Plot No.1,2,3, Sector E, Jalil Town, Chanda Qila, G.T. Road, Gujranwala, Punjab – Pakistan
Land Line: +92 55 4225942
Managing Director: +92 304 5903095
Email: friendsfoundry@friendsfoundryengineering.com
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Friends Foundry was Established in 1989 and since its inception is engaged in production of auto parts in Grey iron, Ductile Iron, Spheroidal Graphite Iron (SG Iron) for various quality automobile assemblers. At present, company is manufacturing a wide range of parts and components for various auto and tractors manufacturers.
Castings are developed for its customers as per their specifications & drawings. After development, these parts are supplied regularly under Rate Running Contracts.
Can produce parts ranging from 0.20 Kg to 800 Kg. Current production capacity of foundry is 200 M/T on per month.
Current Line of Business:
Foundry is manufacturing Ductile Iron castings and besides supplying castings, it also supplies parts duly machined in finished form. It does not have its own machining facility but have developed vendors for machining. Can cast parts ranging from 0.5Kg to 800 Kgs. List of plant and equipment is attached.
Description of technology currently in use and the related production process:
1. Moulds of Silica Sand are prepared by mixing it with Sodium Silicate and passing CO2 Gas to infuse the Sand and to achieve desired hardness of the mould to withstand the pressure of molten metal when poured in it. Moulds are prepared with the help of patterns mounted on plates.
2. Metal is melted in high frequency electric induction furnace and desired specifications and composition is achieved by adding various Ferro-alloys in right proportion and at right temperature. The molten metal is treated to convert it in Ductile Iron of desired grade. At particular temperature, molten metal is melted in the Silica Sand moulds already prepared.
3. Temperature is measured with the help of Pyrometer at various stages of melting and before pouring the metal in moulds. Metal is also tested for chemical composition before pouring.
4. After cooling, moulds are knocked out and casted parts are fettled, shot blasted in shot blast machine and before painting with primer are checked for their quality.
CURRENT MARKET
Auto industry is importing parts on CKD basis and replacement parts for worth over 3 billions of US Dollars. Similarly other industries are importing consumable parts valuing many millions dollars. If these parts can be produced as per international quality standard, then there exist a big market for our production.
Presently all auto and agriculture tractor manufacturers are using imported forged steel crankshafts. Local production of crankshaft is very negligible. Being a laborious process, forged process of production used for manufacturing of crankshaft has been replaced by Austempered Ductile Iron (ADI) technology / material. Now all over the world cranks are being produced in ADI, which is economical and less time consuming. Since there exist ready local market for ADI Crankshafts within the country, we are proposing this project.
FUTURE PLANS
Objectives
1. To increase product line by adding production of crank shafts through ADI technology in the existing project.
2. To produce crank shafts of international standards and quality and to improve quality of products already being manufactured by acquiring heat treatment technology and by adding equipment/machinery.
3. To add more products in manufacturing program keeping in view the market trends and demands.
4. To supply high quality auto products to local manufacturers and to explore the export market for these products.
Rationale
In recent years the Pakistan auto industry has expanded manifolds. The following vehicles / tractors are being manufactured under joint venture / collaboration.
1. Massy Ferguson Tractors
2. Nissan Car & Trucks
3. Suzuki Cars & Vans
4. Fiat Tractors
5. Hino Trucks
6. Kia Cars
7. Hyundi Cars and Trucks
8. Toyota Cars and Vans
9. Mazda Trucks
10. Honda Cars
The above manufacturing plants have been installed with the prior conditions that parts for these will be developed locally under a deletion program. Most of these parts are in ductile iron, which is our expertise. There are very few competitors in this field.
Besides supplying parts to auto manufacturer the parts are required for replacement market in which we have not entered yet but want to do so in near future. So our strength is in the technical expertise, vast experience & credibility in the market, (as we are supplying parts to various auto and tractor manufactures for last many years) and quality control.
OUR VALUED CUSTOMERS
1. Millat Tractor Limited, Lahore
2. Hino Pak Motor Company Limited, Karachi
3. Al – Ghazi Tractors, D. G. Khan
4. Mecas Engineering (Pvt) Ltd Lahore
5. Various auto parts dealers of replacement parts
6. Jobbing work for local industries/customers
7. New entrants of Auto and agriculture tractors
LIST OF COMPONENT BEING PRODUCED
Parts Description For
1. Diff Case (LH) Massey Ferguson Tractors
2. Diff Case (RH) Massey Ferguson Tractor
3. Retainer Rear Axle Massey Ferguson Tractor
4. Brake Pedal Massey Ferguson Tractor
5. Clutch Pedal Massey Ferguson Tractor
6. Lock Combined Brake Massey Ferguson Tractor
7. Control Beam Massey Ferguson Tractor
8. Hub Front (Shahzore) Hyundai Shehzore Truck
9. Diff Case (Fiat) Fiat Tractor F-480
10. Crank Shaft Suzuki Car & Van
LIST OF MACHINERY/EQUIPMENT
Foundry Equipment
1. 500 Kg Solid State High Frequency Furnace (Double Body) 01
2. Rotary Furnace 200 Kg 01
3. Sand Drier 1 Ton/Hour Capacity 01
4. Sand Muller 2 Ton/Hour Capacity 01
5. Sand Muller 500 Kg/Hour Capacity 04
6. Pneumatic Molding Machine 01
7. Sand Aerator 01
8. Over Head Crane 3 Ton Lifting Capacity 01
9. Oil Fired Heat Treatment Furnace 3 Ton Capacity 01
10. Gas Fired Drying Oven 01
11. Water cooling System with Two Water Pump 01
12. Ladles of Various Sizes 04
13. Various Sets of Moldings Boxes
Fettling Equipment
1. Shot Blast Machine (Rotary Table) 500 Kg/Hour Capacity 01
2. Pedestal Grinder 3KW 02
3. Hand Grinder 02
4. Air Compressor 5KW 01
5. Air Compressor 1.5KW 01
6. Air Blower 03
Lab Equipment
1. Carbon Equalent Meter (Metal Analyzer) 02
2. Hardness Tester 01
3. Metallurgical Microscope 01
4. Poly Hardness Tester 01
5. Pyro-Meter (Wall mounted) 01
6. Hand Held Pyro Meter 01
Workshop Equipment
1. Lath Machine 6 Ft 01
2. Shaper 18 Inch 01
3. Drill Machine 1HP 01
4. Pedestal Grinder 1HP 01
5. Saw Cutting Machine 01
6. Set of Electric and Mechanical Tools