A BRIEF REPORT ON FACILITIES AND PRODUCTS OF

TAYO ROLLS
Introduction
Tayo Rolls Limited (TAYO), a subsidiary of Tata Steel Limited since December, 2008, as
!romoted in collaboration it" Yodo#aa Steel $or%s, &a!an and 'iss"o (ai )or!oration
of &a!an for !roduction of )ast (ron and )ast Steel Rolls for metallur#ical industries* Ot"er
!roducts include +or#ed Rolls, ,n#ineerin# +or#in#s and (n#ots* Tayo Rolls Limited,
formerly Tata Yodo#aa Limited as incor!orated in -./8 and started its o!erations t"en*
Since ince!tion, TAYO "as stren#t"ened its !resence in (ndia and abroad as a leadin# and
de!endable Roll manufacturer* TAYO is t"e only )om!any in t"e orld to manufacture bot"
)ast and +or#ed Rolls ri#"t from (ron Ore it" its inte#rated facilities under one roof* TAYO
"as t"e ad0anta#e of "arnessin# t"e tec"nolo#ies from bot" ,uro!ean and &a!anese
collaborators* TAYO "as recently entered into t"e business of manufacture of in#ots,
,n#ineerin# +or#in#s and +or#ed Rolls a!art from t"e establis"ed )ast Roll and 1i# (ron
business* )ommercial !roduction "as commenced from 20t" 3arc",20-- from our nely set
u! inte#rated +or#e S"o!* As a Roll manufacturer TAYO also "el!s its customers in selectin#
ri#"t #rade of rolls to im!ro0e t"eir mill !erformance*
TAYO "as re4uisite infrastructure, e5!erience, ca!ability and e5!ertise to underta%e
manufacture of tailor made )ast and +or#ed Rolls, (n#ots, ,n#ineerin# +or#in#s, and to meet
t"e customer s!ecific re4uirements* Rolls are desi#ned to roll slabs, blooms, billets into
an#les, c"annels, rods, tubes, stri!s, !lates, s"eets and 0arious ot"er flat and section !roducts*
6rot" in automobiles and a!!liances industries "a0e s!aned more and more )old Rollin#
3ills* +or#ed Rolls are used in suc" 3ills and are considered !remium !roducts* T"e
increasin# e5!ectations from customers "as tri##ered tec"nolo#ical c"an#es in roll ma%in#
and TAYO "as res!onded it" ne !roducts7 Su!er 'ic%el 6rain (S'6), 8i#" S!eed Steel
(8SS) and Semi 8i#" S!eed Steel (Semi98SS)*
Products
Tayo Rolls Limited is a leadin# )ast (ron and Steel Roll manufacturer in (ndia* 'o, Tayo
"as !ut u! manufacturin# facility for +or#ed 8ardened Roll and ,n#ineerin# +or#in#s
consistin# of (n#ot 3a%in#, +or#in# and 8eat Treatment includin# (nduction 8ardenin# in
t"e e5istin# !remises*
Hot Rolling Application
Tayo Rolls "as t"e ca!ability and t"e ca!acity to meet t"e most demandin# mill re4uirements*
Tayo rolls "a0e been custom desi#ned to roll flat as ell as lon# !roducts*
Tayo:s Tec"nical ad0ices on sound mill !ractices are bac%ed by t"e e5!erience of Tata Steel,
a frontrunner in t"e steel industry in (ndia*
; )ast Rolls
; +or#ed Rolls
; 1i# (ron
; +or#in# <uality (n#ots
; ,n#ineerin# +or#in#s
Cast Rolls
(t is an inte#rated facility it" meltin#, foundry and mac"inin# ca!abilities* T"e facilities of t"e
com!any, due to t"eir ability to do centrifu#al castin# (S!un )ast rolls) "ile t"ey can also !roduce
static cast rolls, are ell desi#ned to ser0e t"e re4uirements mainly of t"e +1 (=+lat 1roducts>) mills
due to t"eir ability to do centrifu#al castin# (S!un )ast rolls) "ile t"ey can also !roduce static cast
rolls* T"e current tec"nolo#y !artner "ere is Yodo#aa Steel $or%s, &a!an ("o are also co9
!romoters of t"is com!any)*
T"e details are #i0en in Anne5ure ( ? ((*
Forgd Rolls
