meta copper
TRANSCRIPT
META COPPER & ALLOYS LTDMETA COPPER & ALLOYS LTD
Meta copper and alloys limited (formally known as Meta Strips Limited) is state of art
world class manufacturing facilities for Copper and Copper Alloys rolled flat products.
It was incorporated on 11/03/1997, as a 100% Export Oriented Unit, a green field
venture with an initial capacity of 30,000 tons per annum to produce Copper and
Copper based Alloys strips, sheets and foils is a modern mill manufacturing copper and
alloy (brass) roiled flat products. Accredited with the ISO 9001 and ISO 14001
certifications, META is currently serving customers from over 43 countries around the
world. Meta is focused on creating and delivering sustainable competitive advantage to
its customers. This is achieved through our 5 point quality excellence program and is
embodied in META STAR –the corporate logo, to understand customer’s requirements
in this entirety .to be cost effective ,to deliver according to customer’s ability to
receive ,to invest in man and machines consistently and to add exceptional overall value
to society.
Located at the port town of mormugao on the western coast of India, Meta is efficiently
connected to all the major seaports in the world .As an export-oriented unit; Meta
enjoys a tax-free working environment, which adds to its competitive advantage.
Meta uses state of art machines that have been carefully selected from a band of
machine builders of international repute. These machines provide superior tolerance on
critical parameters and thus translate customer’s requirements into delivered products.
A team of experienced professionals with expertise in non-ferrous metallurgy manages
Meta. Professionals are involved in each level and are characterized by the in depth
knowledge of the process and high sensitivity to customer’s requirements .skills up
gradation and human resource development is priority activity in Meta.
Meta believes the quality of the delivered product depends largely on the input quality
and hence uses extensive feed forward control methods to ensure every gram of raw
material used in the production exceeds international standards.
Manufacturing is done under a controlled environment. The process data is recorded,
monitored and preserved through Baan ERP system which guarantees 100% adherence
to customers’ specifications at all levels and ensures traceability to the raw material
supplies. Vertical slab casting, jet flotation annealing, bell annealing, chamber annealing
precision rolling with automatic gauge controllers ,laser pin hole detection, automated
surface detect eliminating system ,semi automatic packaging line etc are some of unique
practices in Meta.
This man, machines and fine raw materials combination along with locational
advantage
Makes meta a cost effective and quality supplier of copper and copper alloys rolled flat
products .products are easily available in over 45 countries through an effective supply
chain system .our quality assurance and technical support team is alert to every
customer need and is in the relentless pursuit of maximizing the productivity of our
customers .
The Chairman & Managing Director of the Company Mr. Sushil S. Khaitan with his
vision, long outstanding and proven expertise in the Copper and Copper Alloy Semis is
leading the group. The team of Meta Strips Limited consists a workforce of 500
motivated employees joined from different organizations with well-qualified
professionals of diverse background and experienced technicians.
The company has acquired 60 acres of land in village Sancoale and Cortalim on which
the plant is spread over with two unique rain-harvesting tanks.
PRODUCT RANGE
Full Widths / Slit Widths:
Coils with internal diameter from 80 mm to 500 mm, thickness from 0.10 mm to 5.00
mm and widths from 20 mm to 400 mm.
Sheets:
In widths of 400 mm max., lengths from 1000 mm to 3000 mm and thickness from 0.15
mm to 2 mm.
Traverse Wound Coils:
Brass Strips of 10 mm to 50 mm width and thickness of 0.20 mm to 2.00 mm, wound on
300/400 mm, internal diameter cores up to a maximum weight of 2 MT.
Hardness range:
Soft (O) up to spring hard (SpH), for all above mentioned products.
PRODUCT APPLICATIONS
AUTOMOTIVE
Meta copper and alloys Limited is a major supplier to the automotive industry in India.
They comply ISO 9001/2000 and ISO14001/2005 standards.
The excellent properties of copper and copper alloys make these products preferred
choices for the automotive manufacturers when it comes to features such as corrosion
resistance, durability, heat transfer, electronics, welding ability, and electrical
conductivity.
Automotive Connectors
We supply copper and brass for electrical and electronic connectors and interconnection
systems. Our customers benefit from the tight tolerances, which is vital for this
application. We present new technology opportunities for cost-effective solutions.
