Beginning its journey in 2009, Precise Castings Pvt. Ltd. is a noted manufacturer of rubber-coated rollers for the paper industry. With a fully-equipped steel melting shop and machine shop for casting pipes and manufacturing other raw materials, Precise has made a name for itself in the market of quality steel castings. Being one of the pioneers to develop pulp molded tableware manufacturing machines in India, the company manufactures and supplies a range of – pulp molded tableware machines, trimming machines for finishing pulp molded tableware, special alloy steel castings for companies like ISGEC and BKT, and suction roll shells for the paper industry.
In a conversation with Paper Mart, Mr. Daksh Singal, Director, Precise Castings Pvt. Ltd., sheds light on the beginnings of the company, the infrastructure setup, technological capabilities, types of products manufactured, and an outlook on the pulp molded tableware segment.
“We are equipped with the necessary in-house capabilities to manufacture the complete machines under one roof… This is one of the major pillars which enables us to provide the customers with timely delivery and all the quality-related checks.”
Paper Mart: Could you please give us an overview of Precise Castings Pvt. Ltd. and its business journey?
Daksh Singal: Precise Castings Pvt. Ltd. was started in 2009 as a backward integration of Amar Elastomers Pvt. Ltd. for its needs for special castings for making heavy press rolls for the paper industry. We have a fully equipped steel melting shop and machine shop for casting pipes and manufacturing other raw materials for our group company. Precise has also made a name for itself in the market of quality steel castings. Since then, the journey of progress started as per the requirements of our customers. The capacity of furnaces was increased to cast a single pipe up to 16 tonnes and shafts, with special alloys like SS 304,316, duplex steel, copper, MS, bronze, cast iron, etc., and equipped with all types of testing equipment.
With experience spanning over about 40 years in the paper manufacturing industry, our Managing Director Mr. M.P. Singal has been a driving force for the organisation. Under his able leadership, we have developed pulp molding machines for manufacturing biodegradable tableware from bagasse pulp to replace single-use plastics and thermocol which are harmful to the environment.
PM: Tell us more about the factory – infrastructure, product portfolio, technology, manufacturing capabilities, investments, etc. of Precise Castings.
DS: Over time, our infrastructure and technology have also grown and have been upgraded from time to time. The company is spread over an area of over five acres of land (with a covered area of nearly 70,000 sq ft) and with 40 tonnes handling overhead EOT cranes.
There are two centrifugal casting machines for manufacturing pin-hole free castings with a higher density and with better grain structure. Out of those machines, the bigger one can handle a weight of up to 30 tonnes. In the engineering section, the company is equipped with 5 vertical turning lathes, 2 horizontal boring machines, several lathes of size from 2 meters to 10 meters (one 6-meter CNC lathe), 1 surface grinder of 10 meters, O.D. turning and I.D. turning machines for pipes up to 6-meter length, 2 CNC gun drilling machines, 1 cylindrical roll grinder of 10 meter, Plano-miller, radial drills, and so many other accessories to count.
The product portfolio includes – machines for manufacturing pulp molded tableware, trimming machines for finishing of pulp molded tableware, special alloy steel castings for companies like ISGEC and BKT, and suction roll shells for the paper industry.
PM: Kindly shed some light on the specifications and unique features of the bagasse fiber molding machines supplied by Precise Castings.
DS: Precise Castings is the first company to develop pulp molded tableware manufacturing machines in India. It started three years back when we went to China to buy these machines for setting up our own tableware manufacturing plant. However, after visiting China, we discerned the need to manufacture these machines in India to meet the growing demand for molded tableware solutions which will further increase amid the recent plastic ban. Since then, we have been manufacturing these machines and have supplied 25-30 machines to different plants which are running up to the expectations of our customers.
