You are on page 1of 11

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT

DEPARTMENT OF MECHANICAL ENGINEERING

REPORT ON INDUSTRIAL VISIT AT

ON

13TH AUGUST, 2016

FOR B.E. (MECHANICAL ENGINEERING) V SEMSTER

ACCOMPANIED BY
PROF. M. G. TRIVEDI

INTRODUCTION
Jayaswal Neco Industries Limited (JNIL), which started in 1976 as a
small Iron foundry unit at Nagpur, is the flagship company of the 3500
Crore NECO Group of Industries. JNIL is today an INR 26 billion (US$ 472
million) turnover company with technologically advanced production
infrastructure and a strong country-wide marketing network. Today their
total production capacity of Iron and Steel castings exceeds 140,000
MTPA. The companys strategy of backward and forward integration has
enabled it absorb the fluctuations in business cycles. The NECO name is
synonymous with Quality, Reliability and Durability of products.
The NECO Group of Industries houses following other companies:

NSSL Limited, a group company produces ferrous & nonferrous Industrial valves from 0.5 to 80 which are used for different
applications in the Petroleum E&P, Refineries, Power Plants, Steel plants,
Chemical plants & pipelines in various other industries.

NSSL Limited has subsidiaries in Chennai (Econo Valves),


Doha-Qatar (NSSL-Middle East) and Milan-Italy (NSSL-Italia SRL). The
Italian subsidiary, NSSL Italia Srl has recently acquired two Italian valve
manufacturing companies.

Neco Heavy Engineering & Castings Limited (NHECL), a group


company at Nagpur produces castings catering to the needs of Heavy
Engineering Sector including Integrated Steel Plants, Mini Steel Plants,
other Heavy Engineering Industries, Material handling equipment
manufacturers, Crane manufacturers, Sugar crushing mills etc.

JNIL-Steel Plant at Siltara Growth Centre (Raipur) has an


installed production capacity of 700,000 MTPA through the Blast furnace
route and another 300,000 MTPA through the Direct Reduced Iron (DRI)
route.

Neco Ceramics produces Refractory items for steel and


cement plants.

Neco Defence Systems Limited (NDSL) is one of the leading


providers of defence and security related products to Government
bodies and authorized private organizations for providing security to
people and assets.

Jayaswal Neco Urja Limited (JNUL) is setting up a 2X300 MW


Power project at Village Hamirpur & Jobra ( Tehsil Tamnar, Raigarh Dist.,
C.G) at a project cost of 3310.80 Crores.

Deify

Infrastructures

Limited

(DIL)

is

dedicated

EPC

(Engineering, Procurement & Construction) arm executing new projects


from grounds up as well as expansion projects and de-bottlenecking
projects for the various divisions of JNIL.

Terra Infra Development Limited (TIDL) is infrastructure arm of


Neco group. It has already developed several projects (Pondicherry
Tindivanam Tollway, Hyderabad expressway, Hyderabad Outer ring road
(ORR) project etc.) across the country as consortium partners.

Neco Group has also been granted Coal and Iron Ore mines in
the State of Chhattisgarh and Jharkhand and has undertaken setting up
of Thermal Power Stations of 3240 MW in the State of Chhattisgarh and
500 MW in Jharkhand in the next few years.

COMPANY PROFILE

Jayaswal Neco Industries Limited, commenced their operations in 1972


promoted by Shri B.L. Shaw, Chairman are now the leading manufacturer
and supplier of a comprehensive variety of sanitary castings which include
Centrifugally Cast Iron Pipe & Fittings, Cast Iron Manhole cover with
Frames, Cast iron castings etc. Their products are highly regarded for their
excellent finish, long shelf life and superior quality. They have a large
clientele, that is spread far and wide.

JNIL have established a state of the art infrastructure that enables smooth
operations. They have streamlined and standardized the processes in
order to gain maximum efficiencies. They are very conscious about the
quality of their products and take multiple measures for that purpose. The
products are tested on several parameters before being made available to
customers.