Radiators & Heat Exchangers
Copper and brass with excellent conductivity, formability and solder ability are the best
choices for heat exchangers. Our focus is to develop a cost effective high-quality thin
strip.
CONSUMER PRODUCTS
Our products are used for zippers, buttons and hose coupling. LME A grade copper
cathodes used in this application ensure good workability and durability.
ELECTRICAL
Our copper and copper-based alloys are widely used in different electrical applications,
such as energy, power and transportation systems. Copper provides the electrical and
thermal conductivity that ensures reliability and high performance in a wide variety of
products. We provide new technology opportunities for cost-effective, high performance
material solutions. Our unique process technologies enable us to provide local supply to
meet your most demanding requirements.
We maintain key features like superior electrical conductivity, bending ability,
consistency and stamping ability to match industry specific requirement. This product is
available in pancake and traverse wound form.
Transformer Strips
Transformer strips are used in electric distribution and power transformers. Our
overall manufacturing process encompasses all stages from hot milling to deburred and
slitted edges.
Soft annealing and excellent ductility of copper enables superb coiling properties; strips
will bend easily along rolling direction. The intermediate surface brushing guarantees a
clean surface.
Strip for Electrical Devices
Copper and copper alloys provide the electrical and thermal conductivity that insures
reliability and high performance.
Recommended alloys for use in the Electrical Industry are copper C110, alloys C260
and C268.
Heating, ventilation, air conditioning and refrigeration
In heat transfer applications like air conditioners, refrigerators and heating unit the
excellent conductivity of copper helps in designing energy efficient equipment and
systems in a cost effective manner.
ORDNANCE
Our product finds its use to manufacture cups, discs and ordnance strips for Military
and commercial markets. The strips are engineered with tight tolerances, deep drawing
properties with uniform grain across sections.
VALUE ADDED PRODUCTS
VALUE ADDED PRODUCTS
Copper Foils
(0.035mm/0.00137 inches
onwards
For Radiator Fins/ Cable Tapes
Cups and Discs For Defense
Brass/ Copper Circles For Electrical Geysers / General
C12000 De-Oxidized Low Phosphorous Copper
C11300 Silver -bearing Tough Pitch Copper
CuZn0.5 Zinc bearing Copper
CURRENT EXPORT STATUS
30%
25%
10%20%
15%
Plant layout
PRODUCTION PROCESS
MELTING AND CASTING
HOT ROLLING MILL
RE-HEATING OF SLABS
FACE MILLING
INTERMEDIATE ROLLING MILL
ANNEALING
EDGE TRIMMING & PICKLING
COLD FINISHING MILL I & II
DEGREASING ANNEALING & PICKLING
SLITTER
PACKING
RAW MATERIAL
FINISHED GOODS
BAY - 1
BAY- 2
PRODUCTION PROCESS
BAY I: A detail overview on production process of
Bay-I is given below.
RAW MATERIAL
Brass is an alloy of Copper and Zinc. Raw materials for manufacturing brass are
Copper Cathodes, Copper Granules, Zinc Ingots and the Brass scrap.
QUALITY OF RAW MATERIAL
The raw materials that would be used for our product should be 99% and more pure.
Other wise the quality of the end product will get affected. The raw materials would
be Imported or made available from Indian markets.
In India Hindustan Copper, Birla Copper and Sterlite Industries are the major
Refineries and Smelters who Manufacture Copper Cathodes from Copper ore up to
the purity level of 99.9%.
Copper Cables are world wide replaced by fibre optic cables and these Copper Cables
contain Copper with above 99% purity. This is being sourced globally as well as from
Indian market. The scrap Copper Cable is being used in all the developed and highly
environment conscious countries for the production of Copper and Copper alloys.
Zinc Ingots are the purest form of Zinc and is available in India and all over the
world. Brass Scrap is the material, which is generated during the process in the form
of Edge and end cuttings.
MELTING & CASTING
The feed that is prepared is melted in the Electric induction furnace at 1200°C. This
furnace is of two types one is channel induction furnace and the other one is the
coreless induction furnace. The function of this 2 furnace is to melt the raw material.
