ABOUT THIS SERVICE

Plan It Right. Build It Right. Start It Right.

Starting a new aluminium foundry in India — or upgrading an existing one to meet Tier-1 automotive OEM standards — is not a procurement exercise. It is a systems engineering challenge that requires simultaneous expertise in component design, process simulation, tooling, quality systems, casting line layout, staff training, and production startup. Very few organisations can deliver all of this from a single source.

InStock International's Casting & Forging Division brings this capability directly to the Indian market. We work with European casting and forging engineers with 25+ years of hands-on experience building production lines and complete foundries for European automotive Tier 1 suppliers. We act as the bridge between European engineering intelligence and Indian manufacturing execution — ensuring every project is planned with the rigour of a European automotive supplier and executed with the agility and cost-effectiveness of an Indian manufacturing environment.

Our European engineering partners have taken projects from initial plant layout all the way through to Start of Production (SOP) — including 3 forging lines, 4 gravity casting lines, 1 CPC plant (including the world's first combined LP+CPC system), and 2 complete foundries built entirely from scratch.

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What We Prevent

The Three Mistakes That Hurt New Foundry Projects

Based on 25+ years of foundry and casting line projects across Europe, these three decisions most often determine whether a new plant reaches Start of Production on time — or spends years fixing avoidable problems.
01

Equipment chosen before process

Most promoters decide on machine tonnage first. The process architecture — casting method, fill strategy, die temperature window — should come first. Equipment follows process. Not the other way around.
02

Layout designed for floor space, not flow

A poor layout creates internal logistics bottlenecks that permanently cost 1–3% of yield. This cannot be fixed without a physical rebuild. Layout decisions at the drawing stage cost nothing to correct.
03

SOP written after commissioning

Plants that document the process after Start of Production record what happened — not what should happen. The best plants define process parameters and standards before the first trial run and use them to measure deviation from day one.

These three mistakes are avoidable. Our team prevents them.

Full Scope

What a Complete Turnkey Project Includes

From the first component drawing to Start of Production — we deliver every stage of the technical project lifecycle.
1

Component Development & Design

Aluminium component development from your specifications — topology optimisation to maximise strength-to-weight ratio, followed by full 3D CAD design. Simulation-validated geometry before any tooling is committed.

2

Casting Process Simulation

Mould filling simulation, solidification analysis, and temperature distribution modelling — performed before any tooling is designed. Identifies potential porosity, shrinkage, and flow defects and eliminates them before the first die is cut.

3

Tooling Design

Complete die and mould design for gravity, low pressure, CPC, or forging processes — engineered for thermal balance, venting, and ejection efficiency.

4

Production Line Design & Layout

From facility layout and machine selection through automation integration and material flow — every element of the production line is designed for maximum efficiency, operator safety, and OEM quality compliance.

5

Line Commissioning & First Articles

Our European engineers are present on-site during line startup — ensuring casting parameters, cycle times, and first-article quality meet target specifications before handover.

6

Staff Training

Hands-on operator and engineering team training at your facility — covering casting process fundamentals, quality inspection methods, die maintenance, and process troubleshooting.

7

Quality System & Process Documentation

DFMEA, Control Plans, Measurement System Analysis, process parameter records, and inspection protocols aligned with IATF 16949 and VDA requirements — giving your team everything they need to run the line independently after Start of Production.
Technologies

Casting Technologies We Support

Gravity Casting (Permanent Mould)

Full turnkey implementation of gravity casting lines — from tooling design and mould layout through to automated extraction, heat treatment, and quality inspection. Our engineering team has implemented 4 complete gravity casting lines, all taken to Start of Production. Ideal for structural components where porosity control and consistent metallurgical properties are critical.

Low Pressure Casting (LPDC)

Specialised support for low pressure casting line design and commissioning — including furnace selection, metal feed system design, mould temperature management, and cycle time optimisation. Delivers superior metallurgical quality over gravity casting for structural automotive parts.

Counter Pressure Casting (CPC)

Our European engineering partners designed the world's first combined Low Pressure + CPC plant — a landmark engineering achievement in aluminium casting technology. CPC delivers the highest possible metallurgical quality for safety-critical components — suspension knuckles, wheel carriers, and structural chassis parts.

Aluminium Forging

Complete forging line setup and process development — from forging sequence and die design through to line commissioning and Start of Production. Our team has implemented 3 aluminium forging lines. Applications include high-strength structural components requiring wrought microstructures and superior fatigue resistance.
Project Types

Types of Projects We Handle

New Casting Line in Existing Foundry

You have a foundry and are adding a new line — HPDC, LPDC, gravity, or CPC. We scope, specify, commission, and take the new line to Start of Production while your existing production continues uninterrupted.

