Manufacturing Processes at STC

1. Iron & Grey Iron Casting

This is STC’s core business, focusing on forming molten metal into final product shapes.

  • Raw Material Preparation: Involves preparing and certifying raw materials (Iron) for melting.

  • Melting: Heating the raw metal to its molten state in the foundry.

  • Moulding: Utilizing processes like Green Sand Reclamation and various Moulding Lines (Jolt and Squeeze Moulding Machines, Form Moulding Lines) to create precise molds for the molten metal.

  • Pouring & Cooling: Pouring the molten metal into the molds and allowing it to solidify into the Iron and Grey Iron Casting components.

  • Finishing (Fettling): Removing excess material (risers, gates) and cleaning the surface of the solidified casting before it moves to machining or assembly.

2. Steel Fabrication & Pole Manufacturing

This process focuses on forming, cutting, and welding steel sheets and pipes into structural products like poles, fences, and complex assemblies.

  • Material Preparation: Sourcing and inspecting high-grade hot rolled structural steel sheets and steel pipes.

  • Forming (Poles): Automated procedures of cutting and folding/pressing the steel sheet into specific shapes (e.g., Octagonal or Round Conical taper).

  • Welding (Poles): Sections are joined longitudinally by Submerged Arc Welding (SAW), a high-quality, high-efficiency method for creating strong, continuous seams.

  • Welding (General): Comprehensive general welding services are provided for all pre-fabricated steel structure and industrial equipment.

  • Finishing (Corrosion Protection): Applying finishes like Hot-Dip Galvanizing (HDG) to poles and safety barriers for long-term corrosion resistance.

3. Precision Machining

Machining transforms raw castings and fabricated parts into pre-finished condition products with high dimensional accuracy.

  • CNC Processing: Utilizing Twin Pallet CNC Horizontal and Vertical Machining Centers for automated, high-precision removal of material.

  • Turning: Employing CNC Turning Centers to machine cylindrical parts up to $500 text{ mm}$ Swing Diameter.

  • High-Volume Drilling: Using Custom Made multi Drilling Machines capable of drilling up to 32 holes at a time for specialized components.

  • Transfer Machining: Utilizing Independent Transfer Machining Lines for efficient, dedicated production runs.

  • Inspection: Using Inspection Gauges for all Parts to verify and certify precision tolerances.

4. System Integration & Final Assembly

This final stage brings together various components and control systems.

  • Assembly: Combining fabricated, cast, and machined parts to form final products, such as industrial equipment and fully assembled structural components.

  • Industrial Automation: Integrating PC, PLC, & CNC Controls into equipment for solutions like Automatic Packing, Liquid Filling, and Conveying Systems.

  • Final Quality Check: A comprehensive quality assurance system is applied throughout the process to ensure full compliance before shipmen