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RAJKOT PRECISION FOUNDRY WORKS • ISO 9001:2015 ACCREDITED
Zero-Defect Thermal Engineering

Engineering & Manufacturing Process

At New Tech Induction, machinery excellence is an exacting discipline. From 3D electromagnetic FEA flux modeling and 99.97% OFHC copper coil mandrel winding to modular solid-state IGBT assembly and live 72-hour molten metal test bay verification, discover how our Rajkot works builds India's most dependable thermal equipment.

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25,000+ Sq. Ft. Rajkot Plant
100% Full Load Tested
sub-5µs IGBT Trip Speed
ISO 9001 Quality Certified
NEW TECH Induction Heavy Foundry Test Bay Rajkot
LIVE TEST BAY
500 kVA SUBSTATION
Peak Temp 1800°C
IGBT Power 100 kW
Resonance 15 - 45 kHz
ISO 9001:2015 FACTORY WITNESSED

Full-Load Molten Metal Pour Bay

Every machine undergoes hot metal pouring under client inspection before seaworthy crating.

Zero Leak Hydrostatic Interlocks
RAJKOT HQ WORKS
Foundry Engineering Roadmap

8 Steps To Machine Perfection

Every induction melting furnace, billet heater, and brazing machine traverses this strict, documented manufacturing sequence.

01

Thermal Simulation

3D electromagnetic flux density, skin-depth penetration (δ), and eddy-current thermal distribution modeled before cutting a single copper tube.

Tool: ANSYS Maxwell FEA
02

IGBT Inverter Build

Solid-state German Infineon power module assembly on water-cooled copper cold-plates with low-inductance laminar busbars and ultrafast snubber protection.

Semiconductors: Infineon Germany
03

OFHC Coil Coiling

Grade C10100 99.97% pure oxygen-free high conductivity copper tube formed on CNC hydraulic mandrels with zero pipe flattening or ovality.

Purity: 99.97% Pure OFHC
04

Rig & Tilting Frame

Heavy structural steel ISMB channels, laser-cut side plates, stress-relieved trunnions, and hard-chrome telescoping hydraulic rams for 0–95° smooth pour.

Chassis: ISMB Heavy Rig
05

Cooling Manifold

Closed-loop deionized cooling skid with stainless steel plate heat exchangers, redundant booster pumps, and digital flow switches on every branch.

Hydro Test: 8 Bar (24 Hours)
06

PLL Frequency Tuning

Microprocessor Phase-Locked Loop (PLL) tracks the tank circuit resonance frequency across cold charge, Curie point, and molten stage with zero jitter.

Accuracy: 0.1% Jitter Lock
07

Full-Power Melt Run

100% full crucible live molten charge pour in our Rajkot test bay. Thermal imaging with Fluke Ti480 verifies zero hot spots before customer FAT sign-off.

Burn-In: 1800°C Live Melt
08

Export Crate Packaging

Cooling loops nitrogen blown dry, VCI anti-corrosion barrier wrap applied, and heavy-duty ISPM-15 fumigated wooden export crating with shock-mounts.

Standard: ISPM-15 Compliant
12-Stage End-to-End Execution Lifecycle

From Metallurgical Study To Hot Pour

Click through any milestone below to inspect our real-world engineering actions, physics calculations, quality gates, and handover deliverables.

CLICK ANY MILESTONE TO REVEAL SPECIFICATIONS & ENGINEERING ARTIFACTS
STAGE 01 / 12 FRONT-END DISCOVERY

Requirement Gathering & Metallurgical Consultation

Standard Turnaround Day 01 - 02
Milestone Gate Thermal Matrix Freeze
A

Inputs & Field Parameters

Collection of customer metal grade, charge density, crucible dimensions, available electrical sub-station capacity (kVA), tap-to-tap cycle requirements, and factory layout constraints.

• Metal: Karat Gold, Brass, Copper, SS
• Infeed Power: 415V 3-Phase 50Hz
• Batch Target: 1kg to 1000kg
B

Engineering & Physics Actions

Theoretical thermal energy calculations (kW needed = mass × specific heat × delta T / efficiency), resonant tank circuit inductance sizing, and coil water flow cooling calculations.

• Thermodynamic delta-T model
• Water flow & pressure drop sizing
• Harmonics feedback simulation
C

Deliverables & Quality Sign-off

Formal Techno-Commercial Proposal accompanied by general arrangement drawings, electrical load schedule, and guaranteed kWh per ton energy consumption benchmark.

✔ Signed Process Definition Sheet
✔ 3D Cell Footprint CAD (.DWG/.STEP)
✔ Guaranteed Tap-to-Tap Time Spec
Jump to Milestone:
Foundry Hardware Engineering

4 Manufacturing Pillars

Every core module is built, tested, and assembled inside our Rajkot engineering plant under strict ISO 9001 supervision.

