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   Shot Blasting Increases Efficiency & surface finish in foundry Industries (1/4)
Shot Blasting Increases Efficiency & surface finish in foundry Industries
By. Mr. P. A. PATEL
A - 2/510, G.I.D.C., Makarpura, VADODARA - 390 010.
E-mail : /    website :    M. : +91 9737061333
The Paper Presented at 60th INDIAN FOUNDRY CONGRESS march 2012 Bangalore
There are about 8000 foundries in India out of which around 5,100 are in organized sector producing 7 million (US $8 billion) tones castings, holding No. 2 position in Global Market. Considering 32% Casting required by Auto Industry. It will need 2.18 million (US $2.5 billion) tone, which will go up to 10 billion by 2016.
Indian foundries manufactures: Grey Iron, Steel & Alloy Castings, S.G. Iron, Non Ferrous Castings, Ductile Iron , ADI, Light metals & copper alloys, Aluminum and many other grades.
Most of the foundries are located at Belgaum, Coimbatore , Batala, Jalandhar , Kolhapur, Rajkot, Ahmedabad, Mumbai, Pune, Gurgaon, Faridabad, Agra, Ambala, Chandigarh, Hawarah , Shimoga, Raipur and many other places.
In addition to foundry mentioned above there many captive and jobbing  foundries to meet export demands. Many foundries are setting up full finished auto components unit with excellent facility, high pressure molding line, modern core shop, automatic fatling and shot blasting systems.
Sector wise Major Consumption of Casting:
1. Auto Industry – 32%
2. Agriculture Machinery – 07%
3. Earth Moving Equipments – 02%
4. Pump & Compressors – 05%
5. Valves – 04%
6. Diesel Engine – 03%
7. Sanitary –  02%
  8. Electrical Equipments – 03%
  9. Machine Tool – 02%
10. Pipes & Fittings – 08%
11. Railway – 06%
12. Defense – 04%
13. Power Generations – 05%
14. Industrial Machinery – 07%
15. Others – 10%
Product Mix of Caste Metal Items
1. Grey Iron – 67%
2. Steel – 12%
3. SG Iron – 10%
4. Nonferrous – 10%
5. Malleable – 01%
Gujarat - New Auto Hub
There are many foundry clusters coming up in Gujarat for manufacturing of automobile components. The reason being large auto projects coming near Sanand, Ahmedabad. Some of the projects are Tata Motors, Ford India, Peugeot, General Motors, Maruti Suzuki, Atul Auto, Bajaj Auto, Asian Motors and the list Is growing. Gujarat Government has put a target of production of 2-3 Lacs cars / year by 2015 through above units which will mean increasing production of existing foundries, setting up new foundries, technology up gradation, cluster development, training and education of the worker.
In addition to Companies motioned above there are many captive and jobbing foundries to meets export demands. In 2010-11 the casting exported US $3 million aaprox (2.5 million tones) to meet export demands.
Fig - 1 “Pressure Blast System”:In pressure blasting system the blast media is stored in pressurized vessel, which is mixed with compressed air. The air flow accelerates the media, through a blast gun on to the surface
10mm Nozzle 5 Bar Pressure.
Blast Media Flow : 22 Kgs./Min.
Air Consumption 275 M/Hr.
Energy Consumption 25 KW.
Specified Energy Consumed 1.14 KW/KG.
Fig – 1  
Fig - 2   In blast wheel system the blast media is fed to the center of the blast wheel, which is rotating at high speed. The media is rapidly accelerated by centrifugal force and is directed on the surface to be blasted.
Blast Media Flow 150 Kgs./Min.
Air Consumption Negligibal
Energy Consumption 7.5 KW/Kg.
Specified Energy Consumption 0.05 KW/Kg.
Fig - 2  
This comparison of different blasting systems, clearly shows that the blast wheel blasting system (fig - 2) has the lowest specified energy consumption. Blast wheels are driven by electric motors, whereas the air required by the air blasting system (fig - 2) has to be generated by a compressor which is to be purchased and maintained in addition to blast machine itself and the additional power cost.