EventReport 6th International Foundry Congress & Exhibition th th Feb 15-16, 2017 at PC Hotel Lahore-Pakistan Abdul Rashid, Secretary-PFA For ages Lahore has been a brilliant symbol of a gracious way of life. It had been the abode of great people, both in the spiritual as well as worldly realms. It has the imposing reflections of its Muslim builder's having ambitions and cosmopolitan tastes. The complex variety of Lahore which has grown form the wilderness, when Changez Khan destroyed its subs, to the 20th century developments, is distinctive character of the city in various places and provides testimony to its cultural heritage. Lahore having been the seat of many imperial dynasties possesses interesting historical reminiscences. There is a fascinating and colorful panorama of extraordinary Mosques, Mausoleums, Fort and Gardens. The grandeur of Lahore cannot be solely attributed to its buildings, gardens, monuments and other historical places. Rather it is its atmosphere and ambience, its moods of joy and sorrow, fairs and funs, pains and pleasures, and above all the colorful life of its people which actually render impetus to the spirit and sole of Lahore. The architectural heritage of Lahore needs no description. The architectural works of Lahore, sensuous in 2
their exploitation of colors, textures, materials, intellectual in vigorous application of intricate formal patrons and spiritual in essence at once seduce the art lovers. The British during their reign (1849-1947) compensated Lahore, by harmoniously combining Mughal, Gothic and Victorian styles of architecture. Victorian heritage is only next to Mughal monuments. The GPO and YMCA buildings built to commemorate the golden jubilee of Queen Victoria - an event marked by the construction of clock towers and monuments all over India. They built some important buildings, like the High Court. the Government College, the Museums, the National College of Arts, Montgomery Hall, Tollinton Market, the Punjab University (Old Campus) and the Provincial Assembly. Students from all over Pakistan come here to receive education. At one end of the Mall stands the University of the Punjab and on the other end stand Fortress stadium. Perhaps Punjab University is the largest center of education in Asia. The city has built a new Campus in the quieter environments on the Canal Bank, but the old University buildings are still functioning. Lahore cuisine refers to the food and cuisine of the city of Lahore in Punjab, Pakistan. It is a part of regional Punjabi cuisine. Lahore is a city with an extremely rich food culture. People from Lahore are famous all over the country for their love for food. The city offers a vast variety of options when it comes to gastronomy. In recent times, the cuisine of Lahore has also achieved dominating popularity in India, especially in the Punjab side as well as spreading its influences to Afghanistan and outside. The food of Lahore is particularly known to have originally derived from imperial kitchens of Mughal empires. In fact its similarity to the Mughal cuisine has even essentially led it to be a virtual twin version of the Style of food. Lahore offers some delightful picnic spots. Tourists can find shady groves and green carpets at Shalamar Gardens, Jehangir's Tomb and the Jinnah Gardens, the Jallo Park, the newly built lqbal Park and Changa Manga Forests. Boats can be hired at the river Ravi, or at Baradari, another of the river-side pleasurehouses built by the Mughals and an ideal place for relaxation. 3
Welcome Dinner Pakistan Foundry Association has the traditions to welcome foreign guest at a sumptuous dinner for a get th together with its executive committee members. On 14 February, 2017 IFCE-2017 was formally opened to welcome foreign guests and special invites. The objective behind get together was to introduce foreign delegates with the hosting members. During the meet they planed visit to potential foundries, training institute and academic center for their mutual interest. Mr. Sikandar Mustafa Khan-President Pakistan Foundry Association welcomed the foreign delegates, Speakers, Foundry Consultants, Exhibitors and executive committee members and foundry friends. He thanked them for their joining in IFCE-2017. He said Lahore is a historic city of Mughal empires and rulers of Sikhs Regime. I suggest you must visit interior of Lahore to have a look on our culture. 4
