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META COPPER & ALLOYS LTD

Meta copper and alloys limited (formally known as Meta Strips Limited) is state of art

world class manufacturing facilities for Copper and Copper Alloys rolled flat products.

It was incorporated on 11/03/1997, as a 100% Export Oriented Unit, a green field

venture with an initial capacity of 30,000 tons per annum to produce Copper and

Copper based Alloys strips, sheets and foils is a modern mill manufacturing copper and

alloy (brass) roiled flat products. Accredited with the ISO 9001 and ISO 14001

certifications, META is currently serving customers from over 43 countries around the

world. Meta is focused on creating and delivering sustainable competitive advantage to

its customers. This is achieved through our 5 point quality excellence program and is

embodied in META STAR –the corporate logo, to understand customer’s requirements

in this entirety .to be cost effective ,to deliver according to customer’s ability to receive

,to invest in man and machines consistently and to add exceptional overall value to

society.

Located at the port town of mormugao on the western coast of India, Meta is efficiently

connected to all the major seaports in the world .As an export-oriented unit; Meta

enjoys a tax-free working environment, which adds to its competitive advantage.

Meta uses state of art machines that have been carefully selected from a band of

machine builders of international repute. These machines provide superior tolerance on

critical parameters and thus translate customer’s requirements into delivered products.

A team of experienced professionals with expertise in non-ferrous metallurgy manages

Meta. Professionals are involved in each level and are characterized by the in depth

knowledge of the process and high sensitivity to customer’s requirements .skills up

gradation and human resource development is priority activity in Meta.


Meta believes the quality of the delivered product depends largely on the input quality

and hence uses extensive feed forward control methods to ensure every gram of raw

material used in the production exceeds international standards.

Manufacturing is done under a controlled environment. The process data is recorded,

monitored and preserved through Baan ERP system which guarantees 100% adherence

to customers’ specifications at all levels and ensures traceability to the raw material

supplies. Vertical slab casting, jet flotation annealing, bell annealing, chamber annealing

precision rolling with automatic gauge controllers ,laser pin hole detection, automated

surface detect eliminating system ,semi automatic packaging line etc are some of unique

practices in Meta.

This man, machines and fine raw materials combination along with locational

advantage

Makes meta a cost effective and quality supplier of copper and copper alloys rolled flat

products .products are easily available in over 45 countries through an effective supply

chain system .our quality assurance and technical support team is alert to every

customer need and is in the relentless pursuit of maximizing the productivity of our

customers .

The Chairman & Managing Director of the Company Mr. Sushil S. Khaitan with his

vision, long outstanding and proven expertise in the Copper and Copper Alloy Semis is

leading the group. The team of Meta Strips Limited consists a workforce of 500

motivated employees joined from different organizations with well-qualified

professionals of diverse background and experienced technicians.

The company has acquired 60 acres of land in village Sancoale and Cortalim on which

the plant is spread over with two unique rain-harvesting tanks.

PRODUCT RANGE

Full Widths / Slit Widths:


Coils with internal diameter from 80 mm to 500 mm, thickness from 0.10 mm to 5.00

mm and widths from 20 mm to 400 mm.

Sheets:

In widths of 400 mm max., lengths from 1000 mm to 3000 mm and thickness from 0.15

mm to 2 mm.

Traverse Wound Coils:

Brass Strips of 10 mm to 50 mm width and thickness of 0.20 mm to 2.00 mm, wound on

300/400 mm, internal diameter cores up to a maximum weight of 2 MT.

Hardness range:

Soft (O) up to spring hard (SpH), for all above mentioned products.
PRODUCT APPLICATIONS

AUTOMOTIVE

Meta copper and alloys Limited is a major supplier to the automotive industry in India.

They comply ISO 9001/2000 and ISO14001/2005 standards.

The excellent properties of copper and copper alloys make these products preferred

choices for the automotive manufacturers when it comes to features such as corrosion

resistance, durability, heat transfer, electronics, welding ability, and electrical

conductivity.

Automotive Connectors

We supply copper and brass for electrical and electronic connectors and interconnection

systems. Our customers benefit from the tight tolerances, which is vital for this

application. We present new technology opportunities for cost-effective solutions.

Radiators & Heat Exchangers

Copper and brass with excellent conductivity, formability and solder ability are the best

choices for heat exchangers. Our focus is to develop a cost effective high-quality thin

strip.

