. The industry which has been estimated to value $19.46 billion in the current year, is expected to grow to a value of $31.77 by 2029, projecting a CAGR of 10.30 percent. Although the sector as a whole is quite massive and segmented based on metal type, the ferrous foundries segment is experiencing exceptional growth amongst all. Technological advancements, the expansion of the automobile sector, and infrastructure development initiatives are among the primary factors fuelling the growth of ferrous foundries, and driving up demand for greater production volumes.
Nevertheless, challenges pertaining to delivery periods, quality of products, price competition, and end-to-end solutions are common in the industry. Addressing these challenges strategically is Behari Lal Ispat of the 100-year-old Behari Lal Group. Through careful investments in CNC machines and technology, establishing multi-step inspections, and a forward integration approach, the firm tackles the prevailing challenges, ensuring a seamless experience for clients.
Leading Iron & Steel Manufacturers
Dedicated to providing high-quality products which align with the customers’ requirements and specifications, Behari Lal Ispat stands as a leading integrated Iron and Steel foundry serving diverse sectors with a range of superior, modern, and reliable products. The company aims to minimize the hot rolling mill operating cost, ensure timely deliveries of its products, foster a strong TQM culture, extend an efficient after-sales service, provide flexibility of solutions, and retain a highly competent and motivated workforce. These objectives and assets together have put the company in a prominent place in the industry.
The company’s client base is wide and diverse, comprising hot rolling mills, aggregate crushers, thermal power plants, cement plants, and more. Across all segments, the firm strives to solve client problems which typically circle around quality and cost of products. Through its robust infrastructure, BLI manufactures high-performance, customized solutions to precisely fulfill client requirements.
“Our plant comprises of modern technology fully integrated digital steel melting shop with vacuum degassing (VD), foundry, heat treatment and machine shop. As a leading integrated Iron and Steel foundry in India with automated, state-of-the-art production technology and a highly skilled workforce, we maintain competitiveness and to meet customer's genuine demands. Our products are consistently superior, modern, reliable, and delivered on time. In a short span, we have become an established manufacturer and trusted vendor for various product lines due to all our processes being consistent with ISO 9001:2015 certification”, shares Dinesh Garg.
Beyond being customer-centric, Behari Lal Ispat is also active in aligning its processes and operations with sustainability goals. The company aims to lower its carbon footprint through significant investments in green energy and efficient machines. BLI continually upgrades its facility to ensure that the plant delivers maximum output with minimal energy and resource usage,
along with ensuring that products are produced to precise specifications, further lowering wastage.
With this objective, the company has an installed capacity of 1.5 MW solar energy. It has also moved from furnace oil to PNG, and is currently running all its heat treatment furnaces on natural gas. Not only the heat treatment furnace, but also the re-heating furnaces in the rolling mills are no longer operated on furnace oil or coal. Lastly, the company is ensuring that it utilizes only clean and processed scraps as raw materials to ensure that impurities are not impacting the rate of emissions adversely.
Maintaining a Competitive Edge
In this highly competitive industry, BLI has established itself as a competent performer, promising efficiency of manufacturing and delivery. Manufacturing Metal Rolls, Engineering Castings and Alloy Steel bars (Rounds, Flats, Hex, and Squares), the company helps diverse industries in minimizing operating costs, and ensuring better operational life and fewer breakdowns. Moreover, its products offer productive sustainability, operational efficiency and greater profits for clients, making BLI their go to choice.
BLI’s commitment to absolute customer satisfaction can also be evidenced from its export-worthy packaging, achieved through an in-house container stuffing facility
The firm is renowned for its made-to-order range of products which are designed and developed by its in-house R&D team that collaborates with customers to understand their specific requirements. Thereafter, the team utilizes simulation software to make pouring plans, making sure the products fulfill the right quality requirements in the first try, reducing time and resource wastage. Moreover, 3D models of the components are created to test quality as well.
“We have a vertically integrated foundry, providing everything in house, right from pattern manufacturing, technical study, melting, heat treatment, finish machining, non-destructive testing, dimensional inspection, shot blasting and painting and packaging. Also, we are located at a strategic location which ensures that we have raw materials available all around the year without any stop in supply. We have one of the highest outputs in foundries in our size class in the nation, with one of our products having the second highest production all across India”, further shares Dinesh Garg.
For quality assurance, the firm also houses a chemical and physical laboratory led by experts. BLI also has NDT testing capabilities such as UT and MPI, which further ensure optimum quality of the products. Furthermore, its state-of-the-art shot blast facility and paint shop are pivotal in impacting surface quality and the creation of ready-to-use parts, particularly for the engineering industry.
BLI’s commitment to absolute customer satisfaction can also be evidenced from its export-worthy packaging, achieved through an in-house container stuffing facility. With the aid of this facility, finished products are loaded into wooden or steel pallets which are then dispatched, making it simple for the users to handle unloading and shifting of products. Lastly, the company’s workforce, particularly the technical manpower provides it a competitive edge by implementing systems for quality inspection and assurance at every step of the manufacturing process.
Future Roadmap
“Behari Lal Group is more than 110 years old and is a fourth generation organization. With the first step taken in 1910 by the visionary Behari Lal Garg, his son, Parkash Chand Garg, expanded their footprint by establishing our presence in Mandi Gobindgarh in 1939. The business is currently managed by the third and the fourth generations who have the right mixture of experience and youth to take it to new heights. Our company’s objective is to fulfill the requirements of our valuable customers by making our products in India. We expect the company to grow in double digits in the years ahead”, lastly adds Dinesh Garg.
Over the years, the company has developed a range of products which were previously imported. Through these developments, BLI has played a critical role in minimizing import dependencies across industries, and strengthened the technical awareness in India. This forward-thinking excellence of the firms has earned it multiple awards from the Government of Punjab for industrial expertise. Today, the firm is actively promoting Make in India.
As the company plans for its future development, it is committed to improving and upgrading consistently, to keep up with the dynamic market demands, and fulfill customer needs. With this objective, it is investing heavily in infrastructure development within the company, ensuring it is capable of manufacturing new requirements for the customers. With this customer-centric approach, Behari Lal Ispat is on track to become an industry leader, setting benchmarks for competitors to follow.
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