IFCE-2017 Inauguration Pakistan Foundry Association organized 6th International Foundry Congress & Exhibition (IFCE-2017) on th th 15-16 February, 2017 at PC Hotel, Lahore-Pakistan. It was organized to provide an opportunity to interact with the international casting machinery manufacturers to upgrade our technology and develop business relations to enhance export. The IFCE-2017 provided an opportunity to investors, machinery manufacturers, foundry material suppliers and service providers to showcase their products and services to their counterparts and potential customers to make alliance. The chief guest of IFCE-2017 was Mian Muhammad Mansha the Chairman of "Nishat Group" & MCB Bank. He is one of the leading exporter and industrialists in Pakistan. We invited him keeping in view of his interest in the field of automobile and get some business advice, financial advice, IPOS from his expertise. He is an entrepreneur, create jobs and interested to create a society. It was very encouraging for PFA to organize a successful IFCE-2017 at the time when there was a slump in the market due to economic situation in Pakistan. But when the exhibition schedule was announced and the stalls were floated in the market of Pakistan and abroad the response from the industry was motivating. Mostly our previous exhibitors responded quickly for stall reservation and even payment was received in advance. Our larger stalls (Customized) were sold to international and local companies rather the whole exhibition was sold out two months before the opening of exhibition. 5
In IFCE-2017 many foundry industries, machinery, equipment and material suppliers joined us from China and exhibited their products. Almost eight companies were present while 20 more companies were interested and applied for visa endorsement. But they could not join us due to their late visa application submission. Anyway they are planning to visit Pakistan and to meet our members after sometime for business development. Mr. Fahad Iqbal-Joint Secretary-PFA invited Mr. Sikandar Mustafa Khan- President, Mr. Masood Akhtar-Vice President, Mr. Asim Qadri-General Secretary-PFA on the stage and then Mr. Mian Muhammad Mansha, the chief guest to take their seats on the stage. IFCE-2017 was formally opened with the national anthem and recitation from Holy Quran. 6
He invited Mr. Masood Akhtar to present an overview of Foundry Industry and profile of Pakistan Foundry Association. He welcomed the honorable chief guest Mr. Mian Muhammad Mansha, Mr. Sikandar Mustafa khan- President Pakistan Foundry Association (PFA) and Mr. Asim Qadri-General Secretary PFA, delegates, exhibitors & all participants. Mr. Masud Akhtar presented an overview of Pakistan Foundry Industry and the activities of PFA since its inception. He said the foremost objectives of PFA formation was to upgrade technology and skills development in foundry Industry with special emphasis on small and medium enterprises. He added there are 1530 foundries operative in Pakistan for the population of 192 million people. We have 400,000 tons installed capacity and producing 250,000 tons inclusive of all types of ferrous & non- ferrous materials (S. G. iron, Grey cast iron, steel, special steels duplex, Aluminum). Our foundries are engaged in the production of automotive & tractor parts, sugar mills, machinery parts, Cement factories consumables, Chemical factories consumables Heavy industrial castings,pumps, valves & electric motor castings, textile, cement, process Industry Machinery. To fulfil the future demands of castings in Pakistan and for export; Japanese, Chinese & others giants are interested to invest with their own strong footprints or their vendors may invest in the Foundry Sector to meet the increasing demand. So we are in a condition to produce all types of castings using various types of materials. Our foundries are primarily engaged in the manufacturing castings for auto sector, tractors and effectively in the cement sector, chemical, paper, sugar, fertilizer industry by manufacturing consumer parts for them. Agricultural implements are also one of the important area and our foundries are providing parts to OEM's. So we cover the entire spectrum of the industry and extend support to them. China Pakistan Economic Corridor (CPEC) bring emerging opportunities in Pakistan for Foundries. CPEC is an infrastructure and logistics project which will join Western China, through western Pakistan to the Indian Ocean via deep water Pakistani port of Gawadar. This project envisages an early projects (Priority Phase) 21 projects in the energy sector valuing US$ 33793 Million 4 projects in the transport infrastructure sector valuing US$ 9784 Million 8 projects for Gawadar valuing US$ 792.62 million. He said we run courses in Foundry Service Center by inviting foreign foundry experts for foundry engineers. He said PFA is also connected with GIZ for Energy management System (ENMs). GIZ visited PFA member's foundries and trained them for the (ENMS). He defined the PFA publications, Element Magazine Quarterly published and distributed among the foundrymen, CEO's, GM's, Junior/Senior Engineers, Academia, Consultants, Government officials. It is also distributed in soft copies to India, Turkey, Germany, 7