BASIC INFORMATION

Nature of Business

Manufacturer

Additional Business

Exporter
Supplier

Company CEO

Kamalkant Singh

Industry

Steel plant, JNIL Foundry, Mining

Registered Address

F- 8, MIDC Industrial Area, Hingna Road,


Nagpur - 440 016, Maharashtra

Year of Establishment

1972

Total Number of
Employees

501 to 1000 People

Legal Status of Firm

Public Ltd. Co. Registered under Indian


Companies Act 1956

Proprietor Name

Mr. Arvind Jaiswal

Infrastructure
Location Type

Semi-Urban

Building Infrastructure

Permanent

Size of Premises

59,955square meters

PRODUCTS MANUFACTURED
5

With a production capacity of 140,000 MTPA, they are Indias largest


manufacturer of Iron & Steel castings. They are manufacturing ferrous castings
for Automotive, Engineering & Construction division.
Sectors served by the Foundry Division
i)

Automotive Sector

ii)

Construction Sector

iii)

Engineering Sector

Automotive Casting Division (ACD)


They are one of the leader suppliers to automotive segment. Their castings are
widely used by OEMs varying from Car, Truck and Agricultural equipment
manufacturers.
They are Indias largest manufacturer of Cylinder Heads and export the items to
countries in Europe, meeting their most stringent norms of sourcing.
Production Facility:
The ACD boasts of 3 state-of the art foundries manufacturing Grey Cast Iron
and Ductile Iron products for the Automotive Industry (including Trucks, Tractors,
Earth moving equipments, Harvesters etc. with a combined production capacity
of approx 70,000 MTPA. The variety of moulding lines gives the flexibility to
produce any castings from 2kg 700kg weight. The different lines comprise
High Pressure Moulding Line- Box size: 2900X1300X500/500mm (Kunkel
Wagner), the largest box size for a moulding line in India, especially designed
for single piece casting for large axle housings
TOKYU High pressure Moulding Line Box size: 700X600X(180~250) recently
installed
High Pressure Moulding Line- Box size: 1000x800x350/350 mm. (Hienrich
Wagner Sinto, Germany)
Normal Jolt Squeeze Moulding Line - Box size: ARPA 660x560x260/250mm
(Dhanalaxmi India)
Normal Jolt Squeeze Moulding Line - Box size: 640X 540X200/150mm
(Dhanalaxmi India)
Normal Jolt Squeeze Moulding Line(WBQ5) Box size: 820X620X200/250

Normal Jolt Squeeze Moulding Line (Sarvamangala Engineers)


A. 900X700X200/150
B. 900X700X325/250
C. 1000X950X250/200
D. 1000X950X200/200
The ACD division has witnessed tremendous growth in the past few years and is
presently on an expansion mode. Recently added High Pressure Moulding Line
has significantly enhanced the production capacity and quality capability. The
associated facilities at ACD Units include:

Induction furnace and Cupola


Core shop: Cold box, No-bake and Shell core methods
Hanger type semi-automatic Shot-blasting facility
Spray painting facility
In-house Radiography
Ultrasonic Testing Machine
Immersion Pyrometer
Optical emission Spectrometer
Sand Laboratory
Ferrous Laborator
Image Analyser
Chemical Laboratory
Mechanical Laboratory
Heat treatment facility

The facilities include plant area of 70,000 sq.ft, 53 CNC Machines (including
MAZAK/MAKINO HMC machines) machining 45 different types of cylinder heads
and other large components, special Purpose Machines, Turning centres, Modern
measuring instruments like: 3-D CMM, Trimos, Air Plug gauges, Bore dials etc.
Customers:
Mahindra & Mahindra
TATA (TML Drive line)
John Deere
Carraro
Oerlikon Graziano
Timken
ZF-India
Spicer
ITL (Sonalika)
Eicher Farm Equipments
Preet Tractors
Man Trucks
Escorts
TAFE
JCB
7

Case New Holland

JNIL- ACD is the only Foundry in India capable to producing very large/heavy
single piece Cast Beam/Swing frame & Carriage etc. Flexibility of moulding lines
gives the capability of producing castings from 2kg-700kg. JNIL is the largest
supplier of Machined Cylinder Heads in India and they are installing 2 High
Pressure Moulding Lines to raise the production capacity to 90,000 MTPA.

