The 55-acre integrated foundry
Melt. Cast. Heat-treat. Machine. Test. Dispatch. One yard. One team.
The casting that leaves Bhawani's gate has never changed hands. Every step from scrap selection to final inspection happens on the same 55-acre site in Mandi Gobindgarh, under the same metallurgical envelope, signed off by the same engineering team — the structural advantage no fragmented supply chain can replicate.
Why one roof changes the maths
One yard. Zero handoffs.
Most Indian foundries pour metal and ship it — you then chase a pattern shop in one city, heat-treatment in another, machining in a third, carrying the risk at every handover. Bhawani built the whole chain in one yard, on purpose.
Two 30-MT + two 10-MT induction furnaces, one 35-MT EAF. LRF + VD/VOD route.
Melt-shop EOT cranes — the hard reason a 120-MT single pour is physically possible here.
30 TPH sand plant + reclamation, in-house pattern shop, 21,000 KVA substation.
PNG furnace 8.5×6.5×3.5 m, stress-relief 10×6×5 m, quench tank 6×7×4 m.
VTLs to 2.8 m, plano-millers to 6 m, Skoda boring, 5-axis VMC. Shipped ready to install.
What you stop doing: owning the gap at every handover. Here the casting never changes hands — one team, one set of certificates, one PO.
The casting production flow
Scrap to dispatch. Ten controlled stages.
- 01 Scrap selection
- 02 Induction melting
- 03 LRF refining
- 04 VD/VOD degassing
- 05 3-ladle pour
- 06 Knockout & riser cut
- 07 Heat treatment
- 08 Fettling & machining
- 09 NDT & inspection
- 10 Stress relieve & dispatch
Every stage is performed by Bhawani's own team, in Bhawani's own facility, with full traceability from scrap heat number through to dispatch test certificate. No outsourcing. No casting hand-offs. No accountability gap.
The heart of the integrated foundry
Steel Melt Shop. 30 MT heat size.
Five furnaces, full secondary refining via LRF and VD/VOD, and continuous casting for billet production — the metallurgical foundation of every casting that leaves Bhawani. Single-piece ingots up to 40 MT.
- Two 30 MT Induction Furnaces
- Two 10 MT Induction Furnaces
- One 35 MT Electric Arc Furnace
- AOD converter (Argon Oxygen Decarb.)
- Ladle Refining Furnace (LRF)
- VD/VOD with dry mechanical vacuum
- Overhead cranes: 80 + 60 MT
- CCM with electromagnetic stirring
Where the casting takes shape
Foundry & Moulding. 6,000 m².
The Bhawani moulding floor is sized for the heaviest castings in India — a 30 TPH continuous sand mixer, in-line reclamation, and a 4,000 m² fettling area staffed for around-the-clock heavy-casting cleanup.
- Moulding area
- 6,000 m²
- Sand handling
- Continuous mixer 30 TPH · reclamation 30 TPH
- Shot blast / paint
- 5 × 7 × 6 m booths
- Fettling
- 4,000 m² · cranes 40 + 35 MT
- Quench tank
- 6 × 7 × 4 m
The detail most foundries outsource
In-house Pattern Shop.
Patterns are not a separate procurement workstream at Bhawani. The pattern is part of the casting decision — designed, made and corrected by the same engineering team that signs off the final casting. CNC routing for precision, an oversize pattern oven for heavy work.
A pattern correction loop that involves three vendors and two cities adds weeks to every iteration. Inside Bhawani, that loop is a corridor walk.
API 6 compliant heat treatment
Three furnaces. Full thermal control.
Heat treatment is where a good casting either earns its service life — or quietly throws it away. Bhawani runs three furnaces calibrated to API 6 standards, with a quench tank sized for the heaviest sections we cast.
- PNG gas furnace
- 8.5 × 6.5 × 3.5 m
- Oil-fired furnace
- 6.0 × 4.0 × 3.0 m
- Stress-relief furnace
- 10 × 6 × 5 m
- Quench tank
- 6 × 7 × 4 m
- Traceability
- Cycle parameters logged & archived per casting
Where castings turn into finished components
23-machine in-house machine shop.
Casting and machining have traditionally been two separate procurement decisions. Bhawani treats them as one. Twenty-three machines — five plano millers, four VTLs, a 5-axis VMC — sized for the heaviest castings we pour.
| Machine | Capacity | Load | Make |
|---|---|---|---|
| VTL × 4 (1.0–2.8 m) | Up to 2,800 × 1,500 mm | 2–18 T | FMUA, TOSS |
| Plano Miller × 3 | Up to 6,000 × 2,700 × 1,700 mm | Up to 15 T | Waldrich Coburg |
| Boring × 4 | Spindle 125–160 mm | Up to 8 T | W.M.W. |
| Skoda Boring | Spindle 200 mm (10,000 × 2,000 × 1,500) | — | Skoda |
| Lathe × 2 | 10 ft × 12″ / 12 ft × 12″ | 14–18 T | Simplex, TOSS |
| Drill × 4 | Dia 38–75 mm | — | Csepel, M.A.S. |
| 5-Axis VMC | X 6,000 · Y 3,600 · Z 1,400 mm | — | Four Star (Taiwan) · Fanuc |
Castings supplied proof-machined or finish-machined to OEM print. A full inspection report accompanies each dispatch.
Certified systems · and the lab that backs every test certificate
Every casting ships with a TC. From a lab that can prove it.
An in-house central testing lab — not an outsourced report.
Chemistry, mechanicals, internal soundness and microstructure are all verified on-site before dispatch, to ASTM, BIS, SAE and DIN. The test certificate that travels with your casting is one we can stand behind on a call — because the equipment that produced it is ours.
Customer-witnessed inspection welcomed · full heat traceability retained.
ISO 45001:2018 is not just a sticker
Safety record.
A 30-ton ladle of liquid steel at 1,600°C is unforgiving. Heavy steel casting is, by physics, one of the highest-consequence working environments in manufacturing. Bhawani is audited and certified to ISO 45001:2018 because the daily work demands it — not because the certificate is decorative.
- ISO 45001:2018 certified OH&S management
- Full PPE compliance protocol with daily audit
- Quarterly safety reviews with senior-leadership accountability
- Trained on-site fire-response team
- Designated emergency assembly points across the site
- Mandatory visitor induction before any plant tour
- Quench-tank, crane and crucible safety SOPs documented and enforced
The 55-acre site, at a glance
Numbers that summarise the foundry.
The site is large enough to handle multiple heavy castings simultaneously without compromising thermal-cycle timing — the silent operational reason lead times at Bhawani don't slip the way they do at congested foundries.
Want to walk the plant?
Customers are welcome.
A half-day tour of the melt shop, foundry, heat-treatment bay and machine shop, with technical Q&A directly with the engineering team. Five hours by road from Delhi.