Metal casting has evolved significantly over the years through technological advancements to meet growing global demand. Modern methods focus on efficiency, sustainability, and quality through automation, simulation modeling, improved melting techniques, and stringent quality inspection. The global metal casting production is predicted to rise to 115 million tons by 2015, led by China, US, and India. Innovation across the casting process aims to reduce costs and pollution while improving productivity and working conditions.

1. Market perspective of modern metal casting
Metal casting has undergone subsequent developments year after year. Ever since the discovery of
metals, new approaches have been followed to meet out the growing needs of cast metals in various
forms. Today, it has grown into a huge global sector where countries around the world compete with
each other in investing millions of dollars to create their impact on world trade. To balance their
production, each country strives to find improved solutions of handling metal casting both efficiently
and productively. As with any other sector, the top most priority of the experts in this field is to find eco-
friendly methods of casting metals to tackle global warming. Another focus is on creating new marketing
opportunities to meet out the fast growing market demands and to educate about the diverse trends in
casting metals. The global production in metal casting is predicted to rise a stunning 115 million tons in
2015. China tops the chart in metal casting production with 41.3 million tons produced from 30000
plants. US is in the second place with 10.33 million tons produced from 2040 plants and India stands in
the third place with 9.99 million tons produced from 4500 plants. Robotics is the new means involved to
help out in meeting the goals of the modern world. Older methods have become obsolete and find no
place in the current industry. Considerable development in technology forms the basis for a sound
industry. This can be achieved only by pushing away traditional methods of designing and incorporating
modern simulation modeling to produce effective cast designs. An improvement in commercial scale
production inevitably depends on new casting methods that are vacuum and pressure assisted.
Efficiency can be improved by automated pouring of metals done by robots. Custom made mold
handling systems have been structured and are used by increased number of plants around the world
who have recognized the need for innovation. They are cost effective and are rugged to withstand harsh
runs in the foundry for several years from installation. Methods to fill molds accurately and efficiently
are developed in such a way to reduce remelting and maintenance charges thereby increasing quality
and productivity. As another important perspective is to avoid pollution, innovative binder methods
have rooted up recently. Traditional baking methods tend to cause harmful emissions that threaten the
atmosphere. Therefore, several no bake binder systems are under operation to facilitate a pollution free
process. The results have been significant like, reduction in smoke and odor, less hazardous gas
emissions and also improved working space for the foundry employees. New vibrating equipments that
are durable and efficient have been implemented in the market to produce quality material handling
solutions. New fluid bed sand coolers, slurry dryers, spiral elevators, furnaces, conveyors, blast charge
feeders are implemented for processing various materials like sand, stone, metal and metal castings.
One of the most challenging steps involved in metal casting is the melting of metals. This high impact
process has smoothened out by means of improved and updated induction melting equipments. Several
Ferrous and Non-Ferrous melting equipments, precious metal melting equipments with state of art
infrastructure of foundry including furnaces are employed. Along with this cost reduction in melting is
considerably cut down by smart usage of electric furnaces. In addition, non-ferrous fluxes, ladle
cleansing fluxes, low silicon nodulizers, hot toppings and exothermics have improved cost reduction in
melting. Another crucial feature is the selection of simulation modeling software. Smart casting
simulation software that is user friendly is used to achieve efficiency. They are both cost effective and
easy to use. They also have combined thermal and volumetric calculations with integrated gating and
riser design. Innovative heat treating methods, cryogenic treatments and age hardening solutions are

