Qadbros Engineering

Capabilities, Products and Services

Introduction
130 Year old Family-owned business spanning over four generations

Vertically integrated manufacturing; foundry, machine shop and fabrication

SUGAR CEMENT

STEEL MINING
Global Presence FLSmidth
Copenhagen, Denmark

Partnership for Pakistan's local cement market

Approved supplier for global market

Fives FCB
Lille, France

Technology partnership for Sugar Plant & Equipment

CMD GEARS
Cambrai, France

Agency for Sales and Technical

services for Pakistan's Sugar market

Invelt Group
Pilsen, Czech Republic

Technology partnership for Sugar Plant & Equipment

Chukrova Kimya
Manisa, Turkey

Partnership for supply of foundry coatings to

Pakistan's local market

Technology Partners

Markets

Customers
Foundry Facilities

FOUNDRY 1 FOUNDRY 2
Specializing in heavy cast iron castings upto 40 Tons and Steel foundry with an annual capacity of 7500 Tons
large quantities of heat and wear resistant castings

Cupola Furnace Induction Furnace

Annual Capacity — 9600 Tons Annual Capacity — 7500 Tons
Single Piece Pouring Capacity — Max 40 Tons Single Piece Pouring Capacity — Max 40 Tons

Induction Furnace Covered Area: 170,000 sqft

Annual Capacity — 2000 Tons
Single Piece Pouring Capacity — Max 2000 kg

Covered Area: 180,000 sqft

Foundry Facilities
METHOD - ENGINEERING
Product design software: Solid works, Inventor

Magmasoft — Casting Simulation

PATTERN SHOP
3 axis & 4 axis CNC Routers

x : 1500 mm, y : 3000 mm, z : 500 mm

Accuracy : ± 0.5mm
Foundry Facilities
MOULD PREPARATION
No bake sand moulding system

Continuous sand mixers — upto 100 Tph

Carousel moulding line for efficient mould throughput while

maintaining precision
Foundry Facilities
MELTING

Cupola Furnace : upto 40 ton single piece casting

Induction Furnace : upto 40 ton single piece casting

Foundry Facilities
HEAT TREATMENT
Four heat treatment furnaces — Upto 4 x 6 x 6 m

PLC controlled process

Normalizing, Annealing, Quenching and

Tempering

FINISHING OPERATIONS
Mechanized riser cutting & surface grinding

Shot blasting — 4.5 x 4.5 m

Machining Capabilities

600,000 hours of Annual Machining Capacity

Covered Area: 100,000 sqft

Machining Capabilities

HORIZONTAL LATHES
Max Turning Diameter : 2500 mm

Max Length : 15000 mm

Loading Capacity : 70 Tons

VERTICAL LATHES
Max Turning Diameter : 7000 mm

Max Height : 5000 mm

Loading Capacity : 100 Tons

Machining Capabilities

HORIZONTAL BORING
Manual and CNC Operated
x : 10000 mm, y : 5000 mm, z : 2000 mm

GEAR HOBBING
Max Turning Diameter : 6000 mm

Upto 40 Module
Machining Capabilities

VERTICAL MILLING
x : 3500 mm, y : 1750 mm, z : 1000 mm

INDUCTION HARDENING
Hardening up to 62 HRC
16 to 40 Module
Max Diameter: 7000 mm
Quality Compliance
Dimensional Inspection

Hardness

Microstructural Analysis

Chemical Analysis

Mechanical Testing (Tensile, Impact)

Nondestructive testing (DPT, MPT & UT)

Certifications
ISO 9001:2015 — Quality Management System

ISO 14001:2015 — Environmental Management System

ISO 45001:2015 — Occupational Health & Safety

Product Portfolio — Sugar
 HEAVY DUTY CANE KNIFE ASLY.
Customized Manufacturing according to customers requirement

Manufactured for LASUCA SUGAR FACTORY , LOUSIANA , USA

 MillMax® 102”
( The Largest MillMax® till now )

Manufactured by QADBROS
 ( QADRI SKODA Design )

