The iron casting market in India has grown exponentially, driven by increased industrialization, infrastructure development, and technological advancements. Traditionally, iron casting in India was a labor-intensive process with limited technological intervention. However, the introduction of advanced manufacturing technologies and automation has revolutionized the industry, improving both efficiency and quality. Calcutta Springs, with its rich history and deep-rooted expertise, has played a crucial role in this transformation. The company has embraced in-house development and tooling of patterns, reducing reliance on external pattern shops and minimizing costs. By manufacturing patterns in-house, the firm has achieved greater control over quality and lead times, enhancing its overall production capabilities.
Calcutta Springs' approach to iron casting is methodical, focusing on five critical aspects: patterns, metal, sand, and quality and dispatch. Traditionally, pattern making was outsourced to pattern shops, incurring significant costs. “We have revolutionized this by bringing pattern making in-house, reducing lead times and costs, and enhancing flexibility in production”, highlights Shreyansh Agarwal, Managing Director. The company uses a mix of pig iron, CRS-cutting scraps, and other metal scraps to create various grades of iron, ensuring the final product meets specific requirements.
By maintaining stringent control over the necessary GCS hardness, moisture, permeability, and compatibility of different chemicals in the sand, Calcutta Springs ensures that the foundry operates at optimal efficiency. Furthermore, the em-phasis on quality and efficient dispatch systems ensures that products meet industry standards and are delivered on time.
One of the primary challenges faced by customers in the iron casting segment is the lead time for developing new products. The initial stages of business involve building trust, which can be a slow process. Clients need to see the quality of the product firsthand, which often requires travel and extensive communication. Calcutta Springs addresses these challenges by maximizing in-house production and minimizing outsourcing. The company invests in developing patterns and tooling without passing these costs to the customers, provided there is a future purchase commitment. This strategy significantly reduces lead times. Furthermore, the company's commitment to customer service includes complete traceability of castings and a readiness to meet clients in person, fostering strong relationships and ensuring satisfaction.
Calcutta Springs has implemented the 5S Kaizen theory in its quality department, ensuring systematic and continuous improvement. Additionally, the Thermomatic Problem Consultant (TPC) program addresses any production issues promptly. Post-production plans (PPP) and detailed process charts ensure consistent quality irrespective of manpower changes.
Calcutta Springs is not just a business. It's a legacy of trust, quality & relentless pursuit of excellence
“Each segment of our factory is dedicated to different customers, tailored to meet their specific requirements, whether it's superior paint quality, surface finish, or mechanical properties”, explains the Managing Director. This customer-centric approach ensures that products not only meet but often exceed client expectations, leading to long-term relationships and repeat business.
Calcutta Springs exports extensively to the United States, Europe, the Middle East, & is eyeing new markets in Bangladesh, Australia, Sri Lanka, & South Africa. Its future roadmap also includes diversification into agricultural wheels, electrical poles, and continued innovation in their product portfolio. “Calcutta Springs is not just a business. It's a legacy of trust, quality, and relentless pursuit of excellence. With a clear vision for the future and a deep commitment to its clients, we shall continue our leadership in the iron casting market for generations to come”, concludes the Managing Director.
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