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Heavy industrial applications expose hydraulic cylinders to harsh, intensive conditions, resulting in severe wear-and-tear and damage that
impacts performance or shuts down machine operations. Replacing your compromised cylinders with new ones can be costly and time-consuming...
1. Chrome Plating

Hard chromium electroplating is a process where an extremely hard deposit of chromium metal is applied to a metal to enhance its serviceability.
Neeraj Industries has over 20 years experience with this process and have established ourselves as a Market Leader in Chrome Plating. By using up to date technology and equipment, Neeraj Industries strives to supply a consistent coating to our many customers.
The advantages of hard chrome plating are many - some being size restoration of worn components, extreme hardness, wear resistance and anti-corrosion characteristics.

Neeraj Industries has six electroplating tanks consisting of:-

  • 3 of 1.400m x 1.400m x 3.300m deep
  • 1 of 1.500m x 7.500m x 2.000m
  • 1 of 1.400m x 1.400m x 1.400m
  • 1 of 1.000m x 1.000m x 1.000m
Some of the items that Neeraj Industries has serviced are:

Longwall Rods

At left is an example of damaged longwall hydraulic rods to be refurbished using cylindrical grinding to remove damage, then hard chrome plated and reground to drawing specifications.

Pinion Shaft

2m by 750 diameter pinion shaft gear blank, hard chrome plated then ground to drawing tolerances.

Level Rolls

Shown here are the re-furbished steel industry leveling rolls and forming rolls. Rolls are cylindrically ground to remove damage, then hard chrome plated and re-ground back to drawing specifications.

Hydraulic Cylinder

Hydraulic cylinder ready for dispatch after re-furbishment.

International

Rough turned rolls ready for grinding and hard chrome plating for export to Asia.
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Hard chrome is used in industrial applications because of one or more of the following qualities:
  1. Wear Resistance
  2. Low Coefficient Of Friction
  3. Chemical Inertness
  4. Hardness
  5. Corrosion Resistance
  6. Abrasion Resistance
  7. Ability To Take High Polish
  8. Resistance To Galling
Hard chrome plating is not restricted to ferrous metals. Here are some of the substrates that may be deposited with hard chrome:
  1. carbon steels
  2. hardened carbon steels
  3. stainless steels
  4. tool steels
  5. cast irons (porosity must be considered -- pit formation)
  6. non-ferrous metals including copper and brass
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2. Hard Chrome Plated Steel Shafts

Hard Chrome Plated Steel Shafts (Hard Chrome Plated Steel Bars) and hardened hard plated chrome steel bars are designed to meet your specific needs for piston rod material in Hydraulic and Pneumatic Cylinders and other applications.  Most advanced techniques of surface removal, polishing and hard chrome plating are used in manufacturing the above bars.

These hard chrome plated Shafts (hard chrome plated bars) being available in standard sizes and can be made available according to customers sizes also, It is used in construction, material - handling equipment, farm equipment, industrial machinery and almost anywhere.

These bars being preprocessed materials, you can save processing, time, energy, money and eliminate multiple vendor tensions. When delivered to you, no processing steps turning, grinding, finishing and plating are required.

All material undergoes extensive visual & electronic inspection before shipping.  This helps us to maintain consistent quality from bar to bar.  All our bars are transported in protective packaging so you can be sure that they will reach in top condition.

In-house facilities for hard chrome plated Shafts (hard chrome plating of bars), is processed under strict quality control and geometrical parameters such as roundness, chrome thickness and surface finish.  Our own designed plant is fully equipped with a wider range of machines and processing facilities that gives tremendous flexibility to cater the needs of demanding customers.

Hardening of the material is done by induction procedure for all carbon content material, En36 material has to go through some procedure of carburizing and then to the hardening procedure.                                                                                                   

Standard Specifications Of hard chrome plated Shafts ( hard chrome plated bars)

* Chrome Thickness

: 20 to 30 microns

* Chrome Surface Hardness

: 850-1000 HV

* Surface Finish

: RMS 8-12    R.A. : 0.2 - 0.3 micron

* Tolerance

: h8, f7, f8, g6……………

* Straightness

: 0.2mm / 1000 mm max.