55'' x 95'' 4-Roll Mill

( Max. Crushing Capacity 20,000 TCD )

Manufactured for LULA – WESTFEILD SUGAR FACTORY

LUSIANA , USA

LULA – WESTFEILD SUGAR FACTORY , LUSIANA , USA

 Mill Crown Pinions
 Fully machined to produce precise and
smooth profile
 Tooth profile induction hardened to increase
wear resistance
 A range of materials available for your choice
 Girth Gear
(For Mining Sector)

Manufactured for Mechprotech, South Africa

 Helical Spur Gear Dia 4080

 Material BS 970
 Induction Hardened Teeths
Product Portfolio — Cement
The Cement Market in Pakistan

26 plants in Pakistan, 52 production lines

69 Million Ton per annum production capacity

Cement production capacity expected to grow by 43% by 2023

Qadbros entered the market for cement wear parts in 2013

Collaboration with FLSmidth in 2019

Qadbros is now the leading supplier in the local cement sector; 80% market share
QADBROS — FLSMIDTH COLLOBORATION

Transfer of technology and product know-how from FLSmidth to Qadbros

FLSmidth conducting routine audits of Qadbros production processes and

quality protocols

Evaluation of RFQs and Specifications as per FLSmidth standards

Training of Qadbros technical staff

Assuring that all products comply to FLS quality specifications

Development of products for the export market, +1000 TiC Hammers delivered to FLS customers globally
Bimetallic Insert Hammers
Low-Wear Crushing Solution

Maximum striking hardness from the start

2 ― 3 times increased life

Case Study — Maple Leaf Cement
Application: Limestone Crusher
Performance: 2.8 MT crushing (still in operation) compared
to 1 MT from Plain Manganese Steel Hammers

Case Study — Fauji Cement

Application: Limestone Crusher
Performance: 14.5 mm wear on one side after 100,000
Tons of crushing. Compared to 32.5 mm wear on standard
manganese hammers

Case Study — Bestway, Kallar Kahar

Application: Clinker Crusher
Performance: 0.3 grams/Ton wear on TiC Hammer
compared to 0.8 grams/Ton on Plain Manganese Steel
Hammers
Grate Plates

Superior resistance against abrasion

Stringent control of microstructural properties

Blow Bars
Titanium Carbide delivering Exceptional wear performance
Specifications
Material : Manganese Steel with TiC Inserts
Dimensions : 120 mm x 500 mm x 3000 mm
Weight: 1500 kg

Delivered to customers in Congo, Africa and Colombia, South America

Dip Tubes
Cast central pipe for high temperature cyclones

Focus on dimensional precision & metallurgy

Stringent process control to comply to chemical composition

Assuring dimensional accuracy through foundry automation and in-

house trial assembly

Case Study — Lucky Cement, Karachi

Material: ASTM A297 Gr.HK
Installation: Cyclone C5
Performance: No issues in installation
12 months life

Case Study — Cherat Cement

Material: ASTM A297 Gr.HK
Installation: Cyclone C5
Performance: No issues in installation
15 months life, compared to 9 months life of local supply
Since 2018, Cherat has ordered 12 sets for two lines to Qadbros
Kiln Inlet & Outlet Sectors

Short installation time

Longer lifetime

Reduced maintenance time

Reduced clinker dust emission

Refurbishment of Roller hub
Loesche LM 32.4 & 56.6

Initial quality inspection of the hub to evaluate worn out surface

Worn out sizes rebuilt through weld repairing and then machined as per original dimensions
Complete in-house assembly of bearings and Tire onto the hub, under customer supervision
Pfister housing + Plates
Refurbishment

Shrink fitting of Stainless Steel Sleeve inside the

Pfister casing

Final Internal Diameter : 1000mm ± 0.2 mm

Cooler Parts
Wear Parts for Ball Mills
Step Liners and Intermediate Diaphragm Plates

Superior resistance against abrasion

Stringent control of microstructural properties

Rotor Discs
For Limestone Crusher
Segments & Tires for Vertical Roller Mills

Roller Segments to Power Cement

Cement Mill FLS ATOX 55
Roller Ø 3212 mm
1,938 kg (each segment)