Netherland, Europe, China etc. He said our website: www.pfa.org.pk is the hub of information, so you must visit it for further details. He also discussed the salient features of 6th International Foundry Congress & Exhibition held every two years. In IFCE-2017 there is a great participation from India, Turkey, Germany, Netherland, Europe and China. Mr. Wei Gao-Joint Secretary-CFA has specially joined us to strengthen our relation's for joint ventures and future collaborations. Mr. Asim Qadri welcomed the honorable chief guest Mr. Mian Mohammad Mansha, Mr. Sikandar Mustafa Khan and Mr. Wei GAO and all the other ladies and gentlemen in 6th International Foundry Congress & Exhibition. Mr. Asim Qadri described the whole activities which will happen in next two days of IFCE- 2017. He said this exhibition has two parts, one is technical sessions and the another is exhibition. He said through this exhibition we introduce modern technologies to our foundrymen. He explained there will be 16 technical sessions, planned to be conducted mostly by foreign experts. He invited all interested persons to participate by registering them to update their technical knowledge. Mr. Sikandar Mustafa khan-president, Pakistan Foundry Association thanked the honorable chief guest Mr. Mian Mohammad Mansha, Mr. Asim Qadri- General Secretary PFA, Mr. Masud Akhtar-Vice President-PFA executive committee and all members, delegates, exhibitors, ladies and gentlemen for their participation in IFCE-2017. He said Mr. Mian Mohammad Mansha s presence is an encouragement for us as he is also moving towards the automobile industry and his words of guidance can benefit our industry. I am really obliged by the participation of delegates from Turkey, China, Australia, Netherland, India, Germany, England etc. We are encouraged by their participation and looking forward to future meeting too. This is an opportunity for them and also for us, to learn whatever the knowledge we can exchange. The lectures as Mr. Asim Qadri suggests will be very useful and can benefit for the improvement of your industry. He emphasized on the importance of the foundry industry which is the base of whole industry. Pakistan Foundry Association was specially developed with the objective to develop the skills & technological level in the country and that's why we are working hard to move in these direction. In the year 2003, when Pakistan Foundry Association was formed we were doubtful whether we will survive or not? But thanks to the executive committee members and members by putting up great efforts and now we are connected at the stage having connections to many foundry associations on the globe. In fact we are not only growing but also having good connection with other foundry associations. I hope technical sessions will be very useful for the GM, CEO's, young engineers and the students as well. 8
PFA is moving rapidly towards achieving its goal and I sincerely hope that we will be able to continue our efforts to develop this important industry. I thank you once again for your presence. Mr. Mian Mohammad Mansha was the chief guest to inaugurate th 6 International Foundry Congress & Exhibition held on 15-16th February, 2017 at PC Hotel Lahore-Pakistan. In his opening remarks he said I am grateful to Pakistan Foundry Association and Mr. Sikandar Mustafa Khan who invited me to be here with you because I have some interest in your business too. He said no doubt I have many businesses in our group and primarily MCB bank. I feel it is not my job to explain you what we are doing rather I will try to help your industry in terms of financing, financial advice, IPOS and all the other things we can do. It is the time of globalization & CPEC which is one of the most important aspect and Pakistan will become epicenter of the world. There are certain changes coming in the world and I can say there will be reverse immigration as opportunities of growth in Pakistan are enormous. When Islamabad was developed many construction companies came up, but they can't maintain their level because of the shortage of the equipment to resolve their major problems and failed to capitalize the business He said we can access to nearby countries China, Afghanistan, India, Turkey etc. Urumqi-China a city of six million people and just at a Journey of 2 & half hours from here. So it is the proximity of China. Similarly Tashkent is as far as Karachi and