CONSUMER PRODUCTS

Our products are used for zippers, buttons and hose coupling. LME A grade copper

cathodes used in this application ensure good workability and durability.

ELECTRICAL

Our copper and copper-based alloys are widely used in different electrical applications,

such as energy, power and transportation systems. Copper provides the electrical and

thermal conductivity that ensures reliability and high performance in a wide variety of

products. We provide new technology opportunities for cost-effective, high performance

material solutions. Our unique process technologies enable us to provide local supply to

meet your most demanding requirements.


We maintain key features like superior electrical conductivity, bending ability,

consistency and stamping ability to match industry specific requirement. This product is

available in pancake and traverse wound form.

Transformer Strips

Transformer strips are used in electric distribution and power transformers. Our

overall manufacturing process encompasses all stages from hot milling to deburred and

slitted edges.

Soft annealing and excellent ductility of copper enables superb coiling properties; strips

will bend easily along rolling direction. The intermediate surface brushing guarantees a

clean surface.

Strip for Electrical Devices

Copper and copper alloys provide the electrical and thermal conductivity that insures

reliability and high performance.

Recommended alloys for use in the Electrical Industry are copper C110, alloys C260

and C268.

Heating, ventilation, air conditioning and refrigeration

In heat transfer applications like air conditioners, refrigerators and heating unit the

excellent conductivity of copper helps in designing energy efficient equipment and

systems in a cost effective manner.

ORDNANCE

Our product finds its use to manufacture cups, discs and ordnance strips for Military

and commercial markets. The strips are engineered with tight tolerances, deep drawing

properties with uniform grain across sections.


VALUE ADDED PRODUCTS

VALUE ADDED PRODUCTS

Copper Foils

(0.035mm/0.00137 inches For Radiator Fins/ Cable Tapes

onwards

Cups and Discs For Defense

Brass/ Copper Circles For Electrical Geysers / General

C12000 De-Oxidized Low Phosphorous Copper

C11300 Silver -bearing Tough Pitch Copper

CuZn0.5 Zinc bearing Copper

CURRENT EXPORT STATUS

U .S .A
10%
20%
E U R O P E (E + W )
25%

M ID D L E E A S T +
SAAR C
30% F AR EAST
15%
SO U TH E AST
A S IA

Plant layout
PRODUCTION PROCESS

RAW MATERIAL

MELTING AND CASTING

RE-HEATING OF SLABS
BAY - 1
HOT ROLLING MILL

FACE MILLING

INTERMEDIATE ROLLING MILL

ANNEALING

EDGE TRIMMING &


PICKLING

COLD FINISHING MILL I & II

DEGREASING ANNEALING
& PICKLING

SLITTER

PACKING

FINISHED GOODS
PRODUCTION PROCESS

BAY I: A detail overview on production process of

Bay-I is given below.

RAW MATERIAL

Brass is an alloy of Copper and Zinc. Raw materials for manufacturing brass are

Copper Cathodes, Copper Granules, Zinc Ingots and the Brass scrap.

QUALITY OF RAW MATERIAL

The raw materials that would be used for our product should be 99% and more pure.

Other wise the quality of the end product will get affected. The raw materials would

be Imported or made available from Indian markets.

In India Hindustan Copper, Birla Copper and Sterlite Industries are the major

Refineries and Smelters who Manufacture Copper Cathodes from Copper ore up to

the purity level of 99.9%.

Copper Cables are world wide replaced by fibre optic cables and these Copper Cables

contain Copper with above 99% purity. This is being sourced globally as well as from

Indian market. The scrap Copper Cable is being used in all the developed and highly

environment conscious countries for the production of Copper and Copper alloys.

Zinc Ingots are the purest form of Zinc and is available in India and all over the

world. Brass Scrap is the material, which is generated during the process in the form

of Edge and end cuttings.


MELTING & CASTING

The feed that is prepared is melted in the Electric induction furnace at 1200°C. This

furnace is of two types one is channel induction furnace and the other one is the

coreless induction furnace. The function of this 2 furnace is to melt the raw material.

