Custom Manufacturing - Calmet
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CUSTOM MANUFACTURING

Calmet brings your ideas to life with high-quality casting and forging solutions tailored to your unique requirements. By integrating precision with personalization, Calmet transforms your perspective on production and design.

Even though the initial costs for custom manufacturing processes may be relatively higher, its ability to improve the production process and prevent waste leads to long-term cost savings, with the benefit of scalability taking advantage of rapid manufacturing processes and short lead times to create products when customers demand.

As a trusted partner in the manufacturing industry, we combine cutting-edge technology, skilled craftsmanship, and a commitment to excellence to deliver products that exceed expectations.

FROM CONCEPT TO COMPLETION

Our experts in various departments, especially in designing, care for your ideas and expectations from product and company. At Calmet, we work closely with you at every stage of the manufacturing process:

  • Design and Engineering: Collaborate with our experts and esign team to refine your ideas.
  • Material Selection: Choose the best materials for performance and cost-efficiency.
  • Production: Precision casting and forging using advanced techniques.
  • Quality Control: Comprehensive testing to required standards with no space for compromise.
  • On-Time Delivery: Reliable timelines to keep your project on track.

CAPABILITIES

Quality and Expertise

Calmet excels through specialized processes, adherence to industry standards, and continuous improvement initiatives, ensuring high-quality products.

Technological Capabilities

Advanced technology, Automation, and R&D enhance Manufacturing Efficiency, 3D Printing, Automation, and Data Analytics.

Cost Efficiency

Calmet focuses on controlling costs, optimizing resource utilization, and enhancing operational efficiency.

Sustainable Manufacturing

Emphasis on energy efficiency, waste management, resource conservation, and supply chain transparency helps reduce environmental impact. In-house machine shop, inspection, testing, and warehousing.

Supply Chain Management

Emphasis on energy efficiency, waste management, resource conservation, and supply chain transparency helps reduce environmental impact. In-house machine shop, inspection, testing, and warehousing.

CUSTOM MANUFACTURING

Pump Pedestal
Pump Pedestal
Iron Pump Housing
Iron Pump Housing
Steel Pump Housing
Steel Pump Housing
Alloy RF Filter Box Assembly
Alloy RF Filter Box Assembly
Bronze Flange
Bronze Flange
Piston Head
Piston Head

CASTING SOLUTIONS

We specialize in producing intricate and durable cast components for a wide range of industries. Our casting process includes:

FORGING EXPERTISE

Our forging services provide superior strength and reliability for critical applications. We offer:

Hot Forging

Ideal for large, complex components where high malleability is needed, ensuring excellent mechanical properties and grain structure. Commonly used in automotive, aerospace, and construction industries for producing parts like gears, crankshafts, and tools.

Cold Forging

Best for smaller components requiring tight tolerances, high strength, and superior surface finish without the need for additional machining. Suitable for automotive, electronics, and hardware industries, making parts like fasteners, bolts, and precision connectors.

MATERIALS

    • Carbon steels
    • Alloy steels
    • Iron
    • Aluminum
    • Brass and Bronze

SPECIAL SOLUTIONS:

High Precision Machining

We continually invest in efficient equipment and technology, allowing us to offer state-of-the-art services at competitive prices.

Our facilities have made significant investments in robotics to increase automation and efficiency with the latest generation Machining Centres, HMCs, VMCs, VTLs, and Special Purpose Machines

Real-time automation software provides instant access to planning, manufacturing, and data collection from the manufacturing floor.

With our expertise in the various alloys, we can make recommendations to improve the processing quality without sacrificing quality and performance.

Component Assembly

We are an extension of the OEM production for several large corporations. We not only partner with our customers in supplying castings and components but also provide assemblies and sub-assemblies from our facilities.

Our experienced team assembles parts through several automated and modern welding techniques such as fusion welding, pressure welding, brazing, and soldering. Using the correct techniques results in saving our customers money and time.

Our cross-trained staff combined with work cells create a flexible welding assembly environment that can support a variety of fulfillment options with optimum methods depending upon functionality.

Design & Engineering

Engineering design is the process of finding a solution based on objectives, constraints, prototyping, testing, and evaluation.

Our experienced team of engineers assists with the design phase and prototyping to ensure that samples and materials deliver products with the required features and specifications for customers.

We work with customers to resolve metal issues and ensure proper design and construction. Brainstorming is an essential part of our design and development programs before a final solution is arrived at.

Our workshop provides samples with different dimensions, materials, and specifications to meet the different requirements of our customers.

Specialized Treatment

We offer all sorts of treatments including heat treatment, normalizing, quenching, tempering, nitriding, carburization, annealing, induction hardening, burnishing, and others.

We can also treat the surface of the products to achieve better properties or just for aesthetic reasons.

The company has expertise in sandblasting, painting, and electroplating for special finishes by zinc, nickel, Chrome, etc. in addition to hot dip galvanizing and thermal spray metalizing.

Calmet regularly reviews the Quality Key Performance Indicators to compare the performance against the preset standards for the best outcomes from treatments.

