Sugar Presentation

IMCO ALLOYS Pvt. Ltd.
WORKING TOGETHER &

WINNING TOGETHER
www.imcoalloys.com WEAR RESISTANT ALLOYS

ABOUT US
 An international company of repute with over a decade in research and

development, manufacturing and marketing of wear resistant solutions to
a wide range of industries in India and abroad.
 The solutions include various applications for crushing hammers, impact

blades, rotors, cutter and liners used in different industries such as Sugar,
Steel, Cement, Power Stations, Refractory, brick and tiles, Mining, etc.
 IMCO caters to more than 600 sugar mills in India and abroad, we export
specialised applications to sugar mills in Thailand, Mauritius, China,
Australia, Africa, Indonesia, France etc.
 Team of skilled, highly professional, enthusiastic engineers within reach

of our customers.

Our Global Presence
IMCO Alloys Pvt. Ltd. (Unit 1) IMCO Alloys Pvt. Ltd. (Unit 2)
176-A, MIDC Phase 1, 129/130, MIDC Additional Ambernath,
Dombivali (E), Dist. Thane, Anand Nagar, Ambernath,
Mumbai, Mumbai – 400 203. Dist. Thane, Mumbai.
India Tel : +91 251 243-5150 / 5250 / 5350 Tel : +91 251 243-5150 / 5250 / 5350
Fax : +91 251 247-0667 Fax : +91 251 247-0667
Email : mail@imcoalloys.com Email : tech@imcoalloys.com
Website : www.imcoalloys.com Website : www.imcoalloys.com
IMCO Alloys SA (South Africa)

IMCO Alloys Global Tekcon
4 Cavendish Park,
51 Kharea Road, Kharwastan, Rungkut Mapan Tengah II CB 16-
Durban, 4093 Durban, South Africa.
South Africa Surabaya, Indonesia (60293).
Tel : + 27796228635 / +
27826286651 Tel/Fax : +62.31.871.5960
Email : daniel@imcoalloys.com
Email : imcoglobal.tkc@gmail.com
IMCO Alloys Global (FZC) UAE Middle East

P. O. Box : 122426, Sharjah Airport International,
Sharjah,
Free Zone, Sharjah – UAE.
United Arab
Tel : + 971505277404
Emirates
Fax : + 971 - 65489542
Email : solomon@imcoalloys.com

Our Supplies to …
 India
 USA
 Central America
 South America
 Africa
 France
 Iran
 Mauritius
 China
 Indonesia
 Thailand
 Malaysia
 Phillipines
 Vietnam
 Australia
…Still on the rise

IMCO - products are used in most industrial areas
Sugar Cement Power Pulp & Paper Petrochemical Mining

OUR TECHNOLOGICAL KNOWHOW

Skilled Operators / Engineers are working in well
equipped set-up 24 x 7

CNC Machining

Wear Resistant Castings

ISO Quality
We at IMCO Alloys P Ltd are committed to
offer quality products and services to all
customers by providing superior
technological edge, innovative wear
resistant products and services backed by
trained, agile & responsive staff.
By deploying the synergy in Sourcing

quality products, offering sound Solutions,
responsive & prompt Service and
unmatched Support, we are committed to
continual improvement leading to total
customer Satisfaction

IMCO Patent
We have patented our
technology and
designs.

Manufacturing process
 BLENDING
 GREEN MOULDING
 SINTERING
 SOAKING
 BACKUP MACHINING
 VACUUM IMPREGNATION
 FINAL FINISHING
 INSPECTION

Blending
Inspection for raw materials for critical Parameters like;
particle size,
article size distribution,
chemistry
Usage of powder matrix carbides of mesh size 1- 3 microns
Pilot batch approval for raw material to ensure uniformity.

Green molding
To shape the powder in the

form as required Uniform
compaction achieved
through close control of
moulding parameters.
Microprocessor controlled
hydraulic presses are in
operation.