SLAB RE-HEATING FURNACE

Once the raw material is melted in the induction furnace, the melted metal is

transferred to the holding furnace, where the temperature of the melted metal is

maintained for getting the uniformity. The Molten metal from the holding furnace is

transferred and poured into the vertical caster, where the mould is casted into slabs of

425x220x9000 mm length. Once these slabs are made they goes to the cold saw

section were the end bits of the slabs are cut with the help of saw and these slabs are

sent to the re-heating for further procedure. The slabs are fed in the reheating furnace,

with the help of where the slabs are preheated up to 850°C with LPG as fuel. The

control system incorporated also ensures that the slabs are heated uniformly.

HOT ROLLING MILL

The plant has been using hot rolling process to produce high quality homogenized

strips. The hot slabs from reheating furnace are sent to hot rolling mill. These slabs

are thereafter hot rolled in the form of coils.

FACE MILLING LINE

During the hot rolling process oxidization of the coils takes place, in order to remove

this, face milling is done. In this process the oxidized layer will be removed by

milling on both the surface and edges of the coils. The scrap generated will be reuse to

melting furnace.
INTERMEDIATE ROLLING

In the Intermediate rolling mill the coil is cold rolled in 4 High Rolling mills. In this

process the coil is rolled up to 1.8mm. During this process heat is generated and

emulsions are used to control the raise temperature.

CHAMBER ANNEALING FURNACE

While undergoing different process, the coil’s hardness, stress increases and to reduce

the hardness annealing is done. Annealing makes the coil softer and reduces the

hardness. In this furnace the coil is heated up-to required temperature, so that the

required hardness, stress and other physical properties of the coil are achieved. For

this purpose chamber annealing furnace and continuous Jet Floatation Annealing

Furnace are incorporated in the plant.

BAY 2: A detail overview on production process of

Bay-II is given below.

EDGE TRIMMING & PICKLING LINE

Edge trimming and pickling, of the coils is done in order to trim of the cracked edges

of the coil and also to clean the surface of the coil in order to obtain the shine of the

metal. The surfaces of the coils are cleaned with the acid with 10% conurbation.

COLD ROLLING

In this process the strip thickness is reduced as per the requirement of the customer.
DEGREASING, ANNEALING & PICKLING [DAP]

ANNEALING Furnace is Jet Floatation, where the strips float in the hot air for

scratch free finish and also to make the coils softer. DEGREASING is done to clean

the surface of the coils. These are coils are cleaned with the help of diluted acid and

Alkali degreasing. After completing annealing and degreasing, PICKLING is done to

obtain the shine of the coils. While undergoing this process the hardness of the coils is

maintained as per the requirement of the customers.

TENSION LEVELING LINE

Tension leveling is done to correct the strips flatness. During this process the excess

stress of the coils is removed and also the make the strips flat, a stretch leveler is

provided. This stretch leveler is also equipped with squeegee rolls to remove rolling

oil, dirt from the strips surface.

SLITTING & CUT TO LENGTH

In this process, the processed strip or foil is then slitted as per the customer’s

requirement on the slitting lines.

PACKING & DESPATCH SECTION

As per MCAL standard and Customer Specification packing is generally done for the finished

goods with almost care. For export either Wooden Box packs or wooden pallet packing been

done. Quality woods are being used for export as per standard. Newly introduced treated

wood pallets are also being used. In the case of country regulations fumigations also been

carried out. The standard packing criteria for DTA and Export packing detail is enclosed

herewith for ready reference. The dispatch section is mainly responsible for dispatch of

finished goods, maintenance of stock of finished goods, staffing of commercially cleared

order in container or trucks and safe custody of finished stock. Material handling & Container

staffing were to be observed for export order execution. Cross verifications of weight in

weighbridge is also to be observed for total understanding of the process.


META COPPER & ALLOYS LTD
Verna Industrial Estates

Roll No: 3850

Class: Fy BBA
Instruments used to Measure Pollution

META COPPER AND ALLOYS LIMITED


Characteristics to
Sr. No. Process Measuring Instruments
be checked

Raw Material Purity Spectro Analyzer


1
Inspection Surface quality Visual
Charge Quantity Weighing Scale
Temperature Temp. Stick
2 Melting & Casting
Chemical
Spectro Analyzer
Composition
3 Slab Saw Appearance Visual
Temperature Thermocouple
4 Re-Heating
Soaking Duration RHF log sheet
Temperature Pyrometer
Thickness Micrometer
5 Hot Rolling
Width Measuring Tape
Surface Visual
Surface Visual
6 Milling
Thickness Micrometer
Surface Visual
Breaking (1 st Cold
7 Thickness Micrometer & Vollmer
Rolling)
Width Measuring Tape
Annealing
Temperature Thermocouple
Bell Annealing
Soaking Cycle PID Control
Temperature Thermo Couple
Speed Speed Controller

