1) RAW MATERIAL PROCESSING (HOT FORGING / DIECASTING)
The Raw Material is first Inspected for quality as per the standards and then taken for the processing.
For the Valves, Brass Rod is cut into desired size of billets on an automatic cutting machine. These billets and then fed through a conveyer to the Automatic Hot Forging Machine where the required type of valve is hot forged to the desired shape. They are then then left for cooling. This cooled material is sent for further process.
For the Regulators, Zinc alloy ingots are fed to the automatic Pressure Die-casting Machine. The hot molten material is automatically injected into the pressure die casting moulds to take the shape of the desired regulators. The machines cast the regulator in 2 parts called the Body & the cover (known as regulator parts). The automatic die casting machine processes the material and gives the desired moulded parts for further processing.
2) TRIMMING & SURFACE TREATMENT
The Hot Forged valves are then trimmed through the automatic trimming machine to remove the extra flashes and material. Then his material is cleaned through the automatic shot blasting machine to clean the surfaces and give a clean surface of the valves. These cleaned valves are then sent to the automated machining centre for the machining.
The Die-casted parts of the regulators are then trimmed through an automated machine for removal of the excessive material. These are then surface treated by the Automated 7 tank cleaning process and Powder coated with the desired colours through the Automatic Powder coating system. This powder coating is done to protect the zinc surface from oxidation and also for the surface finishing and aesthetics of the regulators.
The treated and cleaned valves are then machined for the various dimensions and technical requirements and functions of the valves through the Robotic CNC Machines. The Inlet, Outlet, Threading and other processes are done automatically by the robotic machines as per the specifications of the required product. They are also checked for the dimensions by the quality control inspectors at the machining centre. They are then once again cleaned and sent forward to the assembly and finishing of the valves.
The treated and cleaned regulator parts are then machined for the various dimensions and technical requirements and functions of the valves through the Automated Machines. The Inlet, Outlet and other processes are done automatically by the Automated machines as per the specifications of the required product. They are also checked for the dimensions by the quality control inspectors at the machining centre. They are then once again cleaned and sent forward to the assembly and finishing of the regulators.
The Machined valves are then assembled with various other parts for the functioning of the valves. These other parts are fixed into the valves as per the requirements and then tested for their performance and working. Every piece is checked through automated test equipments.
The Machined regulator parts are then assembled with various other parts for the functioning of the regulators. These other parts are fixed into the regulators as per the requirements and then tested for their performance and working. Every piece is checked through automated test equipments.
5) QUALITY CONTROL
The Company has a state-of-the-art testing Laboratory equipped with all the testing facilities and equipments which can test products of all kinds of Standard requirements.
The Valves & the Regulators are then Picked as samples and tested here for the quality, performance, durability, safety and certifications. This Lab tests the products to perform under all the international conditions and requirements.
The TPIA Inspection Agencies Test the Products in this Lab for the certification apart from the self-certification of the products. The International Agencies use our Lab for testing the products and certifying them.
6) PACKING & SHIPMENT
The products are then packed as per the requirements and are being marked, labelled, sealed for the shipments and sent to the Finished Product Bay and Despatch Section.
These packaged materials are then despatched to the customers as per the despatch instructions received from the customers. The complete documentation and trackability of the production process are done and recorded.