The Institute of Indian

Foundrymen..

Status of Indian Foundry Industry and

Environmental aspects of Foundry
By
Siddhant Kalia
12108034
Metallurgy

The Institute of Indian

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GDP Forecast UN Report

REAL
GROWTH IN
2013

2011

2012

2013

India

7.6

7.7

7.9

China

9.3

8.7

8.5

7.7

EU

1.6

0.7

1.7

0.5

USA

1.7

1.5

2.60

World

2.8

2.6

3.2

2.9

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Location of Major Clusters

There are approx 4600

units
in the country located in
the areas marked in the
map engaged in various
types of metal castings

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Indian Foundry Industry At a Glance

RED FIGURES ARE FOR CHINA

Approx Units : 4600/30000

Production: 9 Million MT PA/39.6
Employment: 500,000Dir/2MN 15,00,000 indirect
Major Clusters: 19/300
Productivity Per unit : 1950 MT PA/1320
Avg Productivity/Man/PA: 20
Max Productivity /Man/PA: 90

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Castings Production Trends in Million MT-India

Casting Production Trends in Million MT-India

10
9
8
7
6
5
4
3
2
1
0

9.05
7.18

7.77
6.84

6.05

2.77

2.9

3.22

Grey C.I.

3.12

3.16

SG Iron

3.51

4.04

Malleable

4.62

Steel

non ferrous

TOTAL

7.44

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Exports
Total engg. exports during

2011 was USD 59.78

Billions i.e. an increase of 83.65% over previous
year Castings export was approx Rs 6500 Cr in
2010-11 Vs Rs 4200 in 2009-2010
The trend may not be sustainable in the next years
as most Asian economies have increased interest
rates to curb inflation & Coupled with rising
commodity prices & crude will dampen demand
However, most respondents expressed stagnant
export market

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Product Mix

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Share of Major Casting Producing Countries

Brazil; 3.24 Germany; 4.79

India; 9.05
Italy; 1.97
Others; 11.63
France; 1.96

World; 91.67
China; 39.6

USA; 8.24
Korea; 2.23 Japan; 4.76

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Top 1-6 Casting Producers

Top Six Casting producers of Castings

45
40
35
Figs in30
Million MT
25
20
15
10
5
0

China
India
USA
Germa
ny
Japan
Russia

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Growth of Metal castings by Major Countries by

Production
While World production in 2010 grew by 14% as
compared to previous years, Brazil emerged as fastest
growing country as per census by Modern Castings
Brazil 40.87%
Germany 22.82%
India 22.3%
Italy 17.96%
China 12.18%
USA 11.35%
Japan 8.18%

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Sectorwise Consumption of Castings

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Auto Industry
Sales of passenger vehicles has been very weak
comparatively in the last 3-4 years but registered modest
growth last year & the annual growth in sales of cars likely to
be 2-4% this fiscal
Sales Growth in 2011-12
Cars +7%
Motorcycles
+23%
Scooters +38%
Commercial Vehicles +35%
Three Wheelers +6%

Share of Components
DRIVE
TRANSMISSION
&
STEERING
PARTS
19%

OTHERS
7%

BODY
CHASSIS
12%

SUSPENSION
BRAKING
PARTS
12%

10% EQUIPMENT

ENGINE
PARTS
31%

9%
ELECTRICA L PARTS

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Tractors

Growth in 2013-14 is likely to be lower than in

2012-13
Expected growth this FY is 10%
The stagnation of farming growth in

Punjab,Harayana and West U.P.

