MERAJ ENGINEERING

Solution For Metal Industry

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MERAJ

ENGINEERING

Solution for Metal Industry

MANUFACTURER, SUPPLIER AND

EXPORTER OF

SECTION, TUBE, ROD, COIL

&

SPECIAL PURPOSE MACHINERIES

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Company Profile

Meraj Engineering manufacture, supply, export and Consult Engineering company from India, mainly provide the facility and the service for the client who wants to establish a new tube, rod, section and coil plant or expand the owned tube, rod, section and coil plant, it mainly provide the machine for producing and testing tube, such as normal annealing furnace, bright annealing furance, normalizing and annealing furnace, extrusion press, cold draw bench, piercer, pilger mill, drawing machine, straightening machine, Hydro Tester, U bend machine, Cutting machine, Point Sheering machine, Bull Block machine ect.. The tube make machine including hot line and cold line are mainly exported to various parts of the world. Those machinery can be applied for the production line for seamless Carbon steel tube, Seamless Stainless steel tube, Copper tube, Titanium tube etc.. Since our inception in 1987, we have worked hard to keep up with changing technology. In the process, we gained knowledge and insight into both the product and customer understanding. This has firmly established us as a renowned epitome in the industry. Our ability to incorporate specialized design and latest trends to develop superior quality and sophisticated machines has given us a further edge over our competitors. Adhering to stringent quality norms and testing measures, we have resolutely developed a wide gamut of our machines in standard and customized configurations. With the unified and dedicated efforts of our expert team coupled with our years of expertise, we have successfully implemented advanced Quality measures at our unit. We have garnered huge clienteles due to our immense efforts to develop quality machines.

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DRAW BENCH

Meraj designs and manufactures a full line of wire, rod, section and tube processing Draw Benches (Hydraulic). Available are both gear box and motorized chain type units along with a full selection of features and accessories.

Draw Benches are used for straight length die-drawing of round rod, wire or tube for producing straight lengths of shaped rod or wire

Meraj offers Single / Double / Triple Type Draw Benches with automatic operations, designed for high yield, perfect quality and precise application

DRAW BENCH

FEATURE :

Automatic tube feeding mechanism.

Motorized Rotating / Indexing Type Back Bench with automatic plug positioning device to minimize handling time.

Spherical die holder for self-alignment.

Fully Guided Carriage with automatic fast return.

Round tooth type pneumatic clamps to avoid tube slippage.

AC Regenerative Drive for power saving.

Heavy duty, high reduction gear box.

Carriage driven by Duplex / Triplex type double sprocket & chain having rupture strength 6 times of the draw force.

Robust Construction

Smooth Running

Centralized Pull to avoid bending

High Production Capacity

Less man power requirement

Less down time

Automatic Tube Discharge at Front Frame.

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MODEL NORMAL MAX.

OD (mm)

MAX. LENGTH OF

PRODUCT (Meters)

PULL FORCE

(M.T)

MDB 10 20 6 0-3.3-10

MDB 15 50 20 0-5-15

MDB 20 76 40 0-6.6-20

MDB 30 90 50 0-10-30

MDB 40 125 65 0-13.3-40

MDB 50 150 75 0-16.6-50

TROLLEY DRAW BENCH

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STRAIGHTENING (TUBE / ROD)

Meraj offers in modern times with technological progress all round, there is a demand from buyers and users of section / rod / tube for greater degree of straightness and roundness free from markings or ripples.

From the view point of manufacturers of section / rod / tube, the benefits of a well-straightened section / rod / tube becomes a clearly visible disaster. Hence the straightening process makes the section / rod / tube either saleable or scrap.

Meraj multi-cross-roll straightening machine allows the section / rod / tube to be rounded / straight during straightening.

The Meraj multi-cross-roll section / rod / tube straightening machines provide all the advantage and meet the requirement of modern industries.

Meraj offers two types of straightening machine with 6 roll and 10 roll design respectively, each of which meets a particular requirement of straightness tolerance.

The 6 roll tube straightening machine caters to straightening tolerance of 1mm in 1 Mtr lenght and the 10 roll tube straightening machine caters to straightening tolerance upto 1mm in 5 Mtr lenght depending on material specifications

STRAIGTHTENING

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FEATURE :

Machines comprise of six / ten work rolls arranged in pairs.

Rolls are quickly and easily adjusted angularly to give a perfect

contact between the tube and roll over the maximum effective

roll profile.

Setting of the machine for different sizes of tube is simple.

All rolls are driven by two identical electric motors.

Machines are fitted with indicators for vertical and angular

setting of rolls.

Accuracy

Long-life straightening rolls

MODEL Capacity (O.D) Range mm

Max Dia mm

Max. Wall Thickness

Min. Wall Thickness

Speed

MTS 10 1-8 9 1.5 1.5 40

MTS 20 3-13 15 2.5 2 38

MTS 30 4-20 20 2.5 2.5 35

MTS 40 6-30 32 3.2 2.5 32 MTS 50 8-40 45 4.5 3.5 30

MTS 60 13-65 75 6.0 4.5 28

MTS 70 20-100 115 8.1 6.5 25

MTS 80 25-125 140 8.5 6.5 25 MTS 90 30-150 165 9.5 7 18

MTS 100 40-200 215 10.0 7 16

MTS 110 45-225 240 10.5 7.5 10

MTS 120 50-250 265 11.0 7.5 6

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ROLLS:

These are manufactured from alloy steel, hardened, hyperbolic profile-ground and lapped to a very high degree of finish to give perfect straightness and good surface finish.