Construction Casting Division (CCD)


JNIL is one of Indias largest manufacturers of sanitary castings. They are the
market leader in India in the field of Cast Iron pipes by the name of NECOCENTRI. They pioneered the centrifugally cast iron pipes (IS: 3989) in India using
the German built DUKER machine. These are widely used and recommended by
leading Builders, Architechts, Consultants, Contractors and Government bodies.
They also manufacture Ductile Iron & Cast Iron manhole covers. They have also
brought the Hubless pipes and fittings in the Indian.
Production Facility:
NECO-CENTRI centricast pipes (IS 3989) are produced using the famed Duker
technology and machine from Germany. NECO CENTRI drainage system is
available in full range of pipes and fittings of nominal sizes between DN75, 100,
150 and 200mm. The production capacity for pipes and fittings exceed 35,000
MTPA while the production capacity for Manhole covers including ductile iron and
Cast iron is 5000 MTPA. They also produce Hubless cast iron pipes (as per ISO6594), Cast iron LA class pipes for drinking water, sand cast pipes (IS-1729) for
waste water use, manhole covers in cast iron ( IS-1726/91)and ductile iron (EN124).

The production facilities include Cupola furnaces and Induction furnaces and
production is done from 4 Units located in Nagpur, Bhilai & Anjora. The products
are ISI marked and ISO-9001:2000 certified.

Process

Customers

NRI Complex Navi Mumbai

ICICI HeadQuarters, BK Mumbai

ITC Grand Maratha Mumbai

Gateway Towers Delhi

Delhi International Airport

NTPC

Engineering Casting Division (CCD)


They make castings (up to 27 tons single piece) for the Heavy Engineering Sector
including Power Plants, Steel Plants, and Cement Plants etc.
Casting Products
This division caters to the need of Heavy Engineering Sector including Integrated
Steel Plants, Mini Steel Plants, Engineering Industries, Material handling
equipment

manufacturers,

Crane

manufacturers,

Sugar

crushing

mills

etc. Products include Duplex Ingot Moulds, Heavy Ingot Moulds, Engineering
Castings, Brake blocks, General Castings, Slag pots, Bottom plates, Trumpets,
Sugar mill rollers, Pump & Gear Housings, Rolling stocks, Counterweights ( for
earth moving equipments, elevators etc) Coke oven door & frames and other
engineering castings.
Fabrication shop products

Coke oven

Rolling Stock: Ladle cars, Ingot cars, Transfer cars, Fabricated ladle, Dump
car etc.

Material Handling Equipments: Overhead crane up to 50 MT capacity, Grab


buckets, Heavy Duty haulage winch, Sinking winch, Automatic lifting
tongs, Travelling tippers, Charging buckets etc.

Technical Structures& other miscellaneous fabrications : Rolling stands,


Rolling table, Guides, Skid systems, Slab extractor, Stoppers, Furnace
platform, Blast furnace shell, Boiling house equipment for sugar plants,
Sewage and effluent treatment plants etc

Pressure vessels: Heat exchangers, Condenser coolers, Heating coils,


Storage tanks, Distillation columns etc.

Production Facility:

10

The factory shed spread over 30 acres can handle job and assemblies up
to 90 tons and with a clear height of up to 9meters.

Complete in-house facility for Castings, Machining, Heat treatments &


Assembly

Fabrication

facilities

include

bending,

pressing,

welding,

painting,

machining, sand blasting, assembly operations and testing as per


customer design, specification and quality norms.
Customers

BHEL

SAIL

KALYANI

HEC

MUSCO

JINDAL

BEML

TATA

IVC

VIRAJ

SIMPLEX

GODREJ

ARCELORMITTAL

FOURESS GROUP

FEEDBACK
It was a nice experience to see the JNIL and see the industrial behavior. Although
the company has been doing great in manufacturing and bringing up new
technologies but it lacks in providing its workers with their basic needs like
safety, proper canteen food, hygiene etc. Many of the workers were without
protection gloves, industrial helmets, apron, shoes. And in such heavy industry a
small mistake may bring a huge destruction. Other than that, it was a great
experience. I got to learn about the recent enhancement in technology in
casting, about the new machine and various techniques.

11