Jainsons Malleables ulfm fittings, galvanised, ductile iron, insulator metal parts, auto spares manufacturer exporter

About Us

INTRODUCTION
JAINSONS MALLEABLES, is a leading manufacturer of Ductile Iron, Malleable Iron & Grey Cast iron foundry in India with more than 20 years of experience. We produce Castings for various applications viz MI pipe fittings , DI threaded pipe fittings, Electrical Insulators, Structural fittings and Ornamental Fence fittings.

To meet our customer’s requirement we are continuously investing in our plant & machinery to offer Quality products with committed delivery period.

Our installed production capacity is about 300 Metric Tonnes castings per month. In 2012, we modernized our plant & migrated from Mollases Hand molding to Green Sand molding which is being done on machine moldings with Sand plant. Now we are manufacturing the castings on – Semi automatic DARPA make & Horiontal High pressure FM-1(Rhino) molding machine.

Chemical test being done via spectrometer (SPECTRO), Mechanical FIE Servo UTM machine & Image analysis (microstructure) testing of manufactured castings is done on daily basis to ensure the quality of products.

We have in-house pattern shop to make required molds quickly on VMC. In 2018 we added CNC turning lathes to offer CNC machined products to our customers viz (Aditya Birla Insulators,G.K.Xianghe Electricals Pvt.Ltd, Spark Insulators, Phoenix Electricals Ins.Mat.Co.Pvt.Ltd.)

In year 2019 we installed 3 Ton electric heat treatment furnace to improve the Quality of our malleable iron castings. In same year 2019 started OEM manufacturing & started direct export of fittings to the U.K.

In Jan 2021 we installed Electrical Hot dip Galvanizing plant with capacity of 100 MT per month.

Moreover seeing the potential in export market for supply of MI & DI fittings, In year 2020 we applied for UL approval for MI fittings (1/2” to 1”) & DI threaded pipe fittings as per American standard ASMEB163.

INVESTMENT & EXPANSION:

In end of December 2020, we got UL approval for MI & DI threaded pipe fittings. To increase our machining capacity we invested further in pipe fittings threaded machines worth USD 120000 approx. These machines will be installed in our factory by end of Sep 2021.

Moreover we have also applied for FM approval of our MI & DI fittings in June, 2021. Our samples have successfully passed the hydrostatic test done at FM USA Lab. We hope to receive the FM approval by end of Sep., 2021.

Moreover in order to increase our tool / mold making capacity, we added another VMC (HURCO USA make) to our Tool Room.

We have vacant industrial (Plot # A3 – just adjacent to Our Machine shop) vacant having an area of about 1.25 acres. There, in next 5 years we plan to setup a 500 MT plant for manufacturing of MI pipe fittings for export.

PLANT & MACHINERY:

In Year 2011, we installed One Hurco Make VMC to develop our own tooling. Further we installed One pair of semi automatic DARPA 300 molding machines.

· In Year 2012, we started modernizing our foundry. We shifted from Mollases sand molding to Green Sand molding. We installed One RHINO make High Pressure line with Supporting Sand plant. One Cold box core shooter was added to Core shop.

· In Year 2015, we installed Spectro (Germany) make Spectrometer to check chemistry of castings.

· In Year 2015~2019, we installed 7 - Tsugami (Japanese) make CNC’s Lathes.

· In Year 2018, We installed another VMC - BFW make.

· In Year 2019, we installed 1 TON Electrical Furnace to HT of our Castings.

· In Year 2020, we installed One Electrical 3 ton per batch capacity BELL furnace for Heat Treating our castings.

· In Year 2020, we Installed Servo based UTM machine to do mechanical testing.

· In year 2020 and 2021 we made investment in international approvals for MI pipe fitting and DI threaded pipe fittings applied. We applied for UL & FM certifications for Malleable and Ductile Iron Threaded Pipe Fittings.

· In January 2021, we installed 100 Metric Ton per month Hot Dip Galvanizing plant.

In Jan 2021 we got UL Listing and December 2021, we got FM approval for (malleable iron) MI & DI (ductile iron) threaded pipe fittings.

· In year 2021, we had made investment worth USD 120,000 approx. thereby increasing our machining capacity of pipe fittings and Steel Nipples.

· In mid of 2021, To increase our machining capacity we invested in pipe fittings threading machines worth USD 120000 approx.

Moreover in order to increase our tool / mold making capacity, we added another Two VMC (HURCO USA make) to our Tool Room.

· In December 2021, we got our FM approval for MI & DI pipe fittings.