* Roundness

: 1/3 of Dia. Tolerance

*Material Std. Size

: 8mm dia to 150mm dia

*Std. Length

: cut to customer length up to 6000mm

* Material Grade

: EN-8 D/ C-45 (other material like En.9 /  En. l9 / En. 24 / En31 / En 36 etc. can be used) As per customer requirement

We manufacture induction harden hard chrome plated bars We manufacture these bars in following specification

01

Material grade EN-8 D grade or CK -45

02

Plating thickness 25 – 30 microns

03

Plating hardness – 800 – 1000 hv

04

Induction hardness – 58-60 hrc

05

Induction hardness on dia upto 3 – 4 mm

06

Straightness : 0.1 mm /per meter

07

Surface finish : better then RA value 0.1

08

Accuracy : g8, h8 , h7 , g6 , as per customers requirement

Induction Hardening Chrome Plated Bar / LM Shaft / Side Rail

Dia mm

Hardening Depth

Dia mm

Hardening Depth

Dia mm

Hardening Depth

Dia mm

Hardening Depth

10

> lm

18

> 2m

28

> 2m

50

> 2.5m

12

> lm

19.05

> 2m

30

> 2.5m

60

> 3.m

15

> 2m

20

> 2m

31.75

> 2.5m

65

> 3.m

16

> 2m

22

> 2m

35

> 2.5m

70

> 3.m

 

 

25

> 2m

38

> 2.5m

75

> 3.m

 

 

25.4

> 2m

40

> 2.5m

80

> 3.m

 

 

 

 

45

> 2.5m

100

> 3.m

Usage :
Shaft for L.M. Bearing / Piston Rod For Earth moving equipment shaft for fitness equipment Guide Pillar, Side Rail.

Remark :
  • Material : C-45 / EN-9 / EN-19 / EN-31/ EN36
                   or as per customer requirement
  • Std size :10mm to 100mm. above 100mm ,Std length : cut to customer length up to 7000mm
  • Hard chrome plating thickness : 20 to 25 micron
  • Surface Roughness : 0.2 RA
  • Surface Hardness : 60 HRC + 2°
  • Chrome surface hardness : 850 to 1000 HV
  • Straightness: 0.1 per meter max.
  • Od Tolerance: h8 / f7 / g6................

Note :
Complete machining on Induction harden bar can be done as per customer requirements like Threading / Kew way / Drilling Tapping on Face / Dia

 
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3. Hydraulic Cylinders

 We are specialize in design, development ,  manufacturing and reconditioning of hydraulic cylinders.

Don’t scrap the hydraulic cylinders let’s rebuilt it’’

We also have Service Division where we aim to recondition a Hydraulic Cylinder by using all possible existing components that are in good and workable condition. However, any component beyond the scope of repairs would be scraped and replaced with new component. Any reconditioned cylinder returned to the

customer would be as good as BRAND NEW CYLINDER for which we stand by a warranty of 1500 working hours or six months, whichever is earlier.

Over last few years we have by now reconditioned and supplied many cylinders of HEMMs like Dozzers, Dumpers, Excavators, Drills Loaders and Plant Side Cylinders like Accumulators, Vertical Raw Mill, Coal stamping cylinders  etc.

Hydraulic Cylinder Rebuild and Test Shop:

We have what it takes to rebuild your hydraulic cylinder group if it is 336" (28') or shorter, and nut torque on/off is 50,000 ft lbs or less. Chances are, most of you reading this are still in our ballpark- those of you who are not are dealing with some massive cylinders, and have probably been featured on a mega-machinery show- cool!