Sintering and Soaking
• High temperature thermal treatment
to densify the green compacted
components
• Better control during sintering

ensures better microstructure which
aids the wear resistance
characteristics
• Sintered components are then heat

treated & soaked at specific
temperatures to achieve the final
microstructure

Microstructure Analysis
Sintered Carbides Conventional Hard facing

Honeycomb structure (Acicular carbides)

APPLICATIONS IN SUGAR INDUSTRY
SUGAR

Zuper Block

Zuper Block with Metal Matrix Composites
Also available in regular

Sizes like 90 x 90
IMCO make Zuper Block of Size 150 x 93 x 145mm thk. impregnated with
Metal Matrix Composites; Also available in regular Sizes

Casted Fibrizor hammer fitted with Zuper block

Fibrizor hammer fitted with Zuper block

Different types of fibrizor hammer bodies

Zuper block fitted to hammer body
with high tensile bolt
Torque applied >300 pounds / ft.

IMCO Swing Type Fibrizor

IMCO Swing Type Fibrizor

Advantages of Swing Type Fibrizor
Swing Type Hammer absorb shock, hence NO breakage of
Hammer body.
Assists in Increasing Preparatory Index (PI) due to better

impact.
Power consumption is Less due to Swing type Hammer as each

Hammer develops its own inertia.
Downtime is Less while changing the Hammer body due to

replacement of bolts with pin.
Efficiency in terms of performance is comparatively HIGH

ZUPER TIP ON LEVELER / CUTTER

Various size / orientation of
Zuper knife tip / Zuper bar

Zuper Knife Body

Zuper Tip for Cane Cutter / Leveler Knife body
Wear Problem:
The present design of conventional knife bodies

was wearing out rapidly; which effects the crushing
ratio.
IMCO Solution and Advantage :

 IMCO make Zuper Knife Tip is made of
Composite Sintered Carbide.
 Excellent abrasive & impact resistance.
 Good edge retention property
 Hardness 60 - 62HRC.
 Cost effective compare to conventional method of

welding.
 Available in Custom made sizes and orientations.

Fixed Type Leveler / Cutter

IMCO Fixed Type Leveller

Disadvantages of Fixed Type Leveller
Fixed Knife does not absorb shock, hence frequent breakage of knife body.
Frequent jamming of leveller due to fixed type knife.
Power consumption is high due to fixed type knife.
Change the set of knife bodies every season hence not cost effective.
Downtime is high while changing the knife body due to opening and
tightening of all bolts
Efficiency in terms of performance is average

IMCO Swing Type Leveller
We can convert fixed type hub leveler to Swing type leveler cutter
along with designing, commissioning, and erection.

Advantages of Swing Type Leveller
Swing Type Knife absorb shock, hence NO breakage of knife

body.
NO - Frequent jamming of leveller due to Swing type knife.
Power consumption is Less due to Swing type knife as each

knife develops its own inertia.
Downtime is Less while changing the knife body due to

replacement of bolts with pin.
Efficiency in terms of performance is comparatively HIGH

IMCO Swing Type Leveller

Commissioned - IMCO Swing Type Leveller

Conventional Worn Out Static Collar

IMCO make Zuper Wear Plate for Static Collar
Crack free &Smooth Hard chrome steel having Hardness 500-550 BHN duly fixed onto
the existing static/ round/ pressure plates collars. Thus protecting seepage on roller ends.

Zuper Wear Plate Application
Static collar / pressure plate / round

collar with Zuper 21 (EDP)Plate
IMCO make Zuper 21 (EDP)

Plate duly welded to the base.

IMCO make Zuper Wear Plate for Static Collar
Key Advantages of IMCO Zuper21 (EDP) Plate:
• Reduces residual stress in base metal due to direct weldability.
• The change in welding direction reduces formation of deep cracks.
• Best wear performance against fine particle erosion.
• Wave pattern leads to improved stability of weld joints
• Enhance life compared to conventional hard facing welding
• Highly cost effective compared to conventional methods
• Available in custom made size as per your drawing

Zuper 21 Plate for Fibrizor Side Plates
SS Plate can
be replaced
with Zuper
21(EDP) plate

Donnelly Chute with Hard Chrome Zuper Plate
SS Plate can
be replaced
with Zuper
21(EDP) plate

