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Staff Login

PROCESS

Building Future with Strength

Manufacturing Excellence

Our Manufacturing Process

At Ambe Structures, we employ a fully integrated manufacturing process that transforms raw scrap into premium structural steel products. Our end-to-end production facility ensures complete quality control from melting to dispatch, with a production capacity of 250,000 TPA.

Our state-of-the-art automated rolling mills, combined with advanced induction furnace technology and continuous casting systems, enable us to deliver consistent quality and dimensional accuracy across all product lines.

End-to-End Manufacturing

Process Overview

Our integrated manufacturing process encompasses 8 critical stages, each monitored and controlled to ensure optimal product quality. The complete cycle from scrap to finished product takes approximately 4-6 hours, with real-time quality checks at every stage.

Raw Material Selection

Quality scrap sourcing and inspection

Melting Process

Induction furnace operations at 1600°C

Continuous Casting

Billet production with precision cooling

Rolling & Finishing

Hot rolling to final dimensions

Production Capacity & Efficiency

250,000

TPA Capacity

98.5%

Yield Efficiency

24/7

Operations

4-6 hrs

Cycle Time

Quality Begins Here

Raw Material Selection

Our raw material procurement follows stringent quality protocols to ensure only premium-grade scrap enters our production line. We source from certified vendors and conduct comprehensive quality checks before acceptance.

Scrap Classification

HMS 1&2, Shredded scrap, Turning & boring scrap - categorized by grade and composition

Chemical Analysis

Spectrometer testing for Carbon, Manganese, Silicon, Phosphorus, and Sulfur content

Physical Inspection

Visual examination for contamination, moisture content, and dimensional suitability

Vendor Certification

Approved supplier list with regular audits and performance evaluation

Material Specifications

Parameter	Specification	Acceptance Criteria
Carbon (C)	0.15% - 0.25%	Within tolerance
Manganese (Mn)	0.60% - 1.00%	Balanced composition
Silicon (Si)	0.10% - 0.40%	Controlled range
Phosphorus (P)	Max 0.055%	Below threshold
Sulfur (S)	Max 0.055%	Below threshold
Moisture	Max 2%	Dry condition

Monthly Procurement: 20,000+ MT from 50+ certified vendors across Central India

Core Production

Melting Process

Our advanced induction furnace technology ensures precise temperature control and chemical composition, producing high-quality molten steel with minimal impurities.

Temperature Control

Induction furnaces operate at 1580-1620°C with ±5°C precision control using advanced PLC systems.

Heating Rate: 8-10 tons/hour
Melting Time: 45-60 minutes
Power Consumption: 450-480 kWh/ton
Furnace Capacity: 15 MT per heat

Chemistry Control

Real-time chemical analysis and adjustment to achieve target composition for different steel grades.

Spectrometer Analysis: Every heat
Deoxidation: Aluminum & Silicon
Desulfurization: Lime injection
Alloy Addition: Ferro-manganese

Safety Systems

Comprehensive safety protocols and automated systems protect personnel and equipment.

Water Cooling System: Closed loop
Fume Extraction: 99% efficiency
Emergency Shutdown: Automated
PPE Compliance: 100% mandatory

Furnace Specifications

3 x 15 MT Induction Furnaces | Medium Frequency (1000 Hz) | Refractory Lining: Acidic/Basic | Tapping Temperature: 1600-1620°C

45 MT/hour

Combined Melting Capacity

Precision Casting

Continuous Casting Process

Our continuous casting machine transforms molten steel into high-quality billets with consistent cross-sections and minimal defects. The process ensures uniform cooling and solidification for optimal metallurgical properties.

Casting Parameters

Billet Size:

100x100mm to 150x150mm

Casting Speed:

2.5 - 3.5 m/min

Strand Length:

12 meters

Number of Strands:

4-strand machine

Quality Control Measures

Electromagnetic stirring for homogeneity
Mold oscillation for surface quality
Secondary cooling zones (8 zones)
Online temperature monitoring
Automatic cutting to length

Casting Process Flow

Tundish Filling

Molten steel transferred from ladle to tundish

Mold Casting

Steel solidifies in water-cooled copper molds

Secondary Cooling

Controlled water spray cooling in 8 zones

Straightening

Billet straightened to remove bow

Cutting & Marking

Automatic cutting to 6m/12m lengths with identification

40 MT/hour

Continuous Casting Capacity

960 MT per day | 28,800 MT per month

Thermal Processing

Reheating Furnace Operations

Our walking beam reheating furnace ensures uniform heating of billets to optimal rolling temperature with maximum fuel efficiency and minimal scale formation.