Grinding Tire to Pioneer Cement

Coal Mill Loesche
Tire Ø 2200 mm
3,700 kg
Under successful operation since Jan 2020

Table & Roller segments to Maple Leaf

Raw Mill FLS ATOX 22.5
Table Ø 2310 mm
362 kg (each segment)

Roller Segments for FLS ATOX 52.5

Roller Ø 3066 mm
1,695 kg (each segment)
Order in production

Grinding Tires to Fecto Cement

Cement Mill Fuller FRM 2430
Tire Ø 1634 mm
2,353 kg
Order in production
Crushing Segments
Clinker Crusher

Compliance with dimensional requirements

Stringent internal testing with inspection fixture

Extensive quality testing

Chemical, Mechanical, Ultrasonic and Magnetic
Particle Testing to ensure enhanced product life
Impeller
Kiln Supporting Rollers
Forged shaft with Forged / casted shell

Recent delivery to Lucky Cement, Karachi

Material : Forged Steel Shaft + Casted Roller

Dimensions : Ø 1600 mm x 850 mm
Weight: 16,000 kg (assembled)

Order from Fives FCB, France, for supply of

kiln supporting rollers for 6500 TPD line in
Senegal, Africa

Dimensions : Ø 2250 mm x 1100 mm

Weight: 37,000 kg (assembled)
Roller for Roller Press
White Metal Bearings
Remetalling Excellence
PRODUCTS — GENERAL INDUSTRY
MANGLA DAM UPGRADATION PROJECT
REFURBISHMENT OF 100MW TURBINE HOUSINGS

Project under supervision from General Electric

 Ultrasonic and Magnetic Particle Testing for Identification of defects

 Weld repairing of defects in compliance to referred standards

 Machining to achieve original dimensions

MANUFACTURING OF JTT PLUG FOR CERN
CASTING AND MACHINING OF OPEN GRAIN CAST IRON

Project supervision by CERN, Switzerland

 Casting and machining in

compliance with defined
standards

 Pre-delivery inspection by
CERN Team
GATING SYSTEM FOR GUDDU BARRAGE
CANAL GATES HOISTING MACHINES

Project undertaken in partnership with

DESCON Engineering

Drawing generation, manufacturing and

assembly

In-house Factory Acceptance Test (FAT) ; UT, DPT,

Dimensional, Mechanical and Load Test
 PAPER & BOARD
FEED SCREW, THROAT CONE & FIBRE DISTRIBUTION RINGS

 Reverse engineering through drawing development and material testing

 Ability to cast in a range of Steel Grades: AISI 1045, SS 410, SS 304
IMPELLER
FABRICATION, WELDING & DYNAMIC BALANCING

Hot air impeller for ZRK, Mardan

 Fabricated in Carbon Steel, Stress Relieved and
Machined for the right airflow profiles