Afghanistan is just 38 minutes away from Lahore. Whenever I have a visiting plan I wake up in the morning and go there and come back in the evening. India border is just at a 20 minutes' drive from Lahore. He added I am fortunate to go to Iran. At times it was completely straggled and a lot was discussed. Then people from Europe & other countries came to Iran for development. They produced 75000 megawatt electricity while we produce 20000 megawatt. They produce 80 metric tons cement while we produce 40 million tons. There is no religious influence in business or other activities. They discuss about religion in mosques, universities and other institutions and brought it into logical care and rest is nothing. I have seen in many meetings women PhD's seating across the audience and they come up with the suggestions for the development of the business and Industry. There is 450 km of motorways in the city of Tehran and without a single security officer deployed. In Pakistan many people have reservations about the involvement of judges in certain matters like valentine day and many more. Our public wants everyone should be independent to celebrate certain events. They are of the opinion judges should do their job to provide justice to the public. We have developed largest mall in Lahore just 10 minutes away from here by investing Rs 25/- million. Look how many jobs we have created for our people. He said I am not only in banking industry, we have put up the largest cement plant to produce 10000 Tons of cement while 7000 people will be working there. 9
Even you go to India there are some of the biggest engineering industries like Escort tractors manufacturers companies & Hero Honda largest manufacturers of motorcycles have connection with the people in Lahore, Samundari etc. They are away because of artificial barriers created by human beings. Hopefully they will come down and we will create opportunities. You can't deal with the reasons without giving jobs to people. We have to create jobs for them by providing opportunities for youth to be employed. In this regard you have multiple choices in this world if you are serious enough. We have to keep religion apart. This is what I expect the enormity of the situation where we are sitting. I am critical sometimes, just have the look on Lahore Airport it does not give a look of international standards. Why don't we make it privatize like Istanbul Airport, Moscow Airport (is managed by Irish Company) and many Arab Airports are privately managed. Please make consensus in this country. I have takeover the bank and had profit of 230 million. Last year we make profit of 40 billion rupees. We have generated 150 billion taxes' direct or indirect to the government. Let's create job opportunities for the people. We want all of you to be the entrepreneurs and creates jobs and I want you to create a society. Souvenirs To Major Sponsors Pakistan Foundry Association organize IFCE every two years and financial support is always extended by our executive committee members Mr. Irfan Aqeel CEO, m/s Millat Tractors (PVT.) Ltd, Mr. Nisar Ahmed Mirani CEO, m/s Bolan Castings (Pvt.) Ltd, Mr. Irfan Qadri Director m/s Qadri Group (PVT.) Ltd, Mr. Ahmed Hassan CEO, m/s Chenab Engineering Works & Foundries (PVT.) Ltd and Mr. Masud Akhtar Managing Director, m/s KSB Pumps (Pvt.) Ltd.They were special exhibitors and provided souvenirs to them. Mr. S.M.Khan also presented a memento to the chief guest Mr. Mian Mohammad Mansha. 10
IFCE -2017 Exhibition 11
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Award to exhibitors 13
TechnicalSessionsIFCE-2017 PresentationsbyMr.StafHenderieckx INOCULATION GREY (FLAKE) & DUCTILE IRON Ductile iron has strict mechanical properties (international standards) and quality requirements concerning porosity and dross presence. It is very well known that nodularity is important and less known that nodule count can deliver important Information concerning these requirements. Nodularity is mainly set by the residual Mg- and S-content and nodule count by the initial liquid metal quality, inoculation and residual small MgS-inclusions. Inoculation supplies nuclei for the free graphite. It is used to improve the liquid metal quality. The liquid metal quality is depending on the charge but more on the highest melting temperature and time on this temperature. The other potential nuclei are the MgS-inclusions as long as they stay in the metal and have less than 15 µm diameter. When they are larger (especially above 50 µm and or floated to the top surface of the metal, they are considered as slag. The inoculation provides extra nuclei, which have a restricted life time. This important lifetime is