  • After disassembly and cleaning, the parts are inspected for damage including galling, cracks, bearing area wear, etc.  complete machining, plating, and welding shops support the cylinder rebuild department with rod and tube section rechroming, rod resteming (with induction hardened, chrome plated rod), barrel honing or retubing, head machining, welding, boring, thread recutting, etc. Once all the metal components are reworked, then new seals and bearings are installed, and the cylinder unit is reassembled and tested to 3,500 psi. Straightening
  • OD and ID Grinding
  • Repair Damaged Rods, Rolls and Tubes
  • Manufacture New Rods, Rolls and Tubes
  • Sub-Arc Welding
  • MIG Welding
  • TIG Welding
  • Resistance Welding
  • Polish Rods (26 1/2" Max. Diameter & 31' Max. Overall Length)
 
Caterpillar cylinder groups available on exchange. Call with your cylinder group part number and machine model to check on availability.
Excavators:

L&T Poclain 

CK 90 170 CK 300 CK

Tata Hitachi

EX 60, EX 100 EX 200, EX 400.
EX-1000 & UH-83, UH-261.

Demag

H-55, H-121, H-185.
O & K RH-30, RH-40, RH-75, RH-90
BEML  PC 220, PC 300, PC 650, PC 1000.

Haulpak Dumpers :

lw-35 / lw-50, hd-785, HM 1035 N, BH40, CAT-773B.
Dresser Rand Make 120 Tonner Dumpers & 170 Tonner Dumpers and MK 30 Dumpers.

Loaders:

Hm-2021 and HM-2071, Escorts L710

Dozzers :

D-80, D-120, D-155 and D-355, CAT D6H.

Cement and Steel Plant Side Cylinder :

Piston Accumulator
Crusher Cylinder
Roller Press Jack
Raw mill Cylinder
Stacker Cylinder
Clay/Mud Gun Cylinder

Extractor Cylinder
Kiln Dumpling Cylinder
Roller Prees Cyinder
Coal Mill Cylinder
Reclaimed Cylinder
Spring Cylinder (HydroPneunatic)

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4. Thermal Spray Coating
Now we have setup advance technology of H.V.O.F. spry to precious items.
our coating has world record breaking wear resistance and continues to break the barriers of conceivable mold coating life. HVOF Spray Coating can be engineered and applied to any broad face or narrow face copper. Specialty cold face coatings offer optimal thermal characteristics and aid in flawless continuously cast slab profiles. Contact Neeraj Industries to see what coatings can be applied to your equipment to promote longer caster life and improved final products.

In continuous casting, the copper mold serves as an effective heat exchanger to quickly remove heat from the steel being cast through it. As the cast shell begins to increase in thickness in the lower half of the mold, it abrades and wears the bottom of the mold. Additionally, the diffusion of the copper substrate from the mold into the surface of the cast product leads to a quality defect called “star cracking.” In most cases, the wear on the copper substrate and the pick-up of copper by the cast product can be eliminated by the use of a mold coating on the bottom portion of the copper mold. Decreasing mold wear is another objective for coating the mold surface. Mold coatings are therefore used on continuous casting copper molds to decrease wear and improve product quality. At present chrome and nickel based coatings continue to be used predominantly for protecting mold coppers from wear. Nickel plating for reconditioning continuous caster mold, allows the

nickel to be deposited in various configurations and deposit thicknesses. The deposited nickel enhances caster product quality by greatly reducing cast product contamination and star cracking problems. The heat transfer properties of nickel are similar to those of copper. Therefore coating of the mold require minimal operational changes at the caster, making it an excellent investment for extending mold life and improving product quality shells, 25,000 repair tube every year’s, Insisting on the concept of "quality first, people oriented, keep improving, customer satisfaction", we serve clients in the metallurgy field both from at home and abroad. We hope to develop and create brilliant future together with all our friends
 
Thermal Spray Coating

Processes - HVOF - Plasma - Twin Wire Arc
Materials - Carbides - Ceramics - Metals
The High Technology Coating Division can handle the complete coating job from prep machining through finish turning, grinding and superfinishing.

Customers
Industries served include a broad spectrum in the chemical, food, marine, military, petrochemical, power generation, plastics, pulp/paper, printing, refining, textile, wire/strip and general metalworking.

  • Hypervelocity oxy-fuel (HVOF)
    • Produces coatings equivalent to or better than detonation gun. Used for some pure metals, alloys and carbides.  Gives highest possible bond strength. Propels gases up to 4,500 ft./sec. at 5,200° F.
  • Plasma
    • Nontransferred arc system. Used principally for ceramics but has the capability to apply some pure metals, alloys and carbides. Propels gases up to 2,000 ft./sec. at 30,000° F.
  • Wire Arc
    • Twin wire system. Used for heavier build-up of pure metals and alloys. Propels gases up to 1,100 ft./sec. at 10,000° F.

