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Production capacity :
20 000 tons of grinding media / Year
2000 tons of wear resistant and heat resistant castings / year
Thus, UCF overall production capacity is 22 000 tons / year.
Production facilities :
Foundry :
- Melting shop:Nine induction melting furnaces of various capacities
- Molding lines:Four moulding lines,One line of jolt squeeze machines,Two lines of DISAMATIC machines,One flour molding line
- Three shot blast machines
- Two breaker drums
- Technical office for design activities and Pattern making workshop for manufacturing araldite patterns.The success of grinding media patterns had been proved through more than 20 years of grinding media production.
Heat treatment Plant :
- Four continuous heat treatment furnaces
- Seven tempering furnaces
- One device for quantitative analysis of retained austenite. Retained austenite, being one of these undesirable phases, is quantitatively measured after heat treatment to assure that it is lower than a definite limit.
Laboratories :
UCF has a group of laboratories that satisfy the needs of :
- process control plans implemented during production running
- The needs of inspection and testing activities of finished products
UCF laboratory facilities include :
- Two spectrometers for chemical analysis
- Complete set of devices for testing new sands and moulding sand mixtures, carrying out tests as:Green compression strength, shear strength, permeability,compactibility, moisture content, grain size.
- Stationary and portable hardness testing devices ( HB, HV, HRC )
- Metallographic laboratory with optical microscopes of magnification X 1200 attached with the necessary devices of grinding and polishing for samples preparation for the metallographic examination
- Non destructive testing for invisible crack detection.
Machining workshop :
- It is equipped with all the necessary machines and tools for conducting machining operations as per customer requirements.
- The machining workshop has a forging line for producing bolts necessary for fixing mill liners. Bolt threads are made by thread rolling machine
- On 2002, UCF had modified its existing management system to comply with requirements of ISO 9002 : 94.
- On 2003, UCF had modified its management system to comply with requirements of ISO 9001 : 2000.
- On 2005, UCF had, once again, modified its management system to adopt and declare its environmental commitment, thus complying with requirements of ISO 14001 : 2004.
- On 2009, UCF management system was modified as per ISO 9001 : 2008 requirements.
- On 2010, UCF management has adopted new specific policies and values that enable UCF to satisfy international market requirements.
UCF is awarded ISO 9001 : 2015 and ISO 14001 : 2015 applicable to :
- Plain carbon and alloy steel castings
- Wear, corrosion and heat resistant steel casting
- Chromium iron castings
- Fabricated wrought steel products
- Foundry patterns.in all its work sites and locations.
In all it's work sites and locations
- As per UCF Quality plans of products , there are process control activities implemented by production dept. and an in –process inspection activities implemented by quality dept.
The process control and the in – process inspection plans of a definite production process shows :
- Aspects need to be measured or tested
- Frequency of testing or measuring
- Means of testing or measuring
- Responsible body of carrying out this testing
- The quality form used for recording testing results
- Specification or criterion of evaluating the testing results.
- UCF is committed to continual improvement of all its processes and its integrated management system. This commitment is the only way for realizing its customer satisfaction and expectations.
- QUALITY is one of the main features of the processes, products and services that UCF offers its customers all over the world.
- Each stage in the process, from the design, material purchasing manufacturing, inspection & testing, and dispatch to the customer is supervised and controlled according to UCF internal procedures and specifications of its Quality Management System, in compliance with the ISO 9001 standard.
- The industrial and quality management processes are continually reviewed and improved through conducting internal and external audits by customers or other monitoring bodies.
- UCF laboratories testing the finished products are spectrometer laboratory, sand testing laboratory, mechanical laboratory, and metallographic laboratory.
- UCF Consider the customer expectations as the most valuable opportunity for improvement.
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