3-STAGE QUALITY CONTROL PROCESS & INSPECTION:

  • The quality assessment process with special testing equipment ensures only the finest products reach the buyers and customers.
  • Here at Calmet, all the employees receive in-depth trainning, guidance, and potential elevation from the mentors or immediate managers who are always observant of the continuous progress and Lean philosophy (Kaizen).
  • This intensive process ensures that the employees are well-equipped with the knowledge and work techniques as per their role in the organization.
  • This task and its needed output will be perfect if performed with thorough understanding. It's crucial for our quality department to look in and stringently advise on any necessary changes to be made to ensure the scope of errors is minimized or removed.

Raw material

  1. Immersion Spectrometer with 24 Elements
  2. Sand Testing Facilities
  3. Universal Tensile Testing Machine
  4. Image Analyzer
  5. On-line Mould checking Facilities

Dimensional

  1. Coordinate Measuring Machine (CNC-CMM) – Range: 1m x 1m
  2. Linear Measuring Machine (LMM) – Range: 1m x 1m
  3. Profile Projector
  4. Digital Height Gauge – Range: 1m
  5. All kinds of Inspection Gauges & Instruments

Specialized

  1. Non-Destructive Test (X-ray)
  2. Ultrasonic Test
  3. Dye Penetrant Test
  4. Hydro Test
  5. Millipore Cleanliness Test
  6. Static Balancing

WHY CALMET?

To maintain a competitive advantage in the steel casting industry, Calmet always evaluates its unique strengths and value proposition. Here are some factors to consider while analyzing the competitive advantage that Calmet offers:

Quality and Expertise

      • Expertise and experience in specialized casting processes, such as investment casting or sand casting, provide an edge over competitors.
      • Certification of quality standards, adherence to industry-specific regulations, and continuous improvement initiatives have immensely helped Calmet and its customers.

Technological Capabilities

      • Cutting-edge technology and equipment that Calmet employs significantly enhance the efficiency and quality of the manufacturing process.
      • Investment in advanced machinery, automation, and digital tools can lead to cost savings, faster production cycles, and better casting outcomes.
      • Strong R&D capabilities to develop new alloys and casting methods can differentiate a firm from its competitors and attract customers seeking innovative solutions.

Supply Chain Management

      • Efficient supply chain management, including sourcing raw materials, logistics, and inventory control, can optimize costs and lead times.
      • Building reliable relationships with suppliers and ensuring a steady supply of high-quality raw materials can give the firm an advantage in meeting customer demands promptly.
      • Implementing just-in-time manufacturing practices and adopting lean principles can enhance competitiveness by minimizing waste and maximizing efficiency.

Customer Relationships

      • Developing strong customer relationships and providing exceptional customer service is a way of life at Calmet. Every employee is dedicated to this philosophy.
      • Understanding customer requirements, providing technical support, and offering customized solutions have helped us stand ahead of competitors.
      • Regular communication and engagement with customers to gather feedback and address concerns helps in continuous improvement and maintaining a competitive edge.

Cost Efficiency

      • To remain competitive, controlling costs throughout the manufacturing process is crucial at Calmet.
      • Implementing cost-effective production strategies, optimizing resource utilization, and managing overhead expenses helps minimize costs.
      • Continuous evaluation of cost drivers and exploring opportunities to enhance operational efficiency contribute to long-term profitability and competitive advantage.

Sustainable Manufacturing

Sustainable manufacturing focuses on minimizing the environmental impact and maximizing resource efficiency throughout the manufacturing process using the below commonly used techniques:

      • Energy Efficiency: Implementing energy-efficient measures like optimizing furnace operations, adopting energy-saving technologies, and utilizing renewable energy sources.
      • Waste Management: Implementing effective waste management techniques, including recycling and reusing materials, reducing waste generation, and implementing proper disposal methods.
      • Resource Conservation: Employing techniques to reduce water consumption, optimize raw material usage, and minimize emissions.
      • Supply Chain Transparency: Ensuring transparency and responsibility in the supply chain, such as sourcing materials from sustainable suppliers and monitoring the social and environmental impacts of the supply chain.

New Technologies

Innovative technologies can revolutionize the steel casting manufacturing industry, enhancing efficiency, quality, and customization capabilities. Some notable advancements at Calmet include:

      • 3D Printing: The introduction of 3D printing in steel casting allows for complex shapes and design optimization, reducing material waste and lead times while enabling customization.
      • Automation and Robotics:Integration of automation and robotics streamlines production processes, enhances precision, improves safety, and increases productivity.
      • Data Analytics and AI: Leveraging data analytics and artificial intelligence can enhance quality control, predictive maintenance, and process optimization, resulting in improved efficiency, reduced costs, and enhanced product quality.
      • Augmented Reality (AR): AR technology can assist in training, remote maintenance and repair, and real-time quality assurance, improving operational efficiency and reducing downtime.

Industry Regulations

The steel-casting manufacturing industry is subject to various regulations, which ensure safety, quality, and environmental compliance. Key regulations include:

      • Workplace Safety: Regulations governing occupational health and safety, including maintaining safe working conditions, providing proper protective equipment, and adhering to workforce safety standards.
      • Environmental Compliance: Regulations related to emissions control, waste management, pollution prevention, and resource conservation to mitigate the environmental impact of operations.
      • Quality Standards: Compliance with quality certifications such as ISO 9001 ensures that products and processes meet internationally recognized quality standards, fostering customer trust.
      • Supply Chain Traceability: Regulations and standards may require documentation and traceability of raw materials, ensuring responsible sourcing and avoiding materials with ethical or environmental concerns.

INDUSTRIES