MAURIA UDYOG LTD. (MUL) situated just an hour’s drive away from its country’s capital New Delhi and 35kms from Delhi’s International Airport, is now a major global player for welded steel cylinders and associated accessories.
Though primarily manufacturing cylinders for the LPG markets, it has recently diversified into making vessels for the refrigeration industry, where keeping the cylinder’s internal cleanliness is a paramount pre-requisite.
With its headquarters and manufacturing facilities in Faridabad and with offices and representatives in Delhi, Dubai and London, Mauria now supplies cylinders to major international companies such as Afrox (Member of the Linde Group), BP, Calor (SHV International), Caltex, Totalgaz to name but a few.
Today Mauria is the largest exporter of cylinders, valves, regulators and associated accessories from India, with 98% of its production being exported to countries as far afield as S. Africa, UK, The Middle East, France, Canada, The Netherlands and Kenya for example.
Facts and figures
Mauria’s roots go back to 1980 when the PLC was formed, with the first LPG cylinders coming off the production line in 1984, rapidly followed by LPG valve production in 1987. LPG regulators arrived in 1998, while during 2008 non-refillable cylinders to either ISO 11118 or EN 12205 will be added to their portfolio. Welded cylinders for refrigeration gases such as ammonia also appeared during 2006.
Mauria’s explosive growth took off during the period of 2001-2003, when over 1.8 million welded cylinders were exported. By 2004, Mauria’s turnover had risen to $44m, which grew to exceed $59m by 2006. With the addition of new capacity, Mauria now produces almost 2 million cylinders annually, but such is their appeal to customers that almost 80% of capacity for 2008 has already been reserved.
The company’s highly trained and motivated staff ensure that both two and three piece cylinders (in sizes from 4.5 up to 113 litres water capacity) are certified by well known inspection/notified bodies, such as Bureau Veritas, Lloyds, SGS with the cylinders being made to International Standards and Specifications such as ISO 4706, EN 1442 and DOT 4BA. It’s this subtle ability to successfully manage a range of worldwide specifications coupled with excellent manufacturing and language skills, which has caught the imagination of customers worldwide. Customers are equally attracted by the low cost structure offered by the Indian sub-continent.
Key technical details
The production process has never lacked investment or attention to detail. These include such aspects as:
•For 3-piece cylinders, optimum use of pneumatic clamps when producing the longitudinal weld ensures minimum effects for both peaking and weld shrinkage.
•A thorough 100% normalisation heat treatment is afforded to all cylinders, rather than the inferior stress relief counterpart.
•Process techniques to maintain a clean internal surface during production for refrigerant cylinders.
•An excellent coverage, to whatever requirements the customer demands, of metallic, hot-zinc spray.
•A finishing line capable of handling 4500 cylinders per day, coupled with an oven at up to 240˚C, suitable for either synthetic stoving paints or powder coatings (see Fig. 1).
•A new radiographic facility installed, to examine weld integrity.
The production capability is matched with a modern, in-house, prototype testing equipment suite (fatigue and burst), mechanical testing units and full metallographic/metrological capabilities.
The whole unit is kept alive and refreshed by statistical quality/process control (SQC/SPC) techniques, which constantly analyse data, thus ensuring effective control with minimum rejection rates, whilst maintaining the ever important continuous improvement process.