Railway Components Foundry

The Pre-Blend Single-Shot Additive for Superior Surface Finish, Peel-Off, and Controlled Casting Weight

Project Overview

Region

Central India

Industry

Leading railway component manufacturer – RDSO-approved integrated foundry & machining facility (No-Bake moulding, electric arc furnace melting, 1,500+ tonnes/month capacity, captive and export markets)

Engineering Focus

Reliance on a competitor single-shot additive with scope to optimize additive consumption, rejection %, and casting weight control.

Solution

Lustronite – single-shot additive combining high-performance bentonite with Lustron-engineered carbon additives.

Project Duration

Production Validation & Continuous Support

Goal

Redefining Railway Casting Performance by Replacing Conventional Single-Shot Additives with Advanced Pre-Blend Technology

Outcome

Premix dosage with Lustronite™ was reduced to 0.60%, compared to 1.00% with the competitor’s single-shot additive (40% reduction).
New sand consumption decreased to 0.66% with Lustronite™, compared to 1.38% with the competitor (52% reduction).
Machining rejection was reduced from 31% to 11%, representing a 64.5% improvement over the competitor benchmark.
Foundry rejection decreased from 2.5% to 2.0%, achieving a 20% reduction.
Scabbing and peel-off defects were significantly reduced at both the foundry and machining stages, resulting in improved casting quality and process consistency.

Net result: consistent improvement in additive consumption and cost, with Lustronite approved for regular production use.

Proven performance. Measurable results.

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

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