Cane Carrier with Hard Chrome Zuper Plate
SS Plate can
be replaced
with Zuper
21(EDP) plate

Impeller Housing with Hard Chrome Zuper Plate
Hardfacing
Welding can
be replaced
with Zuper
21(EDP) plate

ID Fan Application
Conventionally hardfacing is done on ID Fans to resist wear

Zuper ID Fan Solution
Hardfacing
Welding
replaced with
Zuper
21(EDP) plate

Anvil Plate for Fibrizor
Industry : Sugar
Application : Anvil Plate
Details of Machine : Fibrizor
Wear Pattern : High Impact and Abrasion due to cane fiber
M. O. C. : Mild Steel back up with heavy hard facing
Wear Problem : In the rotation of Fibrizor, Hammer bodies hit sugarcane

on the anvil plate for shredding thus creating high impact and sliding
abrasion resulting wear out / breakage of pockets.
Present Solution : Welding with high chrome hard facing electrode thus working for
one crushing season. After which the entire application needs
rebuilding of working area.

Zuper ANVIL Segments
Condition of
Anvil Plate
after one
Crushing
Season

Zuper ANVIL Segments
Old Worn out Anvil Pocket Old Worn out duly machined
Fitting of Zuper Anvil Tip Assembly of Anvil Pocket with Zuper Anvil Tip

Zuper Bars on ANVIL Plate
Sintered Carbide Zuper Bars duly fused on ribs

Anvil Plate reconditioned with Zuper Bars

Anvil Plate - Reconditioning
Reconditioning of
Used Anvil Plate
Anvil Plate after

reconditioning

New Sugar Mill Roller Shells & Re-shelling of used rollers
Zuper Alloys Technology
We provide new rollers and shells made with state-of-the-art Zuper Alloy
technology in GG 25 cast iron or GGG 50 nodular iron , machine , with hard
weld on the grooving.

NEW Sugar Mill Roller Shells
Mechanical Properties of
Zuper Alloys Technology Castings

NEW Sugar Mill Roller Shells
PROVIDING NEW SHELLS

Re-Shelling of Sugar Mill Roller

We offer New Mill Roller Shafts With…
1) 40 c8 or equivalent quality grade confirming to IS 1570 ( part II) 1979.

2) Minimum tensile strength 58kg/mm2.
3) With properties of standard elongation,
4) Duly normalized,
5) Physically and chemically tested including ultrasonic testing.
SUGAR MILL ROLLER
Industry : Sugar
Application : Roller Arching
Details of Machine : Sugar Mill Roller (Top & Bottom)
Wear Pattern : Abrasion, Corrosion due to excessive cane fiber
M. O. C. : Grey Cast Iron
Dimensions : OD 1010 mm x 1950mm length
Wear Problem : In the rotation of sugar mill roller, the sugarcane juice and baggase
passes from roller teeth thus creating sliding abrassion, the entire
teeth gets worn-out thus leading slippage.
Present Solution : Welding with Arching Electrode creating dot matrix thus working
for 2 – 2.5 lacs tons crushing. After which the entire operation needs
rebuilding of roller.

PRESENT SOLUTION – DOT MATRIX ARCHING

PRESENT
SOLUTION –
DOT MATRIX
ARCHING
After 1.5-2.0 lac tons of crushing the roller becomes like as shown in figure (1st season)

ZUPER TEAR DROP TECHNOLOGY
FOR MILL ROLLERS

Pre-machine the
roller
Make the
necessary grooves,
Weld root run

with Zuper RR &
top run of Zuper
TD
Create the
necessary tear
drop

1. Pre-machine the roller 2. Give a complete root-run of
(Reducing the outer diameter welding on the sides of roller teeth
by 5-8 mm) with Zuper RR

Conventional Arching IMCO MAKE ZUPER TEAR DROP
TECHNOLOGY
1. Welding with Arching creates dot matrix. 1. IMCO make Zuper tear drop creates
Which rarely fuses and bonds improperly chevron groove which looks like cycle
with the base material. Thus, creating lean sprocket, thus helps in less dragging and
mean path and crushing inefficiency. improved crushing efficiency.
2. The life of Arching differs between 2-2.5 2. Tear drop technology works
lacs tons crushing and it needs regular uninterrupted for (6-8 lac tons) entire
arching for every intervals, thus causing season without down time losses.
down time
3. After the entire season you need to 3. A small portion of worn out tear drop is
machine the roller, reduce the size and to be built.
arching is made, thus loosing important
material source.
4. Thus repeated expenditure for Re- 4. Efficiency of tear drop gives 6-8 lac tons
building and down-time losses. of uninterrupted crushing. Thus, downtime
is tremendously reduced.