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Machine Tools
Registered growth of 12.24% by volume in Apr-Dec

2011 Vs Apr-Dec 2010

Registered Growth of 18.4% by value during

corresponding period as above

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Power & Infrastructure

Govt of India plans a target of USD one trillion of

investment during 12th plan ( 2012-17)

Power sectors share n above likely to be USD 300

Billions for addition in capacity of 100,000 MW during

the plan period
This

will pull demand from sectors such as

Earthmoving, Power Generation, Electrical Machinery
& Transport

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Vision For Indian Foundry Industry

30

Production In Million MT/PA

25
20
15
10
5
0

2010

2015

2020

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Vision For Indian Foundry Industry

5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0

Avg productivity /unit in MT PA

2010

2015

2020

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Vision For Indian Foundry Industry

Avg Productivity/Man in MT PA

60
50
40
30
20
10
0

2010

2015

2020

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Vision For Indian Foundry Industry

Savings in Sp Energy Consumption in %
10%

5%

0%
2010

2015

2020

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Govt. Initiatives
Current share of Manufacturing in GDP has been 15-16%

since 2005-06
Govt plans to increase share of manufacturing in GDP to
25% in next 10 years
As per Planning commission India needs 250 million new
jobs in next 15 years & therefore focus on manufacturing
NMIZs being planned spread over 2000 Hectares( 8 Sq
Km)
NMIZs will be combination of production units, public
utilities, logistics, environmental protection mechanisms &
residential area

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Govt. Initiatives Contd..

Two Automotive Manufacturing hubs planned one

each in Central & Eastern India spread over 10,000

Acres each in addition to 3 existing at Haryana,
Maharashtra & Tamil Nadu
Setting up Sector Skill Councils for sector specific

skill upgradation
Introduction of Vocational programmes at CBSE level

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Major Constraints affecting growth

Non-availability of skilled manpower
Non-reliable power supply
Raw Materials shortage
High cost of capital
High cost of Energy
Irresponsible waste management leading

to environmental damage

New Trends Observed in Foundries

There are approx 4600 units out of which 85% can

be classified as Small Scale units & 10% as Medium

& 5% as Large Scale units.
Approx 800 units are having International Quality
Accreditation. Several large foundries are modern &
globally competitive & are working at nearly full
capacity.
Most foundries use cupolas using LAM Coke. There
is growing awareness about environment & many
foundries are switching over to induction furnaces &
some units are changing over to coke less cupolas.

CASE STUDY OF AN INTERNATION

FOUNDRY MANAGING THEIR WAST
Precision Disc Castings Ltd.
Company in Dorset,U.K.
Turnover of 246 crore rupees
Frontrunners in manufacturing brake discs.

Precision Disc Castings Ltd

The Problem

All the materials used in the moulding/casting process can be re-used within their own
sand system, but they cant be re-used for core making.

Because the material cant be economically reclaimed for core making they have approx
275 Tonnes of material (equivalent to 105,000 cores sacrificed in the process) excess in
the sand system each week, which must be removed.

There is also 40 tonnes per week of dust extraction fines that

have to be dumped to Landfill.
A further 100 tonnes per week of material that is natural spillage
from the moulding lines goes to landfill.

Precision Disc Castings Ltd

The Solution - Past

In 1996/97 PDC formed a partnership with Tarmac Southern Ltd, which meant that most of
the excess waste greensand would be used by Tarmac in manufacturing asphalt concrete.

PDC made modifications to their plant to allow sand batches to be dumped direct into rigid
lorries rather than onto indirect production line belts & skips.
Tarmac also made some modifications including building a covered storage bay.

This original partnership meant that PDC would send the

excess greensand to Tarmac for re-use rather than landfill.
This was approx 4,000 tonnes/year and saving 59,000/year.

Precision Disc Castings Ltd

The Solution - Current

PDC and Tarmacs partnership has continued to flourish since 1997, which has allowed
PDC to provide Tarmac with more material for re-use.
As more material became available, Tarmac increased the number of sites using PDCs
surplus sand to include three of their South Western asphalt plants, with a fourth coming
online during 2008.
PDC have increased the amount re-used by Tarmac by: Installing blow over units from the dust extraction plants
Installing a Pre-conditioning plant.
Installing a Sand Reclamation belt

Precision Disc Castings Ltd

The Solution - Current
By installing these afore mentioned items of plant PDC have increased the amount of
material re-used by Tarmac from 4,500 Tonnes/year to 12,500 Tonnes/year.