SLAB RE-HEATING FURNACE
Once the raw material is melted in the induction furnace, the melted metal is
transferred to the holding furnace, where the temperature of the melted metal is
maintained for getting the uniformity. The Molten metal from the holding furnace is
transferred and poured into the vertical caster, where the mould is casted into slabs of
425x220x9000 mm length. Once these slabs are made they goes to the cold saw
section were the end bits of the slabs are cut with the help of saw and these slabs are
sent to the re-heating for further procedure. The slabs are fed in the reheating furnace,
with the help of where the slabs are preheated up to 850°C with LPG as fuel. The
control system incorporated also ensures that the slabs are heated uniformly.
HOT ROLLING MILL
The plant has been using hot rolling process to produce high quality homogenized
strips. The hot slabs from reheating furnace are sent to hot rolling mill. These slabs
are thereafter hot rolled in the form of coils.
FACE MILLING LINE
During the hot rolling process oxidization of the coils takes place, in order to remove
this, face milling is done. In this process the oxidized layer will be removed by
milling on both the surface and edges of the coils. The scrap generated will be reuse to
melting furnace.
INTERMEDIATE ROLLING
In the Intermediate rolling mill the coil is cold rolled in 4 High Rolling mills. In this
process the coil is rolled up to 1.8mm. During this process heat is generated and
emulsions are used to control the raise temperature.
CHAMBER ANNEALING FURNACE
While undergoing different process, the coil’s hardness, stress increases and to reduce
the hardness annealing is done. Annealing makes the coil softer and reduces the
hardness. In this furnace the coil is heated up-to required temperature, so that the
required hardness, stress and other physical properties of the coil are achieved. For
this purpose chamber annealing furnace and continuous Jet Floatation Annealing
Furnace are incorporated in the plant.
BAY 2: A detail overview on production process of
Bay-II is given below.
EDGE TRIMMING & PICKLING LINE
Edge trimming and pickling, of the coils is done in order to trim of the cracked edges
of the coil and also to clean the surface of the coil in order to obtain the shine of the
metal. The surfaces of the coils are cleaned with the acid with 10% conurbation.
COLD ROLLING
In this process the strip thickness is reduced as per the requirement of the customer.
DEGREASING, ANNEALING & PICKLING [DAP]
ANNEALING Furnace is Jet Floatation, where the strips float in the hot air for
scratch free finish and also to make the coils softer. DEGREASING is done to clean
the surface of the coils. These are coils are cleaned with the help of diluted acid and
Alkali degreasing. After completing annealing and degreasing, PICKLING is done to
obtain the shine of the coils. While undergoing this process the hardness of the coils is
maintained as per the requirement of the customers.
TENSION LEVELING LINE
Tension leveling is done to correct the strips flatness. During this process the excess
stress of the coils is removed and also the make the strips flat, a stretch leveler is
provided. This stretch leveler is also equipped with squeegee rolls to remove rolling
oil, dirt from the strips surface.
SLITTING & CUT TO LENGTH
In this process, the processed strip or foil is then slitted as per the customer’s
requirement on the slitting lines.
PACKING & DESPATCH SECTION
As per MCAL standard and Customer Specification packing is generally done for the finished
goods with almost care. For export either Wooden Box packs or wooden pallet packing been
done. Quality woods are being used for export as per standard. Newly introduced treated
wood pallets are also being used. In the case of country regulations fumigations also been
carried out. The standard packing criteria for DTA and Export packing detail is enclosed
herewith for ready reference. The dispatch section is mainly responsible for dispatch of
finished goods, maintenance of stock of finished goods, staffing of commercially cleared
order in container or trucks and safe custody of finished stock. Material handling & Container
staffing were to be observed for export order execution. Cross verifications of weight in
weighbridge is also to be observed for total understanding of the process.