|Structure||Easy to handle 3Pcs. Structure|
1. Forming Stage x1 in the middle
2. Hot pressing Stage x2 on the two sides
|Platen Size||1000mm x 950 mm|
|Forming Type||Top Forming|
|Heating Type||Thermal Oil or Electric|
|Max. Pressure||30 Ton Hydro pneumatic Cylinders accompanied with two pneumatic cylinders|
|Max. Product Height||80 mm|
|Control By||PLC + Touchscreen|
|Designed Capacity||400 – 500 KG/Day|
|Remarks||All Parts in contact with pulp will be of S.S. 304 * Complete S.S.304 covers * Rigid stress relieved M.S. square pipe frame|
Manufacturing Process of Pulp Molded Tableware
The non-wood pulp of sugarcane bagasse, rice straws, bamboo, wheat straw, etc. is bought and converted into pulp slurry. Then, waterproof and oil-proof additives are added to it. Afterwards, the pulp slurry is sent to the pulp slurry chest. The pulp stock supply chest moves the pulp continuously to the pulp forming machines. Forming is the key process in the tableware production line. The process is quantitatively pulp supply using a deposition method, back flushing air supply, vacuum dewatering, and forming.
In our semi-automatic molded fiber production machine, the pulp is molded into different products like plates, bowls, trays, etc. The machines are developed using advanced technologies to eliminate holes, and uneven thickness during production to reduce defective goods. The semi-finished product will be moved to the hot press station for mold drying. The product taken out from the hot press undergoes an edge-cutting machine where the extra edge will be trimmed.
After this process, the product is ready for a quality check. Here, all the products are checked for their shape, size, and durability. After the quality check, the product is passed on to the counting division where it is counted and sent for packaging.
PM: Talking about molded fiber products — could you please brief us on the types of the products manufactured by the machine along with their applications?
DS: Manufacturing 100 percent biodegradable and compostable tableware is the need of the hour. There are a variety of molded fiber products that are in huge demand to replace various single-use plastic items; however, we are majorly focussed on molded fiber tableware manufacturing as we feel it to be a very important and one of the biggest segments with huge demand.
On our machine, we can manufacture a variety of tableware products such as plates, bowls, trays, clamshells, containers, lids, etc., to meet the increasing demand – local as well as international, for disposable tableware as it is a very good substitute for single-use plastic disposable tableware.
PM: Please shed some light on the market footprint and clientele of Precise Castings along with the expansion plans.
DS: With respect to our clientele, our machines have been running in many plants which we have supplied either directly or through a marketing agent. A few of our clients include – Ecovore Tableware Pvt. Ltd., Dev Euro Paper Products LLP, Kuber Packaging Industries Pvt. Ltd., Oom Pulp Products LLP, Ecotweet Agriware Pvt. Ltd., and Ecoware Solutions Pvt. Ltd.
With the aim to fulfill the increasing demand of the machines, we are all set to increase our manufacturing capacities of these machines.
PM: What are the key strengths of Precise Castings which enable you to make your mark?
DS: We are equipped with the necessary in-house capabilities to manufacture the complete machines under one roof starting from fabrication, casting, machining, stress relieving, and assembling. This is one of the major pillars which enables us to provide the customers with timely delivery and all the quality-related checks.
Moreover, our longstanding experience in the pulp and paper industry helps us to understand the importance of different processes at various manufacturing stages. Having our own in-house designing and engineering department helps us to work on the regular research & development activities to develop an innovative and better product for our customers.
PM: Considering the surge in the fiber-based packaging market due to the recent ban on single-use plastics by the government; how do you see the market evolving in the future? What is your outlook regarding the potential of this segment in India?
DS: We have a very positive and wide outlook regarding the potential of the pulp molded tableware industry as disposable tableware has become a very necessary consumer product nowadays. After the plastic ban by the government, the demand for these products is increasing multifold. These kinds of products are majorly used in social gatherings such as weddings, parties, religious functions, and even in big corporate offices and railways, airlines as well as airports.
Pulp molded tableware has been accepted as a substitute for single-use plastic products. Also, being a 100 percent biodegradable product, this also opens up the gates for international trade for the industry. Considering all the above-mentioned market demands and trends, we foresee a lot of potential in this market in the upcoming years