India has about 5000 foundries, most of which are MSMEs and are in clusters. 2173 TPA is the average unit production today. When it comes to the range of items produced, each group is renowned for a distinct specialization. But out of all the castings produced, grey iron castings account for the majority or about 68 percent. Metal cast components produced in India by the foundry sector are used in a variety of applications, including wind turbine generators, mining, sanitary, defence, and aerospace. Every other industry is a descendant of foundries. The history of the foundry in India dates back to prehistory. Many of the metal objects unearthed during the Mohenjo Daro excavations (2000- 3300 BC) were cast. The abundance of raw materials, power, technical know-how, and a young workforce in this labour-intensive industry, to name a few, have all acted favourably. The industry has benefited even more from the promotion of Make in India and Ease of Doing Business thanks to the adoption and creation of significant infrastructure. Kajeco Industries, founded in 1972, under the visionary leadership of the Late Vijay Agarwal, is one of India’s premier casting manufacturers and exporters of high-quality castings.
Journey since Establishment
Since its inception in 1972, Kajeco started exporting castings to industrialized nations like the US, Canada, and a number of European nations. Kajeco Industries experienced a major boom when the Middle East Countries planned a rapid infrastructure development. The company was able to keep pace with other technologically advanced foundries because of innovation, infrastructure, and equipment upgrades which made Kajeco a major player quickly. Since its foundation, additional land, several machines, and manufacturing capacity have been added. Customers from varied industries and with a large range of products have been placing orders because the company is able to meet their technical requirements.
“We have a sales team that visits industries that require castings and attends trade fairs, B2B meets, in India and overseas. Our quality control and testing procedures have helped to build trust for our products in the industry. We are known for our reliability and business ethics, it is a policy not to share or disclose other customers’ products or specifications. Due to the trust, we have earned from our vendors, customers, and employees it will not be out of place to mention Kajeco has earned the reputation of an impeccable partner”, shares Jai Agarwal, Partner & CEO, Kajeco Industries.
Kajeco Industries, which is a 50-year-old foundry, was founded by Late Vijay Agarwal, who placed a strong emphasis on the development of the workforce’s skills and expertise.He designed the path keeping in mind veteran employees automatically train new hires. Under his guidance, current partners Jai Agarwal and Sanjay Agarwal received world-class foundry expertise from the grass root levels.
Today, both partners are working to elevate Kajeco Industries to new heights and achieve more laurels. “To stay in line with other world-class foundries we have ongoing technical up-gradation, visits from consultants, and participation in technical seminars. The Central & State Government, several councils & organizations for exports have awarded us year after year since our establishment in 1972. Looking into our manufacturing process test controls our foundry has several approvals from ISO, BVQI, and product certifications”, further adds Jai Agarwal.
Product Range that Promises Quality
Water line fittings, castings for presses, manhole covers, grates, sanitary castings, cooling tower components, ornamental and garden furniture castings, compressor parts, shoe machine parts, synchronizer rings, blocks, alfin, and piston rings are just a few to name from the range of castings Kajeco produces. All castings produced are of the highest calibre and accuracy, and each customer is provided with a tailor-made solution to meet their individual specifications.
Kajeco have targeted problems being faced by foundries, and a smart strategy is being followed to overcome these obstacles. The fluctuating costs of alloys and raw materials are one of the key hurdles in the casting business. Due to a paucity of some natural resources, India is dependent on imports for a few alloys. The prices of these alloys are extremely erratic due to changes in the parity of the rupee with the euro and dollar, freight costs, and import levies, which impact the costs of finished goods. Depending on availability and demand, some suppliers also change their prices. To resolve this, Kajeco Industries keeps a strict inventory control. The company maintains a stock of these raw materials keeping a few months in mind in addition to having MOU and contracts with the suppliers on a yearly and half-yearly basis.
In addition to the wide-ranging products, another unique aspect of Kajeco is providing a one-stop total solution to the customer. The foundry has the in-house facility to manufacture the casting from inception 'cocoon to silk'. As they are so well equipped they are not dependent on outsourcing which makes them outperform competitors in terms of deadlines, pricing, and flawless products. Customers provide samples or technical drawings to Kajeco Industries with their specifications, and they respond with the best solutions or modifications. The technical and R&D teams discuss the product's composition, final use, and more. On reaching a common understanding if pattern development is needed, the samples are given to Kajeco's pattern shop. Alternatively, if the customer provides Kajeco with patterns, the company casts samples. Once all parameters like dimensions, composition, finish, and more, have been checked the samples are provided to the customer for approval. On approval by the customer, the product is taken up for production. It is Kajeco Industries' motto to provide 100 percent satisfaction to the customers in terms of quality and delivery timings.
The Differentiating Factors
Kajeco Industries produces castings for various industries, for example, engineering, rail, agriculture, automobiles, and construction. Diversity places Kajeco on an advantageous edge over manufacturers. Well-versed in metallurgy has helped to manufacture castings in several specifications, metals, and compositions. In Northern India, Kajeco Industries is one of the top producers of Grey and Ductile iron castings. For the production of Grey and Ductile iron castings, Kajeco Industries adheres to a strict set of guidelines. Before taking command, all foundry employees receive training on the procedures and inspections. “We have a personalized handbook especially designed looking into our production process. All the workmen are provided with the handbook and have to adhere to the procedure”, further adds Sanjay Agarwal, COO and Partner, Kajeco Industries.
Kajeco Is Known For Ethics And Reliability, The Trust We Have Built With Our Vendors, Customers, & Employees Has Earned The Reputation Of An Impeccable Partner
All raw materials are initially examined and tested in the company’s lab on approval of quality the raw material is sent to stores, the store manager issues the raw materials for production. The metal is tested twice firstly when in a molten state using online sensors, and secondly in the physical and chemical labs manually by chemists. Before pouring metal, floor supervisors continuously inspect and test the strength of the moulds. After knock-out and shot blasting these castings are submitted for further processing, such as grinding, visual inspection, machining, painting as per the customer's order. With a distinguished reputation in the market, and leading-edge systems in place, Kajeco Industries continues to be a revolutionary contributor to India’s castings industry with the promise of bigger achievements in the coming years.