Temperature Profiles

Zone	Temperature	Purpose
Preheating Zone	600-800°C	Initial heating
Heating Zone 1	900-1050°C	Gradual heating
Heating Zone 2	1100-1180°C	Target temperature
Soaking Zone	1180-1220°C	Uniform temperature

Residence Time: 90-120 minutes for complete heating cycle

Discharge Temperature: 1180-1220°C (±10°C tolerance)

Fuel Efficiency Measures

Fuel System

Primary Fuel: Natural Gas / LPG
Consumption: 35-40 Nm²/ton of billet
Burner Type: High-velocity regenerative
Combustion Efficiency: 92-95%

Energy Conservation

Waste heat recovery system
Ceramic fiber insulation
Automated air-fuel ratio control
Oxygen enrichment system
PLC-based temperature control

35 MT/hr

Heating Capacity

92-95%

Thermal Efficiency

±10°C

Temperature Uniformity

24/7

Continuous Operation

Hot Rolling Operations

Multi-Stage Rolling Process

Our automated rolling mill transforms heated billets into precision structural steel products through multiple rolling stands with dimensional accuracy of ±0.5mm.

Rolling Mill Specifications

Mill Type:	Fully Automatic Rolling Mill
Number of Stands:	12-stand configuration
Rolling Speed:	8-12 m/sec
Production Rate:	30-35 MT/hour
Size Range:	25mm to 200mm
Length Accuracy:	±5mm per 12m
Dimensional Tolerance:	±0.5mm

Rolling Stages

Roughing Stands (1-4)

Initial reduction from 100-150mm billet to intermediate sections

Intermediate Stands (5-8)

Progressive shaping and dimensional control

Finishing Stands (9-12)

Final sizing with precision calibration rolls

Cooling Bed

Controlled air cooling to ambient temperature (45-60 min)

Automation Level

95%

PLC-controlled operations with minimal manual intervention

Precision

±0.5mm

Dimensional accuracy across all product lines

Cycle Time

2-3 min

From entry to exit per piece

Final Processing

Finishing Operations

After rolling, our products undergo comprehensive finishing operations to ensure they meet exact customer specifications and quality standards.

Cutting to Length

Automatic flying shears cut products to standard lengths (6m, 9m, 12m) or custom sizes with ±5mm accuracy. Capacity: 40 cuts/minute.

Straightening

Multi-roller straightening machine removes bow and twist. Maximum bow tolerance: 3mm per 6m length. Straightness: 99.8%.

Bundling & Strapping

Automatic bundling system creates uniform bundles (2-5 MT each) with steel strapping at 3 points. Bundle identification tags applied.

Surface Treatment

Shot blasting for scale removal (optional). Oil coating for rust prevention during storage and transit. Coverage: 15-20 g/m².

Finishing Equipment

Flying Shear

High-speed cutting system

2 Units

Straightening Machine

9-roller configuration

1 Unit

Cooling Bed

Walking beam type, 60m length

1 Unit

Bundling Machine

Automatic strapping system

2 Units

Overhead Cranes

20 MT capacity each

4 Units

Metallurgical Processing

Heat Treatment Process

Specialized heat treatment operations enhance mechanical properties and relieve internal stresses for critical applications.

Normalizing

Heating steel to 900-950°C and air cooling to refine grain structure and improve mechanical properties.

Temperature: 900-950°C
Holding Time: 30-45 min
Cooling: Still air
Result: Uniform structure

Stress Relieving

Controlled heating to 550-650°C to reduce residual stresses from rolling and cooling operations.

Temperature: 550-650°C
Holding Time: 60-90 min
Cooling: Furnace cooling
Result: Stress reduction

Annealing

Full annealing process for improved machinability and ductility in special grade products.

Temperature: 850-900°C
Holding Time: 2-4 hours
Cooling: Slow furnace
Result: Soft structure

Heat Treatment Facilities

2 Units

Batch Furnaces

15 MT

Capacity per Batch

1200°C

Maximum Temperature

±5°C

Temperature Control

Quality Assurance

Quality Inspection at Each Stage

Comprehensive quality checks at every production stage ensure 100% compliance with national and international standards.

Chemical Analysis

Spectrometer testing at melting stage

Every heat tested
5 elements analyzed
Results in 2 minutes

Dimensional Check

Automated measurement systems

Online gauging
±0.5mm accuracy
100% inspection

Visual Inspection

Surface quality assessment

Trained inspectors
Defect detection
Marking system

Weight Verification

Bundle weight confirmation

Electronic weighbridge
50 kg accuracy
Certified scales

Inspection Frequency & Standards

Raw Material Stage

Chemical composition, physical inspection, moisture content - Every batch

Production Stage

Temperature monitoring, dimensional checks, surface quality - Continuous

Final Product Stage

Mechanical testing, dimensional verification, bundle inspection - 100% lots

Final Stage

Packaging & Dispatch Process

Our systematic packaging and dispatch operations ensure products reach customers in perfect condition with complete documentation and traceability.