OFHC Copper Induction Coil with Molten Gold
PILLAR 01 • ELECTROMAGNETIC CORE 99.97% PURE COPPER

OFHC Copper Coil Fabrication

Grade C10100 Oxygen-Free High Conductivity Copper Tubes with Zero Ovality

Coils are formed on hydraulic CNC mandrels with zero pipe flattening. Each turn is insulated with multi-layer Class-H mica tape, high-temperature silicone fiberglass sleeving, and cast refractory cement to withstand 1800°C radiant heat.

  • Zero ovality mandrel bending with internal hydraulic pressure
  • High-frequency silver brazed water manifolds and copper terminal lugs
  • 100% 2.5 kV dielectric breakdown insulation tested
Hydro Test: 8 Bar (24 Hours) Zero Leak Guarantee
IGBT Inverter Modular Power Rack
PILLAR 02 • POWER ELECTRONICS 96.8% EFFICIENCY

Solid-State IGBT Inverter Racks

Infineon Germany IGBTs + Low-Inductance Laminar Busbars

Built with German Infineon / Eupec half and full-bridge IGBT modules. Zero-voltage zero-current (ZVZCS) resonant tank topology guarantees power conversion efficiency exceeding 96.8% with negligible switching harmonics and minimal thermal stress on silicon dies.

  • High-speed optical fiber gate drivers eliminating EMI electromagnetic crosstalk
  • Microsecond electronic over-current & short-circuit latch protection
  • Microprocessor Phase Locked Loop (PLL) tracking resonance from cold to Curie point
IGBT Efficiency: 96.8% Power Factor >0.96
Furnace Structural Frame and Tilting Hydraulics
PILLAR 03 • HEAVY MECHANICAL 0-95° PROPORTIONAL TILT

Structural Rig & Hydraulic Tilting

CNC Laser Cut Steel Chassis & Chrome Hydraulic Cylinders

Structural frames are fabricated from heavy ISMB channels stress-relieved to prevent thermal distortion over decades of heavy foundry operation. Double-acting telescoping hydraulic cylinders deliver smooth 0–95° tilting with zero jerk or slag splashing.

  • Counterbalance safety check valves preventing cylinder collapse during power cuts
  • Hard chrome plated rams resistant to molten metal spatter & foundry grit
  • Ergonomic operator pulpit or wireless handheld pendant control
Pour Precision: 0 - 95° Angle Dual Hydraulic Safety
Deionized Water Closed Loop Cooling Unit
PILLAR 04 • THERMAL MANAGEMENT DEIONIZED WATER LOOP

Closed-Loop DM Water Cooling

AISI-304 Stainless Plate Heat Exchanger & Redundant Pumps

Power electronics and induction coils require ultra-pure, non-conductive deionized water to prevent galvanic corrosion and electrical tracking. Our integrated skids feature AISI-304 plate heat exchangers, dual pumps, and digital conductivity sensors.

  • Individual circuit flow switches & RTD temperature probes per coil branch
  • Automatic changeover secondary booster pump for uninterrupted melting
  • Conductivity cutoff interlock protecting IGBT snubber plates
Cooling Medium: Deionized DM Water Dual Redundant Pumps
Quality Assurance Benchmark

Factory Test Bay Protocol

Every single machine must pass all 6 rigorous quality gates in our Rajkot test bay before the dispatch crate is sealed.

Quality Gate & Inspection Standard Industry Vendor New Tech Induction Protocol Verification Artifact
High-Voltage Insulation Test
1000V DC hand megger test for 5 seconds
2500V AC Hi-Pot test for 60 seconds (Leakage < 2mA)
NABL Calibration Report
Hydrostatic Coil Leak Test
4 Bar tap water pressure for 15 minutes
8 Bar (116 PSI) hydrostatic pressure for 24 continuous hours
Pressure Decay Certificate
Live Thermal Melt Burn-In
Dry coil energization with carbon dummy block
100% full crucible molten charge pour in live test bay
Live FAT Video & Heat Run Log
Harmonics & Waveform Scan
Unchecked analog meter reading
Tektronix 4-Channel DSO waveform capture (THD < 5%)
Oscilloscope Trace Archive
Trip Interlock Verification
Over-temp thermal switch only
12-point trip testing (Loss of flow, over-temp, phase fail)
Safety Interlock Sign-off
Interactive Calculation Tool

Test Bay Melt & Power Estimator

Select your metal type and batch weight to calculate theoretical energy consumption and recommended induction power.

50 kg
1 kg 50 kg 100 kg 250 kg
Send Estimate To Rajkot Engineers
Engineered Calculation
Required Power 71 kW
Est. Melt Time 17 - 22 Min
Energy Consumed ~20.1 kWh
Pour Temp 1085°C
Recommended Fleet Unit New Tech 71 kW Hydraulic Tilting Melter
WITNESS LIVE INDUCTION MELTING AT RAJKOT

Send Your Metal Charge For Live Test Bay Melt Trial

Bring or ship 5kg–50kg of your gold scrap, copper ingots, or brass swarf to our Rajkot test bay. We'll run a live demonstration, record energy consumption in real-time, and hand you ingot samples with zero obligation.

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