Export of castings, forged and CNC-machined components for OEMs in Europe and America
Qualitas Exports Pvt. Ltd.
Pune (Head Office) · Kolhapur Works I · Kolhapur Works IINew on Amplifa
About Qualitas Exports
Qualitas Exports Pvt. Ltd. is a Pune (India)-based 100% export-oriented unit (EOU) for castings and machined components with more than 15 years of experience. As a single-window supplier, the company coordinates a network of over 100 specialized suppliers – including foundries, forging shops, CNC machining operations (turning, 3-/4-axis VMC, 4-/5-axis HMC), gear manufacturing, heat treatment, powder coating and electroplating. The service portfolio covers sand casting, investment casting (lost wax), die casting, closed-die and open-die forging, gears (spur, worm, helical), CNC machining, heat treatment, surface treatment and assembly. Production is carried out in materials such as ductile iron (EN-GJS), grey iron, steel, stainless steel, aluminium, brass, bronze and zinc/zamac; component weights range from 4 grams to 5,000 kg. Customers are OEMs from the pump, valve, actuator, off-highway vehicle, hydraulics, pneumatics, agricultural machinery and gearbox sectors in Germany, Switzerland, France, Italy, the UK, the USA and Canada. Around 250 export shipments with more than 600 different part types are handled annually; the 70-strong in-house staff manages tooling and process development, PPC via ERP, quality assurance, packaging and shipping.
- Site
- 7 Pune
- Processes
- Sand Casting (Green sand, Furron sand, Shell/Croning, CO2, no bake, centrifugal), Green Sand Casting, Shell (Croning) Moulding, Investment (Lost Wax) Casting, Centrifugal Casting, High Pressure Die Casting / Gravity Die Casting, Closed Die Forging, Open Die Forging
- Materials
- Ductile Iron / S.G. Iron, Gray Iron / Grey Iron, Steel Castings, Alloy Steel Castings / Forgings / Round Bars / Plates, Carbon Steel Forgings, Stainless Steel (Castings, Forgings, Austenitic/Ferritic/Martensitic), Aluminium (Castings, Bar), Brass
- Certificates
- Suppliers predominantly ISO 9001, Suppliers partly IATF certified, In-house CMM / X-ray / spectrometer
- Employees
- 70
- Industries
- Pump and valve technology, Drive technology / actuators, Gearbox manufacturing, Off-highway vehicles, Hydraulics and pneumatics, Agricultural machinery
- 01
Tooling and fixture manufacturing (CAD/CAM, rapid tooling)
- 02
Sample and process development (gating/methoding, fixtures, toolpaths)
- 03
Casting (sand casting, investment casting, die casting) or forging (contract
- 04
Heat treatment
- 05
CNC machining (turning, milling, grinding, gear manufacturing)
- 06
Surface technology (powder coating, painting, electroplating)
- 07
Assembly
- 08
Final inspection and pre-shipment inspection
- 09
Packaging, documentation, export logistics
Materials & Processes
Ductile Iron (EN-GJS-400-15, EN-GJS-500-7, EN-GJS-700-2 and others)
Main material for housings, valve bodies, flanges and yokes with high strength and good machinability.
Grey Iron
Castings for housings, rotors and machine components in small and large series.
Cast steel / alloyed steels
Steel castings and alloyed steel cast/forged parts for highly stressed drive and machine components.
Carbon and alloyed steel (forged parts, bars, plates)
Base material for closed-die forged parts and machined components.
Stainless steel (austenitic/ferritic/martensitic)
Corrosion-resistant cast and forged parts for pump, valve and plant engineering.
Aluminium
Castings (sand, investment and die casting) and bar material for lightweight components.
Brass
Cast and machined components, e.g. insulators and fitting parts.
Bronze / Copper
Bushings, bearing and drive components made of bronze and copper materials.
Zinc / Zamac (die casting)
Fine-dimensioned die-cast parts up to 3 kg unit weight.
Austempered Ductile Iron
Heat-treated ductile iron with increased strength and wear resistance.