2. adopted. Quality improvement is achieved by using precision measuring equipment compatibility test
station and ductile iron wire feeding systems. Also, the powder metallurgy composite material is
replaced by melting metallurgy and pouring material that is light weight. This has resulted in an
economical way of casting metals and thus improves workspace for workers than any other processes.
This has become a great support for investment metal casting. This technology is useful to a greater
extent in those areas where weight reduction is a crucial aspect in producing cast metals. This type of
metal pouring improves resistance to corrosion and reduces thermal elongation. It also offers better
thermal conductivity.
Apart from all the new innovative methodologies and technological advancements throughout the
process of metal casting, significant importance is given to the actual working conditions as well. In
order to improve the air quality space efficient and airy shop floors are designed. Appropriate settings of
welding booths, risers and gating improve the workspace for employees in the foundry. Casting floors
are divided based upon the aspects of various castings, this way, cluttering is avoided and there is no
room for any mishaps. A set of well handled procedures and equipments also improves reduction in
abrasive usage. The cleaning and the finishing departments are expected to play their own role in
removing any of the excess material from the castings before it reaches the grinder for further final
touches. In the final stage, the casting is moving to the inspection department to undergo a clean quality
check. A variety of Video Borescopes are used for this purpose. Several advanced versions are being
employed today. They have the capacity to produce sharp and clear images and videos. They have up to
4 way articulation with hard tungsten sheathing. They have a user friendly construction and are also cost
effective compared to any other equipments used in quality inspection.
Revised safety data sheets have been developed and they replace the previous set of material safety
data sheets. Metal casters find help in getting their ISO certification by following these sets of rules to
ensure that they are eligible up to date for their community rights.
The entire metal casting community stands by a combination of suppliers, metal casters, casting
designers and casting buyers. So, it is important to gather and get connected with the supply chain to
improve brand name and merchandise. To achieve a niche market, it is necessary to follow a set of rules.
Contingency plan oriented quote system:
Metal casting units handle different alloys and various buyers. This means, they must have a different
set of quotes for various clients. Their system must give them space to allocate strategies for risk
management to analyze profit and loss. Based on this each part of the system is adjusted to deliver a
goal oriented product with the greatest recognition.
Treating customers as clients:
Today, it is important to make use of every customer to achieve a firm space in the market. With
innumerable competitors, it is necessary to make use of the media platforms to get access to buyers
around the world. By delivering a quality product as per the customer’s expectations, you can overcome

3. market competition by not landing on price tags and turn the customer to be your valuable client for the
rest of the lifetime of your business.
Beat the blues:
Don’t believe in following age old practices in metal casting. Stop following myths that hold your
business. Try new things, new strategies and technologies to take your business to a whole new level.
Stop believing that buyers buy only on the price tags. Quality and efficiency are the properties for
success in today’s world of casting metals.
Reorganize your cash flow:
Correct your plant flow and assign an up to date system to bring in continuous quotes. Improve your
sales and marketing ethics. Implement these by improving client lifetime values. Improve stable
relations with the client sector to have a great business.
Smarter defect management:
Forget the flaws of the past and develop a system that can indicate the risks ahead based upon the
previous problems. Also, it must be able to deliver ways to avoid or fix the risks in revenue and
expenditure.
Estimate revenue from CLV:
A reliable client lifetime value relationship is the effective way to predict your revenue and returns.
Calculate the average expenditure per month and the number of months occupied by the client. Try to
increase any of these two aspects to reap added money with no spend on marketing. Understand the
worth of your client and invest accordingly to hold the hand of your high profile client for a long time.
Following these practices ensures another extra percent of the profit in a metal casting business.
Keeping pace with this on a long term brings in additional quotes and revenue, which means an
additional profit year after year.
Always, additional sale is based on better brand building. Get connected with the casting interests of
high end casting designers and buyers. Increase sales by bonding with your ideal buyers. Create market
awareness about your uniqueness. Establish a relationship with your much valued clients by educating
them the worth of your skill sets. Build a strong foundation for a long term client relationship. Build an
effective tool for sales to reap benefits on a long term basis. Credit your sales team with high profile
leads. Have a circle of your targeted contacts and educate them on your abilities to deliver a quality
service.

4. Calmet that manufactures of ferrous & non-ferrous iron castings foundry made at fully
automated and semi automated cast iron manufacturer in India. Also develops forging parts,
supplies plastic coated copper tubing & more products for various industries.