Conventional Arching IMCO MAKE ZUPER TEAR DROP
TECHNOLOGY
5. Hardness achieved is not more than 50- 5. 100% fusion and hardness achieved is
55 Hrc and the bonding strength of weld is 58-62 Hrc and consistent in all segments
50%. and craters.
6. Under cut stroke grooving required for 6. Under cutting is not required for every
every season, thus leading to lesser self season.
life of roller.
7. Effectivity of crushing is less due to 7. High cane grabbing capacity, good

high slippage and the gripping action gripping between roller and the cane,
between roller and cane is continuously more juice extraction and thus less power
reduced. Thus extraction of juice is less consumption.
and power consumption is more.

Worn out Thrash Plate

Conventional Solution for Thrash Plate

Zuper Solution for Thrash Plate
Zuper Replaceable Carbide Tip Thrash Plate

Zuper Solution for Thrash Plate
“Zuper Replaceable Carbide

Tip (RCT) Thrash Plates”
Zuper Replaceable Carbide Tip Thrash Plate

 The tips are replaceable
 Zuper RCT is manufactured having a dense molecular structure
 The tips are unique with Carbides directly fused with base metal.
 It is extremely strong abrasion, corrosion and wear resistant
 The embedded carbides have hardness of around 60-62 HRC
 The Thrash Plate body can be used for multiple seasons
 Zuper RCT offers considerable savings in down time and lost production

Working Together,
Winning Together
Thank You
email : tech@imcoalloys.com / e mail : aslam@imcoalloys.com

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IMCO ALLOYS Pvt. Ltd.

WORKING TOGETHER &

www.imcoalloys.com WEAR RESISTANT ALLOYS

 An international company of repute with over a decade in research and

 The solutions include various applications for crushing hammers, impact

 Team of skilled, highly professional, enthusiastic engineers within reach

www.imcoalloys.com WEAR RESISTANT ALLOYS

IMCO Alloys SA (South Africa)

IMCO Alloys Global (FZC) UAE Middle East

www.imcoalloys.com WEAR RESISTANT ALLOYS

…Still on the rise

www.imcoalloys.com WEAR RESISTANT ALLOYS

Sugar Cement Power Pulp & Paper Petrochemical Mining

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

By deploying the synergy in Sourcing

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

Usage of powder matrix carbides of mesh size 1- 3 microns

Pilot batch approval for raw material to ensure uniformity.

www.imcoalloys.com WEAR RESISTANT ALLOYS

To shape the powder in the

www.imcoalloys.com WEAR RESISTANT ALLOYS

• Better control during sintering

• Sintered components are then heat

www.imcoalloys.com WEAR RESISTANT ALLOYS

Sintered Carbides Conventional Hard facing

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

Also available in regular

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

Torque applied >300 pounds / ft.

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

Assists in Increasing Preparatory Index (PI) due to better

Power consumption is Less due to Swing type Hammer as each

Downtime is Less while changing the Hammer body due to

Efficiency in terms of performance is comparatively HIGH

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

The present design of conventional knife bodies

IMCO Solution and Advantage :

 Excellent abrasive & impact resistance.

 Good edge retention property

 Cost effective compare to conventional method of

 Available in Custom made sizes and orientations.

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

Frequent jamming of leveller due to fixed type knife.

Power consumption is high due to fixed type knife.

Efficiency in terms of performance is average

www.imcoalloys.com WEAR RESISTANT ALLOYS

www.imcoalloys.com WEAR RESISTANT ALLOYS

Swing Type Knife absorb shock, hence NO breakage of knife