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FACTORY VIEW
MAIN VIEW ADMINISTRATIVE BLOCK

Midland Galvanising Products Ltd | factory main view PLANT VIEW GALVANISING LINE Midland Galvanising Products Ltd | factory administrative block STATE OF ART GALVANISING PLANT WITH FOLLOWING FEATURES:
-Highest Line speed.
-Produces widest (1200mm) and thickest (0.40mm) sheets.
-Operates a Non – Oxidation Furnace.
-Most sophisticated galvanizing technology in the industry.
-Best quality finished products for the end user.


CHROMIC COATER COOLING PENDENTS Midland Galvanising Products Ltd | factory plant view

HYDROGEN AND NITROGEN SUPPLYREVERSE OSMOSIS PLANT Midland Galvanising Products Ltd | REVERSE OSMOSIS PLANT

SHOP FLOOR FINISHED GOODS STORAGE Midland Galvanising Products Ltd | hydrogen and nitrogen supply



Our Process
Three Stage Process
1 ENTRY STAGE

Our Process | Midland Galvanising Products Ltd
- Consists of Pay of Reel which supplies the sheet continuously to the process.
- Welding Unit to join the tail end and head of each the fresh coil.
- Pinch rolls to thread the sheet forward while welding or jogging.
- Bridle rolls to keep the sheet in tension for smooth operation
- Most importantly, the Loopier, also referred as Accumulator, to maintain the continuity in      line processing.
- Steering rolls to maintain the sheet in centre line.
- Degreasing unit to clean the oils and coolant from the sheet prior to coating

Degreasing consists of 3 sections:
- Alkali tank
- Hot rinsing tank
- Dryer unit.

• Alkali tank used to clean the oil and greases by alkali wash
• KOH mainly used as alkali.
• Pairs of brush rolls scrub the sheet properly for cleaning.
• Hot rinsing done to clean through hot water.
• Dryer to dry the sheet completely of moisture. 2 PROCESS STAGE
Our Process Stage 2 | Midland Galvanising Products Ltd
•Entry sheet into the Process Stage
•Process Stage starts with the Non – Oxidation Furnace. (This is the key equipment in the process stage)

The Non Oxidation Furnace is comprised of the following Zones:

– PHF (Pre Heat Furnace)
– RTF (Radiant Tube Furnace)
– SF (Soaking Furnace)
– JCZ (Jet Cooler Zone)
– CALM ZONE
– HBR (Hot Briddle Roll Zone) ANNEALING SECTION IMPORTANT NOTE The first step towards preparing steel for use is to anneal it.
Annealing is a process by which the properties of steel are enhanced to meet machinability requirements. Annealing is a process of heating the steel slightly above the critical temperature of steel (723 degrees Centigrade) and allowing it to cool down very slowly.

The following are some of the advantages of annealing.
1. Softens the steel.
2. Enhances and improves the machinability of steel.
3. Increases the ductility of steel.
4. Enhances the toughness of steel.
5. Improves the homogeneity in steel.
6. The grain size of the steel is refined a lot by annealing .
7. Prepares the steel for further heat treatment.

However, some of the alloys contained in steel, such as manganese, silicon, aluminium, and chromium may result in a thin layer of oxides on the steel surface during the annealing operation preceding the dipping in the Zinc Pot.

The presence of these layer of oxides harms the zinc "wettability" and thus the quality of the coating and ultimately the quality of galvanising. It is well known fact that oxidation (presence of oxygen) causes metals to rust

These phenomena of oxidization are due to diffusion processes of the highly oxidisable alloy components towards the steel strip surface where they can oxidize in the ordinary furnaces.

OUR NON OXIDATION FURNACE PROFFERS A SOLUTION TO THIS PROBLEM BY SUBJECTING THE STEEL STRIPS SURFACE TO TEMPERATURES AND ATMOSPHERE CONDITIONS FIT FOR QUICKLY AND DEEPLY OXIDISING THE ALLOY COMPONENTS IN THE DIRECT FIRED PRE HEAT FURNACE. (PHF)

• PHF
– Here heating is done by direct burner firing flame on the sheet
– Gas with calculated amount of oxygen supplied for complete combustion as extra oxygen can spoil the quality of coating.
– Used to further clean the sheet from oil and coolants.
– Elevate the temperature of the sheet to annealing or re crystallization temperature of steel.

• SOAKING ZONE
– Here, the sheet is held at a constant temperature for some time
– Soaking is done at a constant temperature for refining of the grain structure.
– Shown in graph.