Precision Disc Castings Ltd

The Solution - Current
As a result of this initiative, PDC has managed to save a significant amount of money as
shown below.
Cost of Re-use = 8.75 per tonne
Cost of Disposal in 06/07 = 14 per tonne & 80 transport per load
Cost of Disposal in 07/08 = 15 per tonne & 92 transport per load

Year

Tonnes

Tarmac Cost

Disposal Cost

Saving

2006/2007

9,165

80,193

180,681

100,488

2007/2008

12,664

110,810

273,180

162,370

As you can see from the above table PDC saved 162,370
through their partnership with Tarmac in 07/08.

Precision Disc Castings Ltd

Leading the world in brake
The Solution
- Future
disc
technology
PDC hopes to further increase the amount of material re-used internally before
eventually being transferred to Tarmac for re-use in asphalt.
A pneumatic fines blow over system is currently being installed, which allow approx
another 500 tonnes of material per annum to be re-used.
This will mean that Tarmac will soon be re-using 13,000 tonnes of PDC excess waste
greensand
PDC will therefore, re-use/recycle 14,500 tonnes per annum of
the total 17,000 tonnes of waste generated = 86%.

Precision Disc Castings Ltd

Leading the world in brake
discSummary
technology
PDC and Tarmacs partnership has gone from strength to strength since its beginnings
in 1997.
Tarmac originally took 4,500 tonnes/year in 1997/1998 compared to 12,500 tonnes/year
in 2007/2008, giving considerable environmental and economic benefits to them.
This has had a massive positive impact for PDCs Environmental Performance,
compliance with ISO 14001 and economy of operation.

DARK SIDE OF FOUNDRIES

IMPACT OF FOUNDRIES ON ENVIRONMENT AT
COIMBATORE

The urban areas of India are nowadays growing into bigger agglomerations with ever
increasing pollution due to haphazard and uncontrolled developmental activities. This
increasing pollution can be attributed to a score of factors like lack of environmental
planning, economic issues, social policies and a lot others. There are a lot of
examples of such polluted places in India, and Coimbatore comes into prominence,
thanks to its foundries. Coimbatore, one of India's leading industrial centres with
excellent potential for industrial growth, is spread about 105.6 sq. km and has a
population of 1.1 million highly diverse people. Coimbatore is the second biggest city
in Tamil Nadu after Chennai, and is blessed with a wonderful climate, sweet siruvani
water and high number of educational institutions.
The presence of industrial activities on a large scale, in and around Coimbatore, tends
to have a strong impact on the environmental quality of the City, particularly the vital
component of air. Though vehicular emissions, construction-related activities, and
garbage burning form sources of air pollution, the industrial emissions from smallscale industries mainly the foundries assume higher environmental significance. The
concentration of foundries within the city and the lack of state of the art facilities tends
to take its toll on the city' environment and thereby make Coimbatore a severely air
polluted place. Apart from the proficient and high scale foundries, there are about 250
small and medium scale industries in Coimbatore, which are severe threats for
environmental pollution.

The small and medium sized foundries are located every 2 kms in the industrial
radius Coimbatore, especially in the industrial areas of Avarampalayam,
Ganapathy, and Peelamedu. The emergence of these small-scale industries
coupled with the educational development of these areas made these areas a
great growth for residential developers. Once residences started coming on these
industrial areas, the industries were asked to relocate by the TNPCB (Tamil Nadu
Pollution Control Board), and even after relocation, some industries are asked to
re relocate themselves in the interest of serving excessive population. This is a
clear lack of discipline amongst people, and lack of cohesion for attainment of
common growth.
After finding that relocation won't work out, the TNCPB (Tamil Nadu Pollution
Control Board) ordered the industries to install emission control devices. Earlier
the electrostatic precipitators were suggested and after considering the economic
status of these small-scale foundries, wet collection devices like the cyclone
scrubbers were suggested. The cost of these devices would range to 40,000 and
50,000Rs,and these were found hard to bear for these industries. We should be
reminded that these industries are set up under the initial cost of 75,000 rupees,
and hardly making profits, thanks to the lag of industrial activity after bomb blasts
and huge competition. They are now trying to get time and push another design of
scrubber that costs only 25,000.However the only aim of these time lags is to
avoid actions, as these foundries are never inclined to set up these industries.