META COPPER & ALLOYS LTD
Verna Industrial Estates
Roll No: 3850
Class: Fy BBA
Instruments used to Measure Pollution
META COPPER AND ALLOYS LIMITED
Sr. No. ProcessCharacteristics to be checked
Measuring Instruments
1Raw Material Inspection
Purity Spectro Analyzer
Surface quality Visual
2 Melting & Casting
Charge Quantity Weighing Scale
Temperature Temp. Stick
Chemical Composition
Spectro Analyzer
3 Slab Saw Appearance Visual
4 Re-HeatingTemperature Thermocouple
Soaking Duration RHF log sheet
5 Hot Rolling
Temperature Pyrometer
Thickness Micrometer
Width Measuring Tape
Surface Visual
6 MillingSurface Visual
Thickness Micrometer
7Breaking (1 st Cold Rolling)
Surface Visual
Thickness Micrometer & Vollmer
Width Measuring Tape
8
Annealing
Bell AnnealingTemperature Thermocouple
Soaking Cycle PID Control
Continuous Annealing
Temperature Thermo Couple
Speed Speed Controller
On line Inspection Metallurgist
Surface Visual
Width Measuring Tape
ThicknessVollmer gauge, Micrometer
Physical & Mechanical Test
UTM, Hardness Tester Etc.
9 Edge Trimming Width Measuring Tape
10 Pickling
Surface Visual
Width Measuring Tape
Thickness Micrometer
11 Tension Leveler Flatness I value
12Slitting/cut to length/final inspection
Surface Visual
Physical & Mechanical Test
UTM, Hardness Tester Etc.
Inner & Outer Dia Measuring Tape
WeightWeighing Scale / Weight Chart
Surface Visual
DimensionsMicrometer / Vernier / Measuring Tape
Physical & Mechanical Test
UTM, Hardness Tester Etc.
13 Packing Marking & Packing As Per Customer Requirement
The Environmental Care
We believe that Natural resources like fresh water, clean air and vegetation provide
sustenance and a foundation for social and economic development.
We have supported this by not only voluntarily incorporating State of the Art
Technologyfor taking care of its polluting sources but also by implementing the ISO
14001:2004EMS. We intend to Protect and conserve the quality of air, land, water and
other resources, while fostering economic development & a healthy and safe work
environment. To validate its support to resource conservation, MCAL has adopted the
practice o f rainwater harvesting to meet its water requirements
The company also practices a zero discharge policy. Effluent is treated & reused in
process/irrigation. ZnO and dross is filtered from emissions & molt respectively.
Hazardous waste like used oil, sludge, dross and ZnO are dealt by CPCB/MOEF
authorized recyclers.
MCAL has acknowledged its environmental obligations by operating over & above the
requirements of the Consent to Operate under both the Water (Prevention and Control
of Pollution) Act, 1974 and the Air (Prevention and Control of Pollution) Act, 1981 , as
well as the Authorization of Hazardous Wastes Management & The Registration of
Recyclers under the Hazardous Wastes (Management and Handling) Rules, 2003.
Also, as required under the Environment Protection Act 1986 an Environmental
Statement is submitted at the end of every financial year thus facilitating comprehensive
look at its industrial operations, which further facilitates understanding of material
flows and focus on areas where waste reduction and consequently savings in input costs
is possible.
MANUFACTURING RANGE
Our products have the benefit of technological collaboration and meet international quality standards. The state-of-art equipment we use was hand picked from some of the leading equipment manufacturers around the globe. The technology adopted for slab casting; hot rolling; precision cold rolling help in achieving high standards and consistent production.
The automated system used for Laser based Pin Hole Detection, Mass flow AGC, Auto slow down and Auto shape correction, enables high quality products that meet stringent international quality parameters necessary in the Connector, Radiator, Defense and Electrical Industries.
META 'S COPPER AND BRASS ARE SUPPLIED AS
Coil Pancake
Millimeters Inches
Thickness
0.10-5.00 0.0039-0.1968
Width
10-500 0.393-19.685
Internal Diameter
100/150/200/250/300/400/500 3.93/5.90/7.87/9.84/11.81/11.81/15.74/19.68
Mill Width Coils
305/355/406/457/500 12/14/16/18/19.7
Cut to Length Sheets
Millimeters Inches
Thickness
0.20-4.00 0.007874-0.1574
Width
20-500 0.7874-19.685
Length
400-3000 15.748-118.110'
Packing
Palletised Boxes Palletized Boxes
General Parameters
Standard Tolerances
Thickness: +/- 1.5 % Width : +/- 0.5 %
Tolerances as per Customer' specific requirements or as per the chosen Standard of reference
Temper Annealed to Spring Hard
Coil Weight 11.5 Kg/mm width Approx
Packing Coils wrapped in VCI paper and Palletized
Shipping Factory stuffed and Sealed in 20' Containers or as per Customer's choice