 Dynamic balancing carried out @ 1350 RPM

CHEMICAL PLANTS
CARBONATING TOWER, OVER FLOW BRACKET, BOWL HEAD SHAFT

 Casting and machining operations

 Extensive quality testing to ensure compliance to material grade

 Pressure test of castings to ensure reliable operation

GEAR MANUFACTURING
DRAWING GENERATION UP TO FINAL ASSEMBLY

Manufacturing, Assembly and Installation

 Induction hardening of gear teeth for superior
performance

 In-house assembly and operation to improve

surface contact
STEEL SECTOR
INGOT MOULDS, SLAG POTS

 Slag Pot manufactured in Cast Iron, supplied as-cast

 Ingot mould manufactured in Nodular Cast Iron

 Exporting to N. America
STEEL SECTOR
PINION SHAFTS & FLY WHEELS

 Pinion shafts machined from forged shafts

 Teeth are induction hardened for better life

 Flywheels made in cast steel grades to store

energy

 Supplying to 100+ Steel Mills across Pakistan

STEEL SECTOR
PULLEYS

 Pulleys are supplied in Cast Iron, Nodular Cast Iron

and Cast Steel Grades

 Pulleys are machined and supplied after dynamic

balancing

 Supplying to 100+ Steel Mills across Pakistan

FERTILIZER
CRUSHER & KILN ROLLERS, GRINDING RINGS

 Manganese steel roller for Limestone

crushing

 Forged steel Kiln Supporting Rollers

AUTOMOTIVE
PRESS DIES

 Cutting and creasing dies, supplied in FC30,

FCD and FCG grades

 Polystyrene patterns for casting

MARINE
DELTA FLIPPER ANCHORS

 Reverse Engineering through Drawing

development & Material Testing
 Material
– Shank: Cast Steel to AISI 1045
– Shackle: Forged Steel
to AISI 1045
– Head & Angular Plates: Fabrication
ASTM A36
 Machined in-house according to requirement

 Manufacturing Anchors of 2500 Kg & 3000 Kg with

facility to produce castings up to 40 tons
 Compliant with required Quality Standards
Ground Engaging Tools
Bucket teeth and adaptors with superior wear life and performance

 Compliance to strigent metallurgical and dimensional requirements

 Covering all major brands; Caterpillar, Komatsu, JCB, Daewoo, Etc.

Parts for Undercarriage
Carriage Roller, Chain Links and Idler Wheel

Track Rollers Idler Wheel & Rollers

Track Chains
Misc. Excavator Parts
Cutting Edge, Side Cutter
Tractor Crankshafts
Covering All Tractor Models in Pakistan

 Manufactured in Nodular Cast Iron

 Production Capacity: 1500 Pcs / month
 Breakage Warranty of 6 months
 Models include:

 Massey Ferguson 240 , 265 & 375

 Mazda T-3500

 Fiat 480 & 640

 Belarus & Bedford

 Ford 4600/4000 & 3600/3000

Engineering & Testing Services
Reverse Engineering, Design, NDT & PMI
Design Services
Dedicated team of design engineers

Engineering drawings, 3-D Modelling and

Finite Element Analysis

Providing design services to

European partners

Reverse Engineering
Product development through Faro ScanArm
and 3-D scanners

Providing on-site services for drawing

generation
Casting Simulation

State of the art casting simulation software — Magmasoft

Simulation of metal temperature, velocity and numerous other parameters

Assessment of potential casting defects and high-stress points

Offering services to other foundries to simulate their casting technology

Material Testing
Comprehensive analysis of material chemical composition through state of the art spectrometry equipment

Services for onsite material testing through portable XRF material analyzers

Mechanical Testing (Tensile, Yield, Elongation, Toughness & Hardness)

Microstructural analysis of the material

Testing and analysis can be followed by recommendation by Qadbros R&D team on alternate materials to
improve performance
Dimensional & Geometrical Inspection
High-accuracy measurement tools

On-site dimensional inspection

Portable equipment for testing of surface hardness

and roughness

In-house facility for machine assembly

Services for levelling & alignment of machine parts

Services to check part mating in assembly

In-house test rig for inspection of gear teeth contact

Scratch testing & inspection of paint coat thickness

Dye Penetrant Testing
Detection of surface defects such as pitting
and cracks (Fluorescent & Visible Light)
Defect evaluation and reporting by Level I & II
NDT certified inspectors

Magnetic Particle Testing

Detection of sub-surface micro defects
(Fluorescent & Visible Light)

MPT is classified as a more reliable defect

detection technique compared to DPT
Ultrasonic Testing
State of the art ultrasonic flaw detectors from Krautkramer, Germany

Team of Level II certified ultrasonic testing inspectors

Evaluation as per ASME (welding joints), ASTM and ISO standards

Capability to measure thickness of piping and pressure vessels

Offering on-site services for ultrasonic testing

Engineering Consultancy
With extensive production facilities, design team, quality testing equipment, high
skilled manpower and partnerships with world leading technology companies,
Qadbros offers the complete scope of engineering consultancy services and
solutions