Material Sourcing
Steel
We are experienced in sourcing fully processed electrical steel ranging from 35A350 to 65A1000 in different coatings and thickness, directly from mills of global repute. We have excellent working relationships with our steel suppliers. Special Grade coatings can also be procured as per customer’s requirement. As a standard practice, every input coil is being tested and recorded to maintain traceability.
Aluminum
EC Grade aluminum for rotor die-casting is procured from Hindalco and companies of international repute. Special grade in aluminum is also processed/procured, based on customer requirement.
Product Packaging
We use export suitable, strong, secure sea worthy packaging. Due to our long standing relationships with established logistics companies we are able to guarantee fast and safe delivery of our products. Finished products are packed in wooden/corrugated boxes using VCI covers, thick PVC sheet or stretch wrap. Products are then placed on wooden palettes and securely strapped up ready for their journey.
Tooling Support
To support grinding of tools within tolerance levels we have a hydraulic surface grinder with chuck size 1500x400mm of Toss and 2000×600 mm of Schneider to ensure in-house maintenance to optimize tool life.
Stacking
Our stacking section is equipped with SPMs to make stator packs by tig-welding, cleating, riveting or even skewing
- Welding
- Cleating
- Riveting
- Interlocking
- Segmental Lamination
Decarburizing
We have annealing/decarburizing, batch type pit furnaces with PLC control to ensure proper grain structure growth for lower core loss and improved permeability to enhance the electrical properties of laminations. The process increases inter lamina resistance by adding an oxide coating and relieves stamping stress. These processed laminations are suitable for welding. This process substitutes the expensive fully processed electrical steel for significant cost savings.
Aluminum Rotor Die Casting
We have an in-house aluminum pressure die casting facility for the process of casting rotor packs from 56 to 400 frame size in different polarities and core lengths. Close process control ensures high quality casting, high conductivity and minimum porosity. We have the ability to broach rotors of various sizes.
Furthermore, we have three auto ladling enabled vertical and horizontal die casting machines of 80, 150 and 400 tons capacity to handle 100g to 60kg of aluminum.
Single Notching
We have a set of PLC controlled notching machines from brands including Wuhu and Weingarten to make stampings upto 1200mm diameter. The versatile blanking machines and precise tangential skew function enabled notching machines at our plant are capable of producing large diameter laminations of sizes up to 1200mm for traction motor and generator applications. They are supported by 2 high precision circular sheering machines of ARYMA and RADSON to get 1300 blank.
Gang Punching
KCP has an array of more than 30 H & C type Universal presses ranging from 30 – 200 T capacities suitable for gang punching of blanking stator and rotor, up to dia 500mm in different polarities and core lengths. We are also equipped to produce segmental lamination for the large generator and hydroelectric applications.
Auto Fed Progressive Lines
KCP Factory is equipped with a series of auto-fed high-speed presses like AIDA, YADON and GODREJ ranging from 100 – 250 T capacity to manufacture high volume/large batches of stampings up to 300 mm diameter by using single or multiple row progressive tooling.