Kalika Steel Works Jalna, Maharashtra

In the new established facility of the company, which is highly technically sophisticated and best in class, the square cross section billets go through precise and uniform size reduction in linear movement of material, unlike traditional cross-country mills. This helps impart high quality, bendability and surface finish to our finished products. With a mix of highly advanced rolling mill designs and machinery from Germany, the quality quenching system from Pomini (Italy) and the world renowned SIEMENS automation, the new facility of Kalika Group is one of its kind in India. The Pomini Quenching system makes the Kalika TMT Bars strong and flexible and capable of sustaining massive pressure during earthquakes. The world class quenching system is capable of producing bars of export quality as well. After obtaining the standard length, bars are cut and carried to the finished goods yard, where these finished TMT Bars are labelled as per grade, size and length and stored accordingly. TMT CONTROL With the highly advanced automation of SIEMENS, the quality of every bar is regulated while the reduction itself. The production process includes use of fast, responsive PLCs, high accuracy HMD’s and sensors to ensure that every bar produced is at par the desired characteristics with a uniform cross section and ribs. The quality control department keeps a close watch on the finished goods by conducting various quality tests at fixed intervals. Quality control tests: Universal Testing Machine (UTM) Chemical Etching Test Bar profile measurement system

Billet production We at KSAPL cast square mild steel billets of cross sections 100mm, 110mm and 130mm through a continuous caster. The billets are manufactured by induction furnace route. Billets are manufactured as per IS standards (2831-2012) and are used for manufacture of TMT Re Bars. Mixture of Sponge Iron, DRI and high quality industrial scrap are fed into induction furnaces of capacities 25 and 30 MT in steel melting shop to produce supreme quality mild steel. After going through rigorous treatment and chemical analysis, the molten steel is cast into square billets of the desired cross section in high speed CONCAST (now Primetals) CCM (Continuous Casting Machine). The cast steel is cooled with the help of regulated water and air pressure to form billets of accurate cross section. As the billets pass towards the cooling bed, they are accurately cut into the required lengths by high accuracy shearing machines. Finally, the hot billets are laid on the insulated roller transfer tables to be transported to the rolling mill. QUALITY CONTROL PRACTICES FOR BILLET MFG Quality Control Measures Adopted: Modern chemical analysis equipment German made Spectrometer for quick and accurate analysis Automatic mould level control in caster Billet macro analysis for internal structure control