Benefits
Direct Cost Savings

  • Increase in life of component
  • Reduction in maintenance costs
  • Decrease in equipment downtime
  • Increase in operating efficiency
  • Use of less costly material for bulk of component  

We specialize in design, development and manufacturing of Custom Built Hydraulic Cylinders, with ISO 9001: 2000 certification.

The Unit was setup in 1994 by Techoanal Promoter Mr. Dinesh Pandya an IITian

Ours is an S.S.I unit specializing in manufacturer and servicing of Hydraulic Cylinders. Technocrat Promoter Mr. Dinesh T. Pandya, an IITian, set up the Unit in 1984.

We specialize in design, development and manufacturing of Custom Built Hydraulic Cylinders, with ISO 9001: 2000 certification.
Over the years, we have developed a niche market in developing manufacturing and supply of Hydraulic cylinders of Earthmoving, Road Construction and Material Handling Industries. Today, our range of Hydraulic Cylinders covers entire spectrum of all Equipment manufacturers present in Mining, Road Construction, Material Handling, Cement and Steel Plants.

We are O.E. suppliers to O.E.M such as :
 

1) Atlas Copco (I) Ltd., CMT Division.
2) Tractor Engineers Ltd.
3) Revathi Equipment Ltd.
4) Universal Construction & Machinery.
5) Atlas Copco (I) Ltd. (Formerly Ingesoll-Rand).
We also have in place Rate Contracts for 2 years with Coal India Ltd. Subsidiaries.

We also have Service Division where we aim to recondition a Hydraulic Cylinder by using all possible existing components that are in good and workable condition. However, any component beyond the scope of repairs would be scraped and replaced with new component. Any reconditioned cylinder returned to the customer would be as good as BRAND NEW CYLINDER for which we stand by a warranty of 1500 working hours or six months, whichever is earlier.

Over last few years we have by now reconditioned and supplied many cylinders of HEMMs like Dozzers, Dumpers, Excavators, Drills Loaders and Plant Side Cylinders like Accumulators, Vertical Raw Mill, Coal Mill etc.
shells, 25,000 repair tube every year’s, Insisting on the concept of "quality first, people oriented, keep improving, customer satisfaction", we serve clients in the metallurgy field both from at home and abroad. We hope to develop and create brilliant future together with all our friends.

- Leveler Rolls

- Hard Chrome Plating

- Steel Mill Rolls

- Copper Coating

- Shingle  Manufacturing

- Cylindrical Grinding

- Paper Mill Rolls

- Ceramic Coating

- Aluminum Mill Rolls

- Heat Treating

- Plastic/Sheet Rolls

- Surface Hardening

- Corrugated Rolls

- Carbide Coatings

- Cooling Rolls

- Plus other coatings

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5. Copper Moulds Reconditioning
See Detail Size Below:

90×90, 100×100, 110×110, 115×115, 120x120130x130,
135×135, 140×140, 143×143, 150x150155x155, 160×160,
165×165, 175×175, 180x180200x200, 220×220, 100×170,
100×173, 130x240150x200, 150×210, 150×220, 160×200,
160x220150x225, 160×235, 165×225, 175×225,
180x220200x240, 240×240, 235×235

Radius (mm): 4000, 5000, 5250, 6000, 7000, 7500, 8000, 9000, 10250, 10300, 11000, 12000
Length (mm): 700, 750, 780, 790, 800, 810, 812, 850, 900, 1000

  • We supply high quality and durable copper mould tube  by replanting method . so that do not scrap your copper mould now.
  • Our Copper Mould Tube meets ISO9001 standards, high precision and meet hardness requirement,  perfect taper and coated layer.
  • We have complete facilities to process every copper mould tube,  plating, hardness testing to provide accurate Chrome plating to the Mould Tubes to achieve high performance in heat resistance.
  • We recoated  hundred pieces of copper mould tube every month and supply to several biggest Steel Group . our product is most trusted .
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