Back In 2011 at the Young age of 20 after working for 2-3 years with a few Foundries, Mr Arpit Bhut decided to venture out on his own and become a Foundrypreneur.
Coming from a B.Com stream with no family foundry background, He started with acquiring a small Foundry making 25-50 Tons a month of Cast Iron and Over the years, gradually expanded to 100, 200, 300 and now 800 Tons a month.
Part of Arpit’s winning strategy was his focus on reinvesting all Profits into Capacity and Machinery and value addition while working out of rented properties.
He also distinctly told us that his response time to Casting Clients was within 30 minutes, cementing his relationship with his Customers.
All This allowed him in 2022 to expand to a 3 Acre world class unit in Rajkot’s Lodhika region that he recently moved into.
However Today, at Sunstar Castech 300 Tons comes from Lost Foam Casting Process, our main focus for the Episode being one of the few LFC Foundries in India.
So, What is Lost Foam Casting Process ?
In today’s age of Sustainability, Consistency and Automation, Lost Foam seems like a good Insurance policy for the Future of Foundries Worldwide
The process of Lost Foam largely involves :
- Creating an identical replica of the casting with Foam.
- Sticking together the gating and feeding system resembling something of a Tree structure
- Immersing and Coating the Tree with Refractory Coating for better finish before leaving it for drying.
- Then packing sand around this Tree during the moulding process through vibration techniques.
- Finally, pouring Liquid Metal into the box that slowly burns off the Tree and taking it’s shape.
5 Advantages of Lost Foam Process :
Lost Foam has many Advantages, some of the popular ones being :
- Weight consistency
Due to the consistency of the Process, the Weight of the castings are generally lesser by 3-8% compared to Greensand Castings. - High Volumes!
Lost Foam Casting Process truly returns well when there are high volumes and a high degree of replication is needed for the same component. - Almost 100% Sand Recyclability
One of the biggest problems with Foundries today is the disposal of Sand and Re-usability. LFC Process can reuse more than 99% of the sand or more making it a very clean process to work with. - Coreless Process
Lost Foam might be a more costly process compared to its counterparts.
However since Cores are not required, this entire operation is done away with completely freeing up Capex, Manpower and Space! - Empowering Women to Join the Manufacturing Workforce.
Arpit believes that in Today’s Labor constrained world, encouraging women to join Foundries via the clean process that lost foam has to offer is one of the biggest advantages most people oversee.
Road ahead for Sunstar Castech Pvt Ltd :
Arpit says that in coming years he hopes to set up a 3000 Ton a month Lost Foam Unit and do away with his No-Bake plant completely, using it only for prototypes.
Stay Tuned for More about Lost Foam and the entire Podcast Episode with Arpit coming soon!
Looking to Get Started OR Explore Lost Foam Castings?
Today JK Foundry Engineers has been working with Foundries to establish with and set up Lost Foam Casting Plants for Indian Foundries.
They have 12 such plants in operation around India and offer hand holding local support thereby cementing the MAKE IN INDIA campaign.
Reach JK Foundry Engineers :
Bhargav Patel : +91-9601474617
Email : bpatel@jkfoundryequipments.com
Web : https://jkfoundryequipments.com/lost-foam-process-equipment.htm
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