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Frequently Asked Questions

Customer Support & Guidance

An ISO 9001:2015 certified shell-moulding foundry for critical castings, complex metallurgy, and precision-machined components in CI, SG, ADI, and CGI—ideal for hydraulics, material handling, marine, agriculture, and renewables.

Located in Kagal–Hatkanangale Five-Star MIDC, Kolhapur (Maharashtra)—India’s renowned foundry hub—our plant is strategically close to major ports and airports, ensuring fast and cost-effective domestic and export logistics.

We have an installed production capacity of over 350 MT per month, scalable toward 600+ MT per month through an additional Inductotherm IGBT furnace line. Both batch and mass production programs are efficiently managed.

What component sizes and weights can you handle? We produce shell-moulded castings ranging from approximately 0.10 kg to 40 kg, maintaining consistent wall thickness and clean internal cavities.

Shell casting dimensional accuracy ranges from CT8 to CT10, depending on geometry. Critical tolerances are mutually agreed at RFQ stage. Machined parts meet drawing-level accuracy on sealing faces and ports.

Shell-moulded surfaces have excellent finish, allowing reduced machining allowance. Final roughness (Ra) values are achieved as per customer drawings and functional requirements.

Tooling lead time typically ranges between 4 to 8 weeks from drawing approval, depending on part complexity. Ownership and maintenance terms are mutually agreed and defined in the purchase order or tooling agreement.

Yes, we support both prototype and production tooling. Pilot runs and PPAP/FAI samples are made using the same process to ensure production consistency.

All patterns and gauges are properly tagged, inventoried, access-controlled, and insured. No third-party access is permitted without written authorization.

Yes, we deliver fully machined, ready-to-assemble components using CNC and VMC machining centres. All critical features are validated to ensure dimensional and functional reliability.

Yes, hydraulic castings are validated up to 400 bar pressure, with endurance testing up to 2 million impulse cycles as per customer specifications at customer end. We don’t have in house facility.

We have a fully equipped spectrometer, hardness testers, metallography setup, borescope for internal inspection, sand-testing lab, and dimensional inspection facilities. Third-party NDT (DP/MPI/RG) is conducted through approved labs when required.

We follow structured 8D and root cause analysis methods, implement containment actions immediately, and close issues with documented corrective and preventive actions.

All instruments are calibrated as per an internal plan traceable to national and international standards, ensuring accuracy and reliability.

Yes, we welcome customer audits with prior appointment. We also provide PPAP, Control Plan, and FMEA support for automotive and hydraulic programs as needed.

We require 2D/3D drawings (STEP, IGES, DWG, or PDF), material grade, quantity, machining or testing requirements, and delivery terms. Quotations are generally submitted within three working days.

Base metal costs are linked to the MMR scrap index, with a ±3% variation clause to maintain transparency and fairness. Any major alloy or scrap changes are handled through a mutually agreed revision mechanism.

Payment and delivery terms are finalized during order placement and aligned with EXW, FOB, or CIF Incoterms as applicable.

We accept STEP, IGES, DWG, and PDF drawings, and support Excel or PDF BOMs. Our system can integrate with most CAD data formats.

All customer data is stored securely with controlled access. Projects are shared only on a need-to-know basis. NDAs are executed when required, and old data is archived or deleted per our data-retention policy.

No, we never share customer drawings, 3D data, test results, or photos without written consent. Factory photography is strictly restricted.

Warranty and replacements are handled per the purchase order terms. Any validated defect is addressed through an 8D corrective-action process with documented resolution.

We provide immediate containment, issue a preliminary root-cause report within 48–72 hours, and a final 8D report within the mutually agreed timeframe.

Our shell-moulding process ensures clean internal galleries, tight tolerances, and consistent sealing surfaces. Pressure and impulse tests validate hydraulic reliability under extreme conditions.

Yes, we offer reverse engineering and import substitution under NDA. Each localized component undergoes material validation and functional testing to match or exceed original standards.

We practice energy-efficient melting, metal recycling, and sand reclamation. Our operations comply with all environmental, health, and safety norms. We continuously improve to reduce waste and emissions.

