Urbanization and infrastructure developments, such as metro systems and railway electrification, drive demand for transmission line towers. These towers are vital for upgrading and expanding power networks, ensuring a positive outlook. To meet the growing demand, Metcraft Engineering specializes in manufacturing hot-dip galvanized steel structures and towers for power transmission and distribution, railway electrification, wind and solar energy, industrial buildings, and road safety.
Metcraft, established 12 years ago, has grown from an initial capacity of 250–300 metric tons per month to 1200 metric tons per month. The company now operates two manufacturing units with expanded fabrication and galvanizing capabilities. “Upgrades include the latest galvanizing furnaces using natural gas, which reduce carbon emissions by 75 percent as well as larger galvanizing baths. The company has also invested in advanced material handling equipment and state-of-the-art CNC laser machines for both long and flat products”, says Rohit Agarwal, Managing Partner.
Setting New Quality Standards
Metcraft offers an array of capabilities, including designing, prototyping, manufacturing, in-house galvanizing, and testing transmission towers and substation structures. They also provide customized fabrications, and hot-dip galvanizing services. With state-of-the-art infrastructure, their manufacturing unit delivers comprehensive solutions tailored to customers' unique requirements. As a tower manufacturer, the company provides unique advantages for clients in South India.
Their location in Bangalore offers proximity to major markets in Tamil Nadu, Karnataka, and Kerala, facilitating faster project execution and logistics. Moreover, their extensive experience with local utilities, such as KPTCL and TNEB, has earned them strong confidence among clients, making them a preferred choice for EPC contractors in the region.
However, clients in India face several challenges when availing products from tower manufacturers, including the complexity of multiple tower designs, alignment issues, shortages of parts on-site, and the need for timely deliveries. Metcraft addresses these challenges effectively. The company has identified several unmet needs and developed strategies to gain a competitive edge. Firstly, they have created numerous prototypes around 20-25, ensuring proper alignment and functionality when deployed on-site. Secondly, their robust packing methodology prevents shortages, which is crucial given that a single tower can consist of 250–500 parts. Additionally, their focus on faster deliveries allows clients to execute projects more efficiently.
"The use of CNC lines enhances product quality, meeting the high standards required for timely and reliable project completion. Clients who need reliable solutions and swift execution, particularly those requiring line clearances, find the company a dependable partner in their projects", shares Rohit.
Metcraft does not outsource any part of its manufacturing process or rely on contract manufacturers
Another key advantage is Metcraft's fully in-house operations, from material testing to fabrication and galvanizing, ensuring superior quality control. Unlike many competitors, the company does not outsource any part of its manufacturing process or rely on contract manufacturers. This approach ensures a consistent and high-quality workforce, with many employees having over a decade of experience with the company. However, a robust packing methodology further ensures that clients do not face shortages on-site, minimizing project delays and cost overruns. This meticulous attention to detail helps clients complete their projects efficiently and within budget. These USPs—strategic location, strong client confidence, in-house operations, and robust packing—set it apart in the tower manufacturing industry.
Future expansion plans include increasing production capacity to 2000 metric tons per month and targeting a turnover of Rs.200 crores within the coming years. The company aims to enhance material handling, automation, and software integration to improve accountability and operational efficiency. Additionally, Metcraft is focused on employee training and skill development to maintain high quality and customer satisfaction.
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