HPDC & Melt Shop
Aluminum Casting
The HPDC lines and Melt shop are strategically arranged to facilitate the seamless transfer of molten metal to production machines. The aluminum castings produced are then sent for further processing.
These HPDC lines are designed for high-volume production, accommodating both heavier and more intricate castings, as well as medium-sized ones. The facility's thoughtful layout ensures efficient processing and smooth movement of castings. The machines used come from leading manufacturers such as IDRA, LK, Yizumi, and Toyo.
Casting weights range from a few grams to several kilograms, with LED light housings potentially weighing over five kilograms. The HPDC process incorporates a combination of manual, semi-automated, and fully automated operations.
The latest machines are equipped with auto ladle and auto spray mechanisms, and the company plans to introduce auto-extractors and online trimming and gate-cutting machines in the future.
Transfer Ladle Filling
Melting Furnaces for Aluminum Casting Production
The large tower-type melting furnaces are sourced from top manufacturers like Furnteck India and ZPF Germany. These furnaces feature burners and blowers from Kromschroeder and Wesman, and their automated controls optimize energy usage. All furnaces are gas-fired and equipped with appropriate gas trains, ensuring that no liquid fuel is used across the facility at Esko Casting and Electronics Pvt Ltd, making it environmentally friendly.
Quick Efficiency
Ease of Operation
Tilting Mechanism
Quick Melting
Degassing Process
Melt quality is managed using a Foseco fixed degassing unit and a Density Index machine. This ensures the production of dense, low-porosity castings, free of gas inclusions and entrapments, which are crucial for intricate castings and machinability. Samples are taken before and after degassing and tested for density improvement in the lab.