T"is is a ne facility and t"e only inte#rated one in (ndia "a0in# 3eltin# ca!acities, (n#ot S"o!,
+or#ed S"o! and +inis"in# facilities (Tem!erin#, 6rindin#, 3illin# etc)* T"e tec"nolo#y !artner in
t"is business is S"effield +or#ed 3asters (nternational, @A*
T"e details are #i0en in Anne5ure ((( ? (B*
Pig Iron
T"e )om!any "as a 3ini Clast +urnace of D0000 T1A 3etric ton !er annum ca!acity* T"e 8ot metal
is consumed internally in t"e com!any as a !art of t"e inte#rated roll manufacturin# facility* T"e 1i#
(ron %non for its 4uality is sold to customers, "o !rocess it furt"er*
Forging !ualit" Ingot
As !art of t"e ne facility an in#ot s"o! as commissioned in +inancial Year 200.9-0* T"e !lan as
to use /0E for on consum!tion (in t"e for#ed s"o!) and D0E of in#ot castin#s ere to be sold
directly to se0eral customers* T"e ca!acity of in#ot s"o! is 2D000 3etric ton !er annum*
T"e details are #i0en in Anne5ure B*
Enginring Forgings
T"e e5cess ca!acity of t"e for#e s"o! is utiliFed in !roduction of ,n#ineerin# +or#in#s (Su#ar 3ill,
$ind 3ill s"afts etc)* T"e ca!acity or%s out to G200 3etric ton !er annum*
T"e details are #i0en in Anne5ure B(*
Facilitis
TAYO "as t"e best combination of meltin# furnaces* T"e ,lectric Arc +urnace is used for
manufacture of "i#" stren#t" alloy (ron, "i#" 4uality S6 and Steel Rolls* T"e mains
fre4uency induction furnaces are used for small and medium siFed cast iron, steel and S6
Rolls*
T"ese furnaces also !ro0ide "i#"ly alloyed s"ell metal in indefinite c"ill 4uality rolls "ic"
are cast t"rou#" static and centrifu#al route* S"ell metal for "i#" c"rome iron and Steel rolls
are also !rocessed in t"ese furnaces* T"e ide 0ariety of furnaces offers full fle5ibility in
!roduction of rolls of different siFes and ei#"ts*
T"e meltin# is carried out usin# carefully se#re#ated scra!, !i# (ron and ferro alloys to
ac"ie0e t"e desired com!osition* T"e meltin# unit is bac%ed by a modern analytical
laboratory usin# a com!uterised 0acuum s!ar% emission s!ectrometer and ot"er automatic
analysis for different elements*
+acilities A0ailable7
3eltin# H +oundry
8eat Treatment
3ac"inin#
+or#e s"o!
8eat Treatment
#lting $ Foundr"
TAYO "as t"e best combination of meltin# furnaces used for manufacturin# of different
ty!es of metal #rades for 0arious ty!es of rolls* T"e 2G 3etric ton ,lectric Arc +urnace is
used for manufacture of for#in# 4uality steel*
T"e L+ BD unit !ro0ides stricter control of t"e c"emistry and clean metal free from "armful
inclusions* (t also ensures "ydro#en content restricted beteen 0*I !!m to 2*00 !!m to
!roduce orld class +or#in# <uality Steel* TAYO is also e4ui!!ed it" 8 3etric ton and -/
3etric ton main fre4uency (nduction +urnaces, to#et"er it" 8 3etric ton medium fre4uency
(nduction furnace it" double crucible* T"ese (nduction +urnaces !roduce orld class )ast
Steel Rolls*
T"e (nduction and Arc +urnaces offer fle5ibility in !roduction of rolls and (n#ots of different
siFes and ei#"ts*
STATIC CASTING
Static H 3ono castin# rolls are !oured t"rou#" bottom to ensure cleanliness of roll body
surface* ,lectrical 8ot9To!!in# is a uni4ue feature a0ailable for steel9based rolls to ensure
soundness*
SPIN CASTING
State9of9t"e9art "oriFontal s!in castin# mac"ine is used to !roduce "i#" end cast rolls* T"e
entire !rocess is so!"isticated control and monitorin# de0ice to ensure com!liance to
