Enhancing Competitiveness of Small and Medium-Size Foundries: Scope, Challenges and Way Forward

摘要

There are over 45001 registered foundry units in India. Of these, about 3,000 units are grey iron foundries. Of the total tonnage of 5.1 million tonnes of grey iron castings produced in our country, nearly 60% is through Cold Blast Cupola route. This accounts for about 3.0 million tonnes. In addition, another 1.0 million tonnes is produced by units which are not registered. The baseline study of 80 foundries in Haryana indicated that there is a large potential for saving 10-35% of coke consumed by improving cupola operation, and in some cases by changing over to Divided Blast Operation. This would be a huge saving in coke by any reckoning and would also lead to substantial improvement in pollution levels. It was found that some intervention had been done by Government Agencies, Funding Institutions and Organisations specialised in Energy improvement. However, not more than 100 foundries have so far benefitted from this effort. It was felt that the Cluster Development Approach would be appropriate to ensure wider benefit to a large number of foundries. A small industrial town of Samalkha, about 80 km from Delhi, was chosen as a test case. The details of diagnostic: study, methods adopted for development and sustenance of the cluster, improvements effected in operation of the cupolas and resultant savings in coke are presented in this study. It is felt that this methodology can be replicated in other foundry clusters to the benefit of small and medium-size foundries all over the country. Joint action by private funding Institutions, Industry Institutions like The Institute of Indian Foundrymen and the Government would go a long way in realising this objective.