8 On line Inspection Metallurgist


Surface Visual
Continuous Annealing
Width Measuring Tape
Vollmer gauge,
Thickness
Micrometer
Physical &
UTM, Hardness Tester Etc.
Mechanical Test
9 Edge Trimming Width Measuring Tape
Surface Visual
10 Pickling Width Measuring Tape
Thickness Micrometer
11 Tension Leveler Flatness I value
Surface Visual
Physical &
UTM, Hardness Tester Etc.
Mechanical Test
Inner & Outer Dia Measuring Tape
Weighing Scale / Weight
Slitting/cut to Weight
12 Chart
length/final inspection
Surface Visual
Micrometer / Vernier /
Dimensions
Measuring Tape
Physical &
UTM, Hardness Tester Etc.
Mechanical Test
As Per Customer
13 Packing Marking & Packing
Requirement
The Environmental Care
We believe that Natural resources like fresh water, clean air and vegetation provide

sustenance and a foundation for social and economic development.

We have supported this by not only voluntarily incorporating State of the Art

Technologyfor taking care of its polluting sources but also by implementing the ISO

14001:2004EMS. We intend to Protect and conserve the quality of air, land, water and

other resources, while fostering economic development & a healthy and safe work

environment. To validate its support to resource conservation, MCAL has adopted the

practice o f rainwater harvesting to meet its water requirements

The company also practices a zero discharge policy. Effluent is treated & reused in

process/irrigation. ZnO and dross is filtered from emissions & molt respectively.

Hazardous waste like used oil, sludge, dross and ZnO are dealt by CPCB/MOEF

authorized recyclers.
MCAL has acknowledged its environmental obligations by operating over & above the

requirements of the Consent to Operate under both the Water (Prevention and Control

of Pollution) Act, 1974 and the Air (Prevention and Control of Pollution) Act, 1981 , as

well as the Authorization of Hazardous Wastes Management & The Registration of

Recyclers under the Hazardous Wastes (Management and Handling) Rules, 2003.

Also, as required under the Environment Protection Act 1986 an Environmental

Statement is submitted at the end of every financial year thus facilitating comprehensive

look at its industrial operations, which further facilitates understanding of material

flows and focus on areas where waste reduction and consequently savings in input costs

is possible.

MANUFACTURING RANGE

Our products have the benefit of technological collaboration and meet international
quality standards. The state-of-art equipment we use was hand picked from some of
the leading equipment manufacturers around the globe. The technology adopted for
slab casting; hot rolling; precision cold rolling help in achieving high standards and
consistent production.

The automated system used for Laser based Pin Hole Detection, Mass flow AGC,
Auto slow down and Auto shape correction, enables high quality products that meet
stringent international quality parameters necessary in the Connector, Radiator,
Defense and Electrical Industries.

META 'S COPPER AND BRASS ARE SUPPLIED AS


Coil Millimeters Inches
Pancake
Thickness 0.10-5.00 0.0039-0.1968
Width 10-500 0.393-19.685
Internal 100/150/200/250/300/400/500 3.93/5.90/7.87/9.84/11.81/11.81/15.74/19
Diameter .68
Mill Width 305/355/406/457/500 12/14/16/18/19.7
Coils
Cut to Millimeters Inches
Length
Sheets
Thickness 0.20-4.00 0.007874-0.1574
Width 20-500 0.7874-19.685
Length 400-3000 15.748-118.110'
Packing Palletised Boxes Palletized Boxes
General
Parameters
Standard Thickness: +/- 1.5 % Width : +/- 0.5 %
Tolerances
Tolerances as per Customer' specific
requirements or as per the chosen
Standard of reference
Temper Annealed to Spring Hard
Coil Weight 11.5 Kg/mm width Approx
Packing Coils wrapped in VCI paper and
Palletized
Shipping Factory stuffed and Sealed in 20'
Containers or as per Customer's choice