• JET COOLING SECTION
– Cooling starts from here.
– Provided with fans and heat exchanger to cool the sheet
– Use the fume of inside furnace and circulate through the heat exchanger unit.
– Fan force the cooled gas to the sheet to carry the cooling action. Inner stage

• CALM ZONE
– Here the sheet is passed undisturbed by any turbulence
– This is very important for the quality of sheet.
– Protective gases N2H2 supplied through this zone. These protective gases provide the environment to avoid oxidation of the sheet and excellent quality of coating

• HBR SECTION
– This is termed as exit section of furnace.
– Provision of two rolls called Hot Bridle Rolls.
– Deflects the sheet into the Pot for coating after heat treatment from the furnace.

ZINC POT SECTION
– Coating kettle is loaded with the molten zinc to carry out the hot dip coating process.
– Consists of dipped roll called Sinker roll to deflect the sheet out after coating.
– Has jet wiper unit from both sides to control the coating.
– Jet wiper wipes extra coating off the sheet by utilizing jet of the air.
– Coating can be controlled by the amount and pressure of air.

COOLING HOOD SECTION
– Cooling is done after coating.
– This section provides towers with several cooling ducts to assist in bringing down the sheet temperature.

QUENCH TANK SECTION
– It is desirable to have sheet temperature at room temperature.
– Further cooling to room temperature is therefore done by a special kind of water
    i.e. De-mineralized water (Dm).
– This helps in improving surface luster also.

SKIN PASS MILL & LEVELLER SECTION
– Skin Pass Mill and Leveller sections provide shape control.
– Both work together in giving perfect shape to the sheet by removing buckling, waviness and dents.
3 EXIT STAGE
Exit Stage

CHROMATING SECTION
Passivation is an important activity that takes place in chromating section. Passivation is designed to further prolong the life of galvanized sheets by creating a barrier between the finished sheets and the environment.
Passivation includes the following processes:
– Chemical coating
– Chromating
– Phosphating
– Acrylic base application

DRYING SECTION
• Drying is a must after passivation.
• For optimum treatment the temperature of sheet is raised to 100°c - 110°c.

ACCUMULATOR SECTION
• After passivation, sheet passes through steering gear into the exit accumulator.
• Exit accumulator helps in maintaining the continuity of the production process at the time of coil cutting.
• It adjusts its position to provide enough time to start fresh coiling.
• The processed coil is taken out by coil car and can be sent for further processing as desired, for example, into colour coated sheets and for corrugation etc.



Galvanised Iron Roofing Sheets and Coils
Galvanised Iron Roofing Sheets and Coils- Plain And Embossed Finish

  • Galvanised Iron Roofing Sheets and Coils- Plain And Embossed Finish.
    The galvanised iron sheets are produced in a continuous hot dip coating line after heat treatment in the lpg gas fired non-oxidation furnace. The main processes are given as follows:
    • Strip cleaning section
      • Steel strip is cleaned in an alkali cleaning section
      • After rinsing with water, and drying, it passes through the non oxidation furnace
    • Heat treatment section
      • The cleaned strip is passed through the non oxidation furnace and heated to a range of 500°c to 700°c (500 to 550 for hard steel and 680 to 700 for soft steel, depending on customers requirement) for further removal of oil traces and reduction of iron oxide
      • The strip is closed controlled heat treated to get the desired mechanical properties and pre heated before dipping into the molten zinc bath
      • Pre heated strip is coated in the bath and the coated surface is wiped out through the special designed air wiping coating jets
      • The coated strip is forced cooled by air and then water quenched to bring down the strip temperature from 600°c to 50°c.
      • The strip is tensioned levelled to achieve the desired flatness.
      • After passivation, the sheets are either recoiled at Exit point, packaged and delivered to the consumer in coil form, or they are passed through automatic rotary shear to be cut as per required size and passed to corrugation section to give shape to the sheets before being packed and delivered to the consumer in bundles.
      • Galvanised iron sheets produced in non ox furnace line have better lustre; surface finish and have longer life compared to those produced on wet flux lines.

  • Pre painted galvanised iron roofing sheets and coils- plain and embossed finish
    • Oil colour coating is the continuous and highly automated process for colour coating coiled pre-galvanised sheet metal
    • The pre-galvanised coil of sheet metal is cleaned by hot detergent spray and then rinsed with warm/cold flowing water.
    • Chemical conversion with chrome and non chrome pre treatment is then applied, after which the sheet metal undergoes another round of rinsing in warm/cold water and dried thoroughly by hot air.
    • Application of primer coating is done and sheet is oven dried.
    • Application of thermoset acrylic/polyester/polyurethane coating is made as top coat in compliance with the standards of ecca (european coil coaters association).
    • Colour coated sheets are again oven dried and afterwards cooled by water spray, inspected for quality, recoiled and packaged for delivery to the con sumer in coil form, or they are passed through automatic rotary shear to be cut as per required size and passed to corrugation section to give shape to the sheets before being packed and delivered to the consumer in bundles.



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