After a low profile activities for the past half a dozen years, the foundries suddenly saw a great
business opportunity when the European countries concentrated on importing foundry products
from India. The European market in itself is a telling story. The European foundries were ordered
to close since they couldn't cope up with the Environmental Standards (given that their emissions
are 50% less toxic than ours), and the Europeans moved on to Howrah and Coimbatore for their
foundry products. The business starved foundry owners were too concerned not to miss the offer,
and started competing with each other for production. And at this stage, any investment in
pollution control devices would be a mis-investment for them.
While the TNPCB is fighting for the community and the small-scale foundries for themselves, no
one has cared for the 3000 odd workers who work in these foundries. Their health conditions are
entirely harmful. Health effects affect almost 95% of these workers (simpletons and uneducated
persons). And nobody has thought of providing them with safety equipments. Yours truly couldn't
find a 15 minute emission breathable, just imagine the plight of the persons who inhale them for 6
hours a day. A nearby doctor says that these people suffering continuous emissions are prone to
death in 8-15 years. For the past three or four years, this problem is getting aggravated by NGOs,
but the TNPCB and these foundries are yet to come to a solution, and never seem to come to one
in the near future. The valuable lives of neighbouring people and workers deteriorate, thanks to
the money greedy people. The study of a solution to this problem lead to two significant points
that are however not related to environmental areas. First one being the lack of discipline in our
people, and the other is to put economy the top priority even prior to safety in life When will India
place environment more prior to economy?
An Indian life is worth the same value as the English life.

GENERAL SOLUTIONS REGARDING WASTE MANAGEMENT

SOME METHODS OF WASTE MANAGEMENT SUGGESTED BY AFS
>Highway Subbase
Laboratory and case studies have shown that with proper design and
construction compacted foundry sand provides adequate support as a working
platform or subbase material in flexible pavement design.
>EMBANKMENT
Several states have allowed full use of foundry sand as an embankment material
with little or no restrictions, though the majority of states continue to place
restrictions on foundry sand use and require some type of encapsulation.

>HOT MIX ASPHALT

The Federal Highway Administration (2004) reports that in the United States, asphalt
concrete is used to cover over 2 million miles of roadway, accounting for over 94
percent of all pavements. Recycled foundry sand has successfully been used as a
partial replacement for aggregate in hot mix asphalt (HMA) in Pennsylvania,
Michigan, and Tennessee.
>FLOWABLE FILL
Natural sand is a major component of most flowable fill mixes. Foundry sand can be
used as a replacement for natural fine aggregate because foundry sand consists of
greater than 80 percent fine uniform silica sand. Foundry sand has been used in
flowable fill in the states of New York, Pennsylvania, Ohio, Wisconsin, Tennessee,
and Indiana (Smith 1996, Collins and Ciesielski 1994). Pennsylvania has reported
successful use of foundry sand as a sand substitute in flowable fill, as well as Ohio
where a field demonstration showed performance on par with conventional sand
flowable fills .

FUTURE OF FOUNDRIES- EMBRACING GREEN FOUNDRY TECHNOLOGY

The minimization of emissions, efficient raw material and energy usage, optimum
process chemical utilization, there covering and recycling of waste and the
substitution of harmful substances are all important principles of the Green
Foundry. For foundries, the focal points are air emissions, the efficient use of raw
materials and energy, and waste reduction, in conjunction with any recycling and
re-use options.
BAT BEST AVAILABLE TECHNIQUE (BAT)
For a Green Foundry you have to use Best Available Technique (BAT). BAT is to
optimize the management and control of internal flows, in order to prevent
pollution. BAT is related to storage and handling, such as the storage of scrap on
an impermeable surface with a drainage and collection system, the separate
storage of incoming materials and residues, optimization of the metal yield.
Environmental considerations can be taken into account in the selection of the
furnace type, induction vs cupola. Metal melting consumes 40-60% of the energy
input of a foundry. Energy efficiency measures should therefore take both the
melting and the other processes

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