Greenfield Aluminium Foundry

You are building a new foundry from the ground up. We cover everything from initial site layout to Start of Production. Our team has taken 2 complete aluminium foundries from an empty building to fully running production.

Aluminium Forging Line Setup

Setting up a new aluminium forging operation for automotive structural parts — control arms, subframes, steering knuckles. We have taken 3 forging lines to Start of Production in Europe.

EV Component Manufacturing Line

New entrants setting up aluminium casting for EV structural components — battery housings, motor mounts, subframes. We bring the process expertise that new EV manufacturers typically lack when moving from steel to aluminium.

Casting Line Takeover & Restart

You have acquired a casting plant or line that is not performing. We diagnose the issues, revalidate the process, retrain the team, and take the line back to stable production on a clean process baseline.

Not sure which category your project fits? Tell us what you are building — we will tell you exactly how we can help.

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Track Record

What Our Engineering Team Has Delivered

Our European engineering partners have delivered the following across 25+ years of foundry and casting line projects in Europe. Every project listed here was taken from layout all the way through to Start of Production.
4
Gravity Casting Lines
Designed, built, commissioned, and taken to Start of Production
12
CPC Casting Lines
Including the world's first combined Low Pressure + CPC system
14
Low-Pressure (LPDC) Lines
Built and taken to Start of Production across European Tier 1 plants
2
Complete Foundries from Scratch
Empty site to Start of Production — layout, equipment, commissioning, training
3
Aluminium Forging Lines
Control arms, subframes, steering knuckles — taken to Start of Production
100+
Components to Series Production
From product design through tooling, simulation, validation, and Start of Production
How It Works

How a Turnkey Engagement Works

Clear steps, fixed scope, and defined sign-off at every phase. You never move to the next phase until the current one is validated.
  • 1

    Discovery Call — Free, 30 Minutes

    Tell us about your project — what you are building, your timeline, volume targets, and product mix. We give you an honest view of scope and complexity. No commitment required.
  • 2

    Written Proposal — Within 5 Business Days

    Fixed price. Defined scope. Clear phase-by-phase deliverables and timeline. You know exactly what you are getting and when — before signing anything.
  • 3

    Project Kickoff

    Our European engineering team is assigned to your project. InStock International manages India-side coordination — site access, local vendor liaison, logistics, and scheduling throughout.
  • 4

    Phase-by-Phase Delivery

    Each phase has defined outputs, sign-off criteria, and a handover document. You do not move to the next phase until the current one is fully validated.
  • 5

    Start of Production & Handover

    We stay on-site through your first production run. Handover happens when the line is producing to target yield, cycle time, and quality — not before.
Partners

European Supply Partner Network

Access to Europe's leading casting and foundry technology suppliers — through our European engineering partners' established industrial network. InStock International provides Indian foundry projects with direct access to this network for equipment sourcing, tooling, and technical components.
Innhelon
Wollin
Costamp Group
Gambazzi srl
Caliper
SCF

Frequently Asked Questions

We support the full range — from adding a new casting line to an existing foundry, to building a complete greenfield aluminium foundry from scratch. We also handle aluminium forging line setup and EV component manufacturing lines. If you are planning any new aluminium casting or forging capacity in India, we can help.

Gravity casting uses gravity to fill the mould — lower tooling cost, suitable for moderate volumes and thick-wall parts. Low pressure casting (LPDC) uses controlled gas pressure to fill from below — better metallurgical quality, preferred for structural automotive parts like wheels and suspension components. Counter pressure casting (CPC) applies pressure both above and below simultaneously — delivering the highest possible metallurgical integrity for safety-critical parts like steering knuckles and wheel carriers.

InStock International manages the India-side of every engagement — initial scoping, client coordination, local vendor liaison, logistics, and ongoing communication. Our European engineering partners lead all technical work — process design, simulation, commissioning, and quality systems. You have one Indian point of contact from first call to Start of Production.

Our European engineering team works to IATF 16949, VDA 6.3, and automotive OEM-specific standards — including those of the VW Group, BMW Group, Stellantis, Daimler, and Renault. All quality documentation — DFMEA, Control Plans, MSA — is structured for Tier 1 automotive supply chain approval.

A new casting line in an existing foundry typically takes 8–16 weeks from kickoff to Start of Production. A greenfield foundry project is typically 4–8 months depending on civil works timeline. All timelines are defined in the written proposal before any commitment is made.

No. Civil works and building construction are outside our scope. We provide plant layout requirements and coordinate with your civil contractor, but we do not manage construction directly.

Yes. We work with clients across India. Travel, accommodation, and logistics for the European engineering team are included in the project proposal.