Sites
Pune (Head Office)
INHead office, sales and project coordination
Kolhapur Works I
INContract manufacturing, casting and machining
- Part weight / size
- up to 5.000 kg (castings)
- Lot size
- Small to large series
- Materials
- EN-GJS, GJL, steel, stainless steel, aluminium, brass, bronze
- CNC lathes (up to Ø 700 mm, 0.02 mm)
- VMC 3-/4-axis (1400x1000x750 mm)
- HMC 4-/5-axis (1000x800x750 mm)
- Grinding and lapping machines (0.01 mm, 0.6 Ra)
- Gear hobbing machines
- Core shooting machines Shell/Coldbox
- Induction, cupola and arc furnaces
Kolhapur Works II
INContract manufacturing, machining and assembly
- Part weight / size
- up to 5.000 kg (castings)
- Lot size
- Small to large series
- Materials
- EN-GJS, GJL, steel, stainless steel, aluminium, brass, bronze
- Sliding-/Swiss-type automat lathes (up to Ø 100 mm, 0.006 mm)
- Turn-mill centres (up to Ø 200 mm)
- Closed-die and open-die forging presses (up to 5,000 t)
- Screw presses (up to 2,500 t)
- Heat treatment furnaces
- CMM, roughness and hardness testing equipment
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Sand Casting (Green sand, Furron sand, Shell/Croning, CO2, no bake, centrifugal)Casting | – | Up to 3 m length | 50 grams – 5 tons - single piece | – | Ductile Iron (nodular iron), Gray Iron, Steel, Aluminum, Copper, Bronze, Brass |
| Green Sand CastingCasting | – | – | – | – | Ductile Iron, Gray Iron |
| Shell (Croning) MouldingCasting | – | – | – | – | Ductile Iron, Gray Iron |
| Investment (Lost Wax) CastingCasting | – | Up to 300 mm length | Up to 65 kg single piece | – | Iron, Steel, Stainless Steel, Aluminium, Brass, Bronze, Copper, over 150 alloy types |
| Centrifugal CastingCasting | – | – | – | – | Ductile Iron, Gray Iron |
| High Pressure Die Casting / Gravity Die CastingCasting | – | Up to 600 mm in diameter | 5 grams – 3 kg - single piece | – | Aluminium and alloys, Zinc, Zamac |
| Closed Die ForgingForming | – | upto 600 mm in length | upto 100 kgs - single piece | – | Carbon steel, Alloy steel, Stainless steel, Aluminum, Brass and alloys |
| Open Die ForgingForming | – | upto 4.5 mtrs in length | upto 2 tons | – | Carbon steel, Alloy & stainless steels, Aluminum, Brass & Its Alloys |
| Ring Rolling / UpsettingForming | – | – | – | – | – |
| CNC TurningMachining | 0.02mm · 1.6 Ra | Up to dia 700 mm | – | – | Ductile Iron, Gray Iron, Alloy Steel, Stainless Steel, Aluminium, Brass, Bronze |
| Sliding Head Automats / Swiss Type AutomatsMachining | 0.006 mm · 1.6 Ra | Upto Dia 100 | – | – | Alloy Steel, Carbon Steel, Stainless Steel, Aluminium, Brass, Copper, Bronze |
| Turn Mill CentresMachining | 0.02mm · 1.6 Ra | Up to dia 200 mm | – | – | – |
| Thread WhirlingMachining | – | Upto Dia 200, upto pitch 10 | – | – | – |
| Vertical Milling (VMC)Machining | 0.02mm · 1.6 Ra | 1400x1000x750mm × 750mm | – | – | Ductile Iron, Gray Iron, Alloy Steel, Stainless Steel, Aluminium, Brass, Bronze |
| Horizontal Milling (HMC)Machining | 0.02mm · 1.6 Ra | 1000mm × 800mm × 750mm | – | – | Ductile Iron, Gray Iron, Alloy Steel, Stainless Steel, Aluminium, Brass, Bronze |
| Grinding and LappingMachining | 0.01mm · 0.6 Ra | – | – | – | – |
| Gear Hobbing (Spur, Worm, Helical)Machining | Gear Quality up to Class 7 (CNC, up to 400 mm) | CNC up to 400 mm; conventional up to | – | – | – |
| Gear ShapingMachining | – | up to 10 Module | – | – | – |
| Gear Grinding / Gear ShavingMachining | – | – | – | – | – |
| Broaching (Splines, Keyways)Machining | – | up to 1200 mm (Pull Type, 12 Ton) | – | – | – |
| Camshaft MachiningMachining | – | – | – | – | – |
| Conventional Lathe, Milling and Drilling / Horizontal & Vertical Boring / Tapping / Pillar andMachining | – | – | – | – | – |
| Honing and BurnishingMachining | – | – | – | – | – |
| Heat Treatment (Annealing, Normalizing, Quench & Temper, Austenitizing, Surface & ThroughHeat treatment | – | – | – | – | – |