different depending on the chemistry of the inoculant. It is preferred to add the inoculant in 2 stages; the last one during or close to the pouring. Process control will assure a consistent and proper nodule count. Process Control The process should be identified properly in a way that each activity is known. These activities are more than pattern making, moulding, core making, melting and pouring, heat treatment and fettling! Each of them consists of many partial activities. Just take melting as an example: raw material charging, slag removing, temperature testing And what about internal transport of patterns, moulds, metal, poured moulds, shake out castings, fettled castings And what about inspection by quality control employees? The activity inventory is classified in three groups: value adding, non-value adding and problem related. The customer does only pay for the value adding activities, not for the other ones (non-value adding are transport, storing between operations and repair)! It is fact to evaluate the necessity of the non-value adding activities as well as problem related ones. Are they really required and or can they be decreased in cost?... Presentation by Mr. Murat Ackin Economic Effects through Casting Process Simulation Mr. Murat Ackin - Magma Soft - Turkey apprised the house with the success in development and improvements in castings on the globe. He said it is difficult to survive for any foundry industry Without Simulation Software if he is in export business. Simulation is becoming an integral part of the today's foundry industry, in order to achieve consistently high quality castings and optimal yield. Simulation is required to achieve following objectives: 1- Quality enhancement, 2- Yield improvement 3- Product development Furthermore, simulation is name of culture change. It helped the industry by improving the internal quality of casting but also it leads to improve the processes involved in casting. Understanding of casting defects is far 14
more easy and predictable with the help of this modern tool. Foundry is now being converted from art to science. Quality of casting is no more a SURPRISE, but it is predictable in advance Presentation by Mr. Virendar Khosla Innovative Refectory Solution for Coreless induction furnace A coreless induction furnace exist of a nonconductive refectory crucible, surrounded by a coil of copper cube. Running a powerful alternating current through the coil creates a magnetic filled that induces electric currents inside the metal and quickly melts the charge in the furnace proper and well maintained refectory linings or important for a safe operation of the induction furnace. Choosing the right refectory material for a given melting or holding application is important. Magnesia based refectory has a poor thermal shock resistance and silica Based things are quickly corroded. So the new generation concept is the Neutral Ramming Mass.. Presentation by Mr. Unsal Minoglu Feeders and Exothermic Feeder Materials in Casting The feeding of cast parts and the use of exothermic feeder materials in the feed is an important, complex and therefore a matter of interest to foundries. Proper feeder design is crucial in order to improve quality in the casting and reduce production costs. In this review study, basic feeder calculation rules in casting and information on applications of exothermic feeder materials are presented. Casting feed; it is very important for today's foundries to get an accurate and quality casting product and to provide an economic production process. Metals and alloys can be used as a shrinkage during cooling and solidification, this natural situation is called volumetric shrinkage. During casting, there must be enough liquid metal in the system to fill the voids that will be formed by volumetric drawing of the solidified metal. The pouring of the cavities to be formed by said pulling, of a metal with liquid metal. The feeder must be in liquid form until the main casting part is solidified so solidified later from the casting part. Topic: Digital Pattern Making high accuracy in Less Time.: Topic: Shifting of Molasses to no bake sand. 15
Topic: Gating system Design and filter application in Iron Castings. Sanam Marvi performs Sufi concerts around the world. She is considered among the 3 of the finest performers in the Sufi, Ghazal and folk genres. performance and received a lot of applause. Gala Dinner and Musical Evening 2017 Sanam Marvi Topic: 3-D printing- Role of Modern Technology in Manufacturing of Components. She entertained the audience with the high level Pakistan National Council of Art presented folk and cultural dances and provided lite entertainment. 16