customersJ s!ecifications*
Hat Trat%nt
$e "a0e s!ecialiFed S)ADA controlled, #as9fired "eat treatment furnaces e4ui!!ed it"
so!"isticated control mec"anism to facilitate uniform tem!erature distribution*

T"e con0ersion from oil to #as ill furt"er stren#t"en our commitment toards en0ironment
and reduce )arbon foot!rint*
#ac&ining
TAYO:s 3ac"ine S"o! is e4ui!!ed it" a 0ersatile set of 3ac"ine Tools from &a!an, Russia,
)Fec"oslo0a%ia, 6ermany, (taly and (ndia* Strin#ent demands of accuracies and desi#ns are
met by )') Lat"es*
S!ecial !ur!ose mac"ines carry out t"e millin# o!erations* S!ecially desi#ned Du!le5
3illin# 3ac"ines are used for cuttin# clo0e leaf obblers, flats and %eyays* +lutin# and
s!ecial #roo0in# are done t"rou#" suitably desi#ned fi5tures*
S!ecified tolerances and desired surface finis" are obtained t"rou#" so!"isticated 6rindin#
3ac"ines*
)ADH)A3 tec"nolo#y is a0ailable for translatin# t"e )ustomer:s Drain#s to internal
standard as ell as direct !ro#rammin# of t"e )') Lat"es for finis" mac"inin#*
TAYO also enKoys t"e !resence of dee! borin# mac"ine and uni4ue Submer#ed Arc $eldin#
facility*
Forg S&op
TAYO +or#e S"o! is e4ui!!ed it" modern Oil 8ydraulic 2G00 3etric ton H2000 3etric ton
1us" don 1ress it" inte#rated mani!ulator of 2G Ton HG0 3eter Ton* Associated "eatin#
and "eat9 treatment facilities are a0ailable it" Oil and $ater <uenc"in# facility to meet all
strin#ent 4uality re4uirements as !er national and international standards*
8,AT TR,AT3,'T
L16 fired bell and bo#ie furnaces of G0 3etric ton and -00 3etric ton ca!acity it" control
of t"e tem!erature uniformity it"in L 2M ) and oilH ater 4uenc"in# facilities for "eat
treatment of for#in#s*
Induction'Hardning s&op
Our (nduction 8ardenin# s"o! is e4ui!!ed it" &ournal and Carrel (nduction 8ardenin#
mac"ine it" associated "eatin# and "eat9treatment facilities it" Sub9Nero (cryo#enic)
treatment facility for +or#ed Rolls* T"is is t"e s"o! "ere +or#ed Roll ta%e birt" from +or#ed
Clan%*
At t"e "eart of t"is s"o! e "a0e state of t"e art (nduction 8ardenin# mac"ine su!!lied by
(nductot"erm (Cel#ium) for (nduction 8ardenin# of +or#ed Roll Carrel* T"e e4ui!ment is
Dual )oil Dual +re4uency !ro#ressi0e ty!e induction "ardenin# mac"ine "ere e can
!roduce for#ed roll "a0in# diameter ran#e of 2D0mm to 8D0mm*
$e can !roduce $or% Roll , (ntermediate Roll and Lo diameter Cac% @! Roll* Cased on
t"e )ustomer S!ecification, 3ill ty!e, 3ill usa#e etc e select "ardenin# !arameter to meet
)ustomer:s e5!ectation*
T"is s"o! is uni4ue in a ay t"at "ere e "a0e t"e facility of "ardenin# Kournal !ortion
t"rou#" "i#" fre4uency induction "ardenin# to ac"ie0e Kournal "ardness re4uirement of
0arious customers*
All t"e for#ed rolls !roduced are !assed t"rou#" )ryo#enic +urnace OSub Nero TreatmentP
after barrel "ardenin# to reduce retained austenite and im!ro0e de!t" of "ardness and
"ardness uniformity*
)ou!led it" t"ese e are also a0ailable lo tem!erature and "i#" tem!erature furnaces to
reduce internal stresses and ac"ie0e customer s!ecification*
<uality bein# a Dri0in# force e "a0e number of orld class instruments to c"ec% our
!roduct 4uality and monitor our e4ui!ments and furnaces for consistent o!eration*
!ualit" Assuranc (acilitis
Tayo Rolls Limited "as folloin# facilities7