It was 2006 and a historical year in the expansion journey of Caparo India when the company started its CDW Tubes and Cold Drawn Welded Tubes manufacturing operations through the strategic acquisition of the Dewas-based company Steel Tubes of India. The said acquired company used to manufacture high-precision steel tubes for the Automobile Industry, General Engineering and Power Sector. This mega manufacturing facility of Caparo India has been operational since August 2006 owning a total area of 73, 608 sqm. and a built-up area of 30,812 sqm.
An ISO 9001:2000 & IATF 16949 certified facility with a current output of 3000MT
Caparo India’s Tube Division is an ISO 9001:2000 & IATF 16949 certified facility with a current out of 3000MT tubes per month. All the tubes in the facility are manufactured conforming to all national and international standards. The facility is manned by skilled engineers and allied workforce while acting upon well-established processes for tube manufacturing. This premier tube manufacturing facility of Caparo India aims at enhancing its capacity with each passing year so that it can meet the needs of customers through faster product development, technology upgrades as per contemporary requirements, and prompt response and delivery.
Meticulously planned manufacturing set-up at a glance
Caparo India’s Tube Division has a meticulously planned manufacturing infrastructure that makes it a perfect venue for a comprehensive range of tubing solutions. The division manufactures 3300MT Precision Carbon & Alloy Steel ERW and CDW tubes per month while operating on the latest in tubing technology. Backed by world-class infrastructure manned by a dedicated and committed workforce, the facility includes the following:
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Various tube-finishing machines
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Offline eddy current testing
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Hydro-testing – up to 3000 Psi
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Coil Slitting – 1250mm and 400mm wide
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Tube rolling – 15.88mm to 101.6mm OD up to 5.5mm thick
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Tube annealing – 84 Tons per day
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Tube drawing – 60 Kms /Day
Tube Mills
The tube mills that Caparo India has installed in its facility utilize high-frequency, variable induction welding technology ensuring high-quality welding strength using nothing as filler. The offline Eddy Current Tester makes a comprehensive analysis of the tube for any kind of flaws in the welding quality. A series of forming rolls is also installed to anatomize the rolled strips so that they can be molded into tubular form with high precision. The quick rollover changes not only capacitate the tubing division for reduced production time but also speed up the overall efficiency.
Specifications at a glance
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Three Tube Mills with capacity – 40000 MT/ annum
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Thickness from 0.90 mm to 5.5 mm
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Up to 200 KW High-Frequency Solid state Welders on all mills.
There are so many factors that play a crucial role in ensuring the overall strength, quality, durability, reliability, excellent final finish, and accuracy of the ERW tubes manufactured. Some of them include the following:
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Especially designed rolls for progressive movement of steel strip
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High-frequency induction welding
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Efficient removal of weld flash
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Turks head and sizing roll for straightening and perfect sizing
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Eddy current testing, annealing, pressure testing, and cutting for better fitness and overall quality intended for particular applications.
CDW (Cold-drawn Welded)
Tube manufacturing is a very complicated process wherein there are chances of not getting the perfect shape directly from the mill. This is where the cold-drawing process enters the game to give tubes the desired sizes. In the cold-drawing process, all the tubes undergo a very sophisticated surface treatment to lower the intensity of friction that happened during the cold-drawing operations. All Cold Drawn Welded (CDW) tubes manufactured are supplied with the following by default features and attributes:
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Excellent finish
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Outstanding durability
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High-precision dimensional tolerances
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Corrosion resistance
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Controlled and uniform mechanical properties, and
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Uniform sectional thickness.
Major steps in the manufacturing process'
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The manufacturing process begins with annealing and surface treatment
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Cold swaging/push pointing procedures for making pointed ends
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Outer diameter control by using high precision close machined die
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Plug placed coaxially with outer die for inner diameter control
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Straightening and final testing.
Product galore at a glance
Caparo India’s Tubes Division adopts the world’s best manufacturing practices since the company has always been deeply concerned about the quality parameters of the products to be manufactured. Keeping in view the same, Caparo Tubes procures raw materials from the world’s best sources to live up to quality expectations. With a state-of-the-art facility for tube manufacturing, the company manufactures 3300MT tubes per month offering the following Precision Carbon & Alloy Steel ERW and CDW tubes and Seamless tubes:
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Electric Resistance Welded Tubes (ERW)
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Cold Drawn Welded Tubes( CDW)
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CYL Bore Quality Tubes (CBQ)
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Section Tubes.
Research & Development
Caparo Tubes has a dedicated Research & Development (R&D) facility wherein the company strives hard to be in sync with the current technological trends of the industry. And in this pursuit, R&D plays a very crucial role. The personnel deployed in the research and development department always work with a spirit to get breakthroughs through innovation with the least possible negative product margins.
Quality Parameters
Achieving the highest quality parameters has always been the credo at Caparo Tubes. Each and every aspect of quality is taken care of right from the very beginning. Be it the procurement of raw materials, manufacturing processes and procedures, or any other area, constant quality monitoring is a way of work at Caparo Steel Tube. A series of stringent quality control is conducted to meet all the predefined quality guidelines.
Concluding Remarks
Caparo Tubes, a division of CEIL, is a leading manufacturer of steel precision tubes (CDW & ERW). The company has been a strategic supplier to all major auto and auto-components manufacturers in India for years. The company also supplies Boiler and APH tubes, and Heat Exchanger tubes to the Energy sector. The formidable reputation the company has earned has resulted from its dedication and commitment to delivering innovative products to its customers across the globe. For more details regarding the complete product profile, one can visit the website of company.