Packaging Standards

Bundle Formation: 2-5 MT bundles with uniform piece count
Strapping: High-tensile steel straps at 3 points per bundle
Identification: Color-coded tags with heat number, size, grade, weight
Protection: Oil coating + waterproof wrapping for export
Traceability: QR code linking to production records

Dispatch Capabilities

Daily Capacity:

800-1000 MT

Loading Bays:

6 simultaneous

Truck Types:

20-32 MT capacity

Rail Siding:

Available

Dispatch Process Flow

Order Processing

Sales order verification and production allocation

Material Selection

Picking from finished goods inventory by specifications

Quality Verification

Final inspection and test certificate preparation

Weighment

Electronic weighbridge with printed weight slip

Loading

Crane-assisted loading with proper securing

Documentation

Invoice, test certificates, e-way bill, delivery challan

15,000+ MT

Monthly Dispatch Capacity

Serving 500+ locations across India

Industry 4.0

Process Automation & Control Systems

Advanced automation and digital control systems ensure consistent quality, optimal efficiency, and real-time process monitoring across all production stages.

PLC Control

Programmable Logic Controllers manage all critical equipment with millisecond response times

SCADA System

Supervisory Control and Data Acquisition for real-time monitoring and control

MES Integration

Manufacturing Execution System tracks production from order to dispatch

Automated Handling

Robotic material handling reduces manual intervention by 80%

Automation Features

Temperature Control

Automated temperature regulation in furnaces and reheating systems with ±5°C accuracy. PID controllers maintain optimal heating profiles.

Speed Regulation

Variable frequency drives control rolling mill speeds. Automatic adjustment based on product size and material grade.

Dimensional Control

Online gauging systems with automatic feedback to rolling stands. Real-time corrections maintain ±0.5mm tolerance.

Cutting Automation

Flying shears with encoder-based length measurement. Automatic cut-to-length with ±5mm accuracy at full speed.

Control Room Operations

Centralized control room monitors and manages entire production line with 24/7 operator presence.

50+

Monitoring Points

15

Display Screens

24/7

Operations

3

Shift Teams

Key Capabilities:

Real-time production monitoring
Alarm management system
Historical data logging
Remote diagnostics capability
Production report generation

Operational Excellence

Lean Manufacturing Practices

We implement world-class lean manufacturing methodologies to eliminate waste, optimize processes, and deliver maximum value to customers.

5S Implementation

Systematic workplace organization for efficiency and safety.

Sort (Seiri): Remove unnecessary items
Set in Order (Seiton): Organize workspace
Shine (Seiso): Clean and inspect
Standardize (Seiketsu): Create standards
Sustain (Shitsuke): Maintain discipline

5S Score

92%

Kaizen Culture

Continuous improvement through employee suggestions.

Suggestions/Year: 450+

Implementation Rate: 68%

Cost Savings: ?2.5 Cr

Active Participants: 85%

Waste Elimination

Targeting 7 types of manufacturing waste (Muda).

Overproduction - Minimized
Waiting Time - Reduced 40%
Transportation - Optimized
Over-processing - Eliminated
Inventory - JIT approach
Motion - Ergonomic design
Defects - less than 0.5%

Lean Performance Metrics

98.5%

Yield Efficiency

85%

OEE (Overall Equipment Effectiveness)

4.2 hrs

Average Cycle Time

99.2%

On-Time Delivery

Future Ready

Process Innovation & R&D

Our commitment to innovation drives continuous improvement in manufacturing processes, product quality, and operational efficiency.

Energy Efficiency Projects

Waste heat recovery systems, LED lighting, VFD installations reducing energy consumption by 15% annually. Target: Carbon neutral by 2030.

Process Optimization

AI-based predictive maintenance, machine learning for quality prediction, digital twin technology for process simulation and optimization.

Product Development

Research on high-strength steel grades, corrosion-resistant coatings, and specialized alloys for demanding applications.

Sustainability Initiatives

100% scrap-based production, zero liquid discharge, slag utilization in cement industry, and comprehensive recycling programs.

Innovation Investments

?5 Cr

Annual R&D Budget

12

Active Projects

25+

Technical Team

3

Patents Filed

Recent Achievements:

15% energy reduction through waste heat recovery
New TMT bar grade with 600 MPa strength
Automated quality inspection system
Zero liquid discharge certification
Industry 4.0 readiness level 3 achieved

Collaboration Partners

IIT Raipur | NIT Raipur | CSIR-NML Jamshedpur | RDCIS Ranchi

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