· In September 2021, we had applied for PGCIL (Power Grid Corporation of India Ltd) for supply of Galvanized Metal End Fittings for Composite Long Rod Insulators.

· In March 2022, we Installed an MPI (Magnetic Particle Inspection) machine to test our fittings for any kind of cracks.

· In April 2022, Two new Cold box core shooters were added to core shop.

· In May 2022 we got PGCIL Approval for Galvanized metal End Fittings.

· In June 2022, We have ordered 4 new Tsugami CNC’s to increase our machining capacity for Insulator Metal Part Fittings business.

· In July 2022, we intent to add another VMC to our TOOL Room to meet the increasing demand of new tooling and fixtures.

· Further we are planning to order Two Hydrostatic and pneumatic testing machines to test Malleable and Ductile threaded pipe fittings.

Expansions Plans :

We have vacant industrial Plot # A3 – (just adjacent to Our Machine shop unit) having an area of about 1.25 acres. There, in next 3 years we plan to set up a 500 MT plant for manufacturing and export of DI and MI pipe fittings.

“PERFORMANCE WITH EXCELLENCE”

CLIENTELE LIST

Spark Insulators Pvt. Ltd. (INSULATORS)
Phoenix Electrical Insulating Material Company (INSULATORS)
Shree Radhe Industries (INSULATORS)
Export Customer OEM Manufacturing Companies

Research & Development

R&D

OUR PLANT AND MACHINERY
Following machinery & equipment are installed at our works:

We have 3 units –

Jainsons Malleables - Foundry (Plot # B3).
Machine shop (Plot # A2 – About One Acre).
Jainsons Industries having Sales Office & warehouses.
We have vacant industrial (Plot # A3 – just adjucent to Our Machine shop) vacant having an area of about 1.25 acres. There, in next 5 years we plan to setup a 500 MT plant for manufacturing of MI pipe fittings for export.

One Induction Furnace With installed capacity of 300 MT per month.
One Horizontal High Pressure Machine (Rhino) with 20MT sand plant.
Two Semi-Automatic Moulding Machines (DARPA 300).
Three Cold Box Core Shooter and Two Hot box Core Shooters.
In House Pattern Shop (Equipped with VMC, Lathes, Milling M/C etc).
One Pollution Control Equipment with 10 HP Motor.
Two Diesel Generator 650 KVA & 125KVA.
Three Shot Blasting Machines 20MT per day.
8 sets of pedestrial and 2 sets of Belt Grinders.
In house Chemical & Mechanical testing and image analysis facility.
One Electrical heat treatment furnace with 3 Ton per batch capacity.
2 Ton Elevator for material handling. Material handling pallet trucks & stackers.
3 Ton EOT Crane for material handling in foundry.8 Chain hoists for Molds & boxes handling.
Hot Dip Galvanizing Plant having Capacity 100 MT /Per month.
500 Steel mesh crates for material handling. Another 400 additional crates be added by October 2021.

MACHINES LIST:-
Two HURCO (USA) make VMC. One BFW make VMC.
Four CNC Tsugami (Japan) make.
Three Lathe Machine, Four Air Compressor.
Four Drill Machines up to 2" Capacity.
Two Drill & Tap Machines up to 1" Capacity.
Three Auto Core Shooter Machines, Two Hot Box Core Shooter Machine.
Four Three Head Tapping Machines for 1/2” to 2” fittings. Another 4 pipe fittings ½” to 2” threading machines will be installed by end of Sep 2021.
One Automatic Double Elbow SPM Machines for 1/2” to 1” Elbows. Another Automatic Double Elbow SPM Machines will be installed by end of Sep 2021.
One Three Head Tapping Machines for 2.5” to 4” fittings.
One Pipe Fittings Facing Machine.
One Pipe Fittings Sizing Machine to Fix roundness of warp fittings.
Material Handling Equipment- 2 Stackers & 5 Pallet Trucks.
8 Pneumatic test benches for air pressure leakage fittings at 100 psi.
2 Hydro test benches for water pressure leakage fittings at 2000 psi.
Two Epoxy Powder Coating plants.

Pipe Nipple Threading machines:-

One Automatic Pipe Nipple threading machine Pipes Diameter 3/8” ~ 1” & making nipples length from close ~ 12” long (Taiwan).
Four Lanco Die head pipe threading machines – ¼” to 2”
One Pipe Nipple Deburring machine.
One Double head parallel Lanco die head machine ½” to 2” pipe diameter and nipple length upto 8” will be installed in end of Sep 2021.