Commercial Vehicle & Trailer Axle Components Foundry

High Thermal Durable Bentonite Blends – Best-in-Class Peel-Off & Controlled Casting Weight

Project Overview

Region

Eastern

Industry

Manufacturer of safety-critical, precision-forged and cast components for commercial vehicle, tractor, and trailer axle segments – heavy-duty auto components, trailer axles, suspension assemblies (high-pressure moulding line)

Engineering Focus

Frequent scab and mould wall shift defects, low mould hardness (65–70) and cracks, variable sand erosion, bentonite dosing error (11.33% over-dosing).

Solution

Smecbond and Sandiron – engineered bentonite blends combining imported and Kutch-based bentonite for high WTS and GCS.

Goal

Improving Casting Quality Through Advanced Bentonite Blend Technology

Outcome

Bentonite consumption reduced by 10.56% (1.23% to 1.1%).
LCA consumption reduced by 21.62% (0.37% to 0.29%).
Mould leakage rejection reduced by 32.81%; patch in castings reduced by 50%.
Total rejection reduced by 43.89% (10.32% to 5.79%).
Bentonite cost reduced by 33.11%; LCA cost reduced by 11.00%.

Net result: ₹11.34 lakh/month savings in additive costs plus ₹24 lakh/month through reduced rejections.

Proven performance. Measurable results.

We deliver solutions that drive real improvements in quality, efficiency, and productivity.

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