Yes, plant visits and audits are welcome with prior appointment. Visitors must follow EHS and confidentiality protocols. Photography inside the facility is restricted.

We supply to leading OEMs in India and regularly export to the UK, USA, Germany, China and Switzerland with full export-grade documentation, packing, and compliance.

Yes, EnGenius Metals is ISO 9001:2015 certified. Our systems ensure traceable, audited processes from melting to dispatch.

Grey Iron (CI): FG-200, FG-250, FG-300

SG Iron: 400/12, 500/7, 700/7, 400/22

ADI and CGI; SiMo

Yes, our team assists in design for manufacturability through gating and riser design review, wall-thickness balancing, core design, yield improvement, and simulation-based performance validation.

Shell moulding offers tight tolerances, clean cavities, superior dimensional repeatability, and lower machining allowance—making it ideal for high-pressure hydraulic and precision components.

We use custom resin-coated sand blends (locally sourced and imported), controlled baking parameters, interlocking core assemblies, and borescope inspection to verify internal cavity integrity.

We use Inductotherm IGBT furnaces with precise charge control. Each heat is spectro-tested and documented to maintain uniform composition and properties.

Every melt undergoes spectrometer analysis, microstructure evaluation, sand-lab testing, and statistical process control to maintain metallurgical consistency across batches.

Yes, through approved partners. Each treated batch is traceable to its original heat record and linked with testing documentation.

We provide FAI/ISIR and control plans as per customer requirement. All critical dimensions are checked with calibrated gauges. CMM or 3D scan reports can be provided on request.

We maintain week-wise coding systems for every production batch, linked to its melt, inspection, and dispatch records. This ensures complete traceability from raw material receipt to final delivery, integrated within our ERP.

We follow ISO 9001:2015 QMS and adhere to IS, EN, and ASTM material standards as per customer drawings. Customer-specific requirements are reviewed and implemented when applicable.

We offer powder coating, zinc/manganese phosphating, trivalent zinc plating, and hot-dip galvanizing (HDG) through validated partners. Coating certifications are provided upon request.

We use VCI wraps, anti-corrosion oils, desiccants, humidity indicators, and ISPM-15 export-grade wooden crates. Each box is labelled with part number, PO number, and heat/batch codes.

All castings carry unique identification marks or gate IDs as per drawing. Shipping labels include week-wise production codes, heat numbers, and quantity details.

Prototypes: 4–8 weeks after drawing approval

Serial (domestic): 4–6 weeks

Serial (export): 6–8 weeks Lead time may vary based on machining, coating, and logistics.

MOQ depends on part complexity, tooling size, and setup requirements. We also cater to low-volume pilot and PPAP lots.

Yes, we execute LTAs with scheduled releases to support stable pricing, efficient production planning, and secured raw material availability.

All shipments are packed in ISPM-15 compliant wooden crates or pallets with VCI protection, desiccants, corner protectors, and shock labels. Every package carries corresponding week codes and batch traceability.

We supply the invoice, packing list, certificate of origin (if required), inspection/test certificates, and compliance documents as per order terms.

We maintain advance production planning with buffer capacity, monitor vendor-managed operations like coatings or heat treatment, and issue early alerts in case of any potential delay.

Precision machining fixtures ensure correct thread depths and port alignment. All sealing faces are gauged, and leak tests are performed per customer specifications.

Through optimized gating and riser design, simulation-based validation, metal filtration (where required), and borescope checks on internal cavities.

We eliminate cold shuts, misruns, core shift, porosity, and shrinkage through design optimization, proper venting, and controlled moulding parameters.

Share your RFQ with CAD models and specifications → attend a DFM alignment meeting → receive a quotation → tooling plan → pilot/PPAP approval → production ramp-up. We align with your APQP process if required.

Commercial & Operations: Avinash Deomore +91 9595959000

Production & Development: Dinkar Gaikwad (+91 9823022306)

Email: avinash@engeniusmetals.com | gaikwad@engeniusmetals.com | engeniusmetals@gmail.com