| Painting, Powder CoatingSurface | – | – | – | – | – |
| Plating (Zinc, Nickel, Chrome, Tin)Surface | – | – | – | – | – |
| Sand Blasting, Shot Blasting, Chemical Cleaning, Pickling, Fettling/De-burringSurface | – | – | – | – | – |
| AssemblyAssembly | – | – | – | – | – |
| Castings from 4 grams to 5000 kg (sourced via partner foundries)Casting | – | – | 4 grams – 5000 kg | – | Ductile Iron, S.G. Iron, Gray Iron |
| Inspection / Testing (CMM, Radiography, X-Ray, Spectrometer, Hardness, Tensile, Impact, Magnaflux,Testing | – | – | – | – | – |
24 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC Turning Machines | – | – | Up to dia 700 mm, Accuracy 0.02mm | – | Works I/II Kolhapur (contract manufacturers) |
| Vertical Milling Machines / VMC (3-Axis und 4-Axis) | – | – | 1400x1000x750mm, Accuracy 0.02mm | – | Works I/II Kolhapur (contract manufacturers) |
| Horizontal Milling Machines / HMC (4-Axis und 5-Axis) | – | – | 1000x800x750mm, Accuracy 0.02mm | – | Works I/II Kolhapur (contract manufacturers) |
| Sliding Head Automats | – | – | Upto Dia 100, Accuracy 0.006 mm | – | – |
| Swiss Type Automats | – | – | Upto Dia 100, Accuracy 0.006 mm | – | – |
| Turn Mill Centres | – | – | Up to dia 200 mm | – | – |
| Thread Whirling Machines | – | – | Upto Dia 200, pitch 10 | – | – |
| Grinding and Lapping Machines (Precision Grinders: Cylindrical, Centerless, Surface, Internal) | – | – | Accuracy 0.01mm, 0.6 Ra | – | – |
| CNC Gear Hobbing Machines | – | – | up to 400 mm, Gear Quality up to Class 7 | – | – |
| Gear Hobbing Machines | – | – | up to 1500 mm, up to Module 20, Quality Class 5 | – | – |
| Hydraulic Gear Hobbing Machine | – | – | up to 550 mm, Module 7, Class 5 | – | – |
| Gear Shaping Machines | – | – | up to 10 Module | – | – |
| Broaching Machine (Pull Type) | – | – | up to 1200 mm, 12 Ton | – | – |
| Gear Rack Cutting Machine / Gear Grinding Machine / Gear Shaving Machine / Internal Gear Cutting | – | – | – | – | – |
| Cold Chamber Die Casting Machines | – | – | up to 2000 tons, incl. fully automatic machines | – | – |
| Hot Chamber Die Casting Machines | – | – | up to 60 tons | – | – |
| Forging Hammer (Gravity Drop & Pneumatic) | – | – | upto 10 tons capacity | – | – |
| Forging Presses | – | – | upto 5000 ton capacity | – | – |
| Screw Presses | – | – | upto 2500 tons capacity | – | – |
| Special Purpose Machines (Crankshafts, Connecting Rods, Multi-Spindle Drilling, Camshaft Machining | – | – | – | – | – |
| Conventional Lathe, Milling and Drilling Machines / Pillar and Radial drilling / Tapping Machines / | – | – | – | – | – |
| CMM (CNC controlled Co-ordinate Measuring Machine), 2D measurement machine, Surface roughness | – | – | Vernier/Micrometer up to 1000 mm | – | In-house QC |
| Moulding Equipment (Disamatic/High Pressure, Jolt Squeeze, Manual moulding, Automatic sand plants, | – | – | – | – | Partner foundries |
| Furnaces (Medium Frequency Induction, Cupola, Arc Furnaces; Induction/oil fired for investment | – | – | – | – | Partner foundries |
Additional services
Reference customers
Quality
An in-house QA department with engineers under the leadership of the Quality Manager prepares quality plans, performs process and final inspections and handles deviations via CAPA. The equipment includes a CNC-controlled 3D coordinate measuring machine, spectrometer, X-ray/radiography, microstructure microscope, hardness and tensile testing, Magnaflux crack testing as well as leak/pressure testing; gear inspection is performed using lead profile testers, roll testers and roughness measurement.
| Evidence | Qualitas Exports (Kolhapur/Pune) |
|---|---|
| Suppliers predominantly ISO 9001 | |
| Suppliers partly IATF certified | |
| In-house CMM / X-ray / spectrometer |
History
- ca. 2008
Start of export activities; over 15 years of experience in exporting cast and machined components to Western Europe and North America.