Except for the purchase of rolled Steel Wire Rods and proprietary surface treatment chemicals, all other Product Realisation Processes are carried out in-house with provisions of in-house Tool Management & under exhaustive surveillance of well established Integrated Quality Management system.

After detailed & thorough incoming inspection carried out on 100% of the raw material i.e. As-rolled steel coils, the accepted coils are passed on to wire processing & the rejected ones are returned to vendor. Each accepted coil is assigned a unique no. to serve the purpose of Identification & Traceability of each Batch of fasteners made out of each coil.

Wire Processing

Wire rod is thoroughly cleaned in HCl. After pickling, wire rod is rinsed in running water in tank and then it is subjected to jet water rinsing, thereafter it is heated up in hot water bath. Then the absolutely cleaned steel coil is phosphate coated & rinsed. It is finally dipped in Bond lube bath and thereby soap coating is applied on phosphate coating.

Wire Drawing:
Wire rod if Mild Steel or Boron Steel requiring a light pass is given skin draw on Wire Drawing Machines & made ready for cold forging of fasteners.

Wire rod requiring a heavy reduction in Cross Sectional area to get a comparatively much smaller size and the Wire Rod requiring spheroidise annealing for softening are drawn with a heavy reduction in order to crush the structure into small grains to facilitate annealing.

Spheroidise Annealing:
Spheroidise Annealing is a state of the art of sub critical annealing of the wire rod for spheroidisation of the micro-structure in order to augment cold formation of metal in the wire to take critical shapes. The entire annealing cycle in terms of temperature, time and atmosphere control is governed by U.K made FGH Controls, thereby eliminating human error in the entire annealing process.

Final Wire Draw:
After spheroidise annealing the wire rod is pickled & phosphated & Bond Lube coated and lastly given a skin pass in the wire drawing machine. The wire is now ready for forging.

Forging

After the wire rod is converted into the desired size of wire the same is put into the cold forging operation for making Industrial Fasteners like Bolts, Studs, Screws, Nuts, Special fasteners etc.

Bolt Forging:
There is a large battery of 21 multistation Cold Bolt Formers of internationally renowned makes, large no. of High Speed Single Die Two Blow Cold Headers as well as vertical power presses.

All these enable Pooja Forge Ltd. to employ State-of-the art techniques & prowess for forging highly special & precision Bolts/Screws/Studs etc along with the vast range of standard fasteners.

In course of Cold Forging, Pooja Forge ensures the desired quality of grain flow, normal Extrusion/Trap-extrusion, Precise shank diameter, good surface quality & ensuring optimum raw material consumption.

Nut Forging:



There are again 21 Cold Nut Formers & Pooja Forge has the state-of-the art know-how to forge any type of Cold Forgeable nut – Specials backed by very wide range of standards.

Thread Rolling facilities:



Pooja Forge has a large battery of Thread Rolling machines comprising of 30. nos. of flat die type machine and 13 rotary die machines. Cold thread rolling ensures more precise & stronger threads than cut threads. For obtaining a better fatigue resistance threads are rolled after heat treatment as is needed in critical automobile engine bolts.

Nut Tapping:



Pooja Forge have as many as 10 nos. of 4 spindle Auto nut tapping machines of the latest high speed technology for tapping nuts with high precision.

These are in addition to the earlier batch of 10 nos of two spindle gothic tapping machines.

Other secondary operation machines:
Pooja Forge have Turning machines, Centreless Grinders, Copy Turning lathe, Special pointing & grooving machines, Cylindrical & surface grinders, milling machines – all for special & precision fasteners.

Product Heat Treatment:
Pooja Forge Limited has 3 nos. of the gem of in-house heat treatment facilities.

Each of the three plants comprises of continuous, fully automatic, electrically heated mesh belt conveyor type hardening and tempering furnace line with all duly calibrated controls operated by PLC’s. The system is human error proof in so far as output quality is concerned.

The system ensures the required tempered Martensitic structure with right hardness traverse & devoid of any temper brittleness particularly in Chrome bearing steels. There is no scope of mix-up between as-hardened & tempered material or heat treated & un-heat treated material. The CP Controller ensures avoidance of decarburisation or carburisation both of which are banned in heat treatment of fasteners.

Surface Treatment:

Automatic Electrogalvanising: Pooja Forge Ltd. have a state-of-the art automatic Electrogalvanising plant processing White (Bluish), Yellow, Black and Green Passivation. The entire system is PLC Controlled eliminating, thereby, human error affecting output quality. Pooja Forge also provides phosphate coating to their products, if customer demands the same.

Final Inspection

The stage Quality control System Controls the population quality by SPC & routine check up.

Each lot gets passed on to the last stage only if ok to specification in the line Inspection. It is subjected to quality check in the final Inspection based on statistical sampling plan as per IS: 2500.

Standards Room

The company has well equipped standards room with temperature, humidity & dust control to do the scheduled calibration of all the Inspection, Measuring and Test Equipments. The calibration system covers both in-house & external calibration. The external calibration laboratories are traceable to National and International Test Houses & are atleast NABL certified. Color codifications exist for calibrated & accepted as well as rejected instruments.