The hyperbolic profile are designed and generated to accept the widest range of tube diameters for a particular size range of the machine.

All the rolls are manufactured to the same dimensions, thus ensuring a matched set.

Rolls are mounted on antifriction bearings.

ROLL CARRIERS:

These are designed to effect maximum roll stability, the carrier stalks being of substantial proportions to eliminate any instability when fully extended.

MAIN DRIVE:

These are designed to effect maximum roll stability, the carrier stalks being of substantial proportions to eliminate any instability when fully extended.

The drive to the rolls is accomplished from two totally enclosed gear boxes, each having three/five output shafts, which are connected by universal joints.

The lower three/five rolls are driven independently of the top three/five rolls.

All the gears are single helical made out of alloy steel, through hardened and ground.

The electric motors are connected to the input shaft of the gear boxes by flexible coupling / Vee-Belt drive.

MACHINE LUBRICATION:

All the points requiring regular lubrication are provided with grease nipples. The helical gears and bearing in the gear box operate in a totally enclosed oil bath and are splash lubricated

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STRAIGTHTENING

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STRAIGHTENING (SECTION)

Meraj Offers A Range Of Section Straightening :-

Strip straightening

Hydraulically section de-twisting

Stretch straightening

Reciprocating strip decampering

FEATURE :

Different size of the section can be straightened

Fast process of Straightening

Capable of making finish corner during straightening

Very Less Maintenance cost

Easy Operation

MODEL MAX WIDTH mm

MIN WIDTH mm

MAX THICKNESS mm

MIN THICKNESS mm

MSM 32 30 10 4 1 MSM 52 50 20 10 3

MSM 102 100 50 20 6

MSM 130 125 75 25 8

STRAIGTHTENING

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ROTARY SWAGER

Meraj Rotary swaging is a process for reducing the diameter of a length of

tubing. The reduced diameter can be any length, from a short end up to the

entire length of the tube, or any length in between. The tubing is fed by

hand, or mechanically, into custom made, hardened steel dies. Through the

reciprocating action of the die halves, the tube is worked into the shape cut

in the dies.

MERAJ Manufactures different kind of hydraulic based fully Automatic &

Manual Swaging Machines, Rotary Swaging Machine for tubes OR Pipes

depending on the size & design of swaged tubes.

FEATURES:

Externally rigid Construction

Temper-Free Alignment

Excellent finishes & accuracy

Fast Set-up & Change over.

User-Friendly machines.

Cost-effective process

Increased tensile strength

An improved surface finish

The machines has no heating, hence this is purely a cold process. Hence, less

power consumption and highly suitable for industries engaged in mass

production of swaged parts/components. The machine circuit is

internationally designed & consumption of power is very less

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Model Mo.

Min. Dia mm

Max. Dia mm

Max Wall Thickness

Motor Capacity

MS 10 2 12 1 1

MS 12 3 16 1.2 1.5

MS 20 4.5 22 1.6 3 MS 25 6 30 3 5

MS 30 7 35 3.5 7.5

MS 50 9 52 5 10

MS 60 12 65 6 20

MS 70 16 75 5 25 MS 80 25 90 6 30

ROTARY SWAGER

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HYDRAULIC TUBE POINTING

Meraj offers hydraulic tube pointing machine shall put an end to the age of rotary swaging concept involved in pointing a Tube by hammering. Its time something like this tube pointing machine was adopted and its efficiency, precision, reliability and noiseless operation availed of.

This machine involves a Hydraulic process to give you pointed Tube ends where heavy reductions in size is possible with a round concentric point.

HYDRAULIC POINTING

FEATURE:

Free of VIBRATION

Free of NOISE

Free of MAINTENANCE

Free of FOUNDATION

Free of MOVABILITY

Round concentric reduction POINTING FOR EASY GRIP

Smooth operation with LOW TOOLING COST

LOW POWER COST

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TECHNICAL SPECIFICATION:

Capacity of the Machine:

Tube Diameter A. Maximum reduction in one stroke 15mm 150mm to 75mm

B. Maximum reduction in one stroke 10mm 75mm to 30mm

C. Maximum reduction in one stroke 5mm 30mm to 15mm

TECHNICAL DATA OF THE MACHINE

TOOLS Set of dies (As per customers requirement) OPERATION CYCLE TIME

7 to 14 Second depending upon size of Tube & Reduction

POINTING LENGTH 150mm or less (As per customers requirement) POWER RATING

A) 10 HP / 3 Phase / 50 Hz / A.C. B) 7.5 HP / 3 Phase / 50 Hz / A.C. C) 5 HP / 3 Phase / 50 Hz / A.C.

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CUT TO LENGHT

MERAJ Pipe / Tube / Section Straight & Cut Machine

This machine is to straighten the Pipe / Tube / Section from coil, measure at

certain length and cut.

The coiled pipe / tube / section is uncoiled, measured, cut automatically.

After cutting the straightened pipe / tube / strip fall into the hopper.

The machine is make up of decoiler, straightening and cutting , collector,

electric system, hydraulic system, pneumatic system, etc. Installed within

decoiler of wadge of copper pipe after spread out and get across to

detector, straightening, pedrail feeding structure, scrapless cutting

equipment, upbear tube clamp, bending structure, fixed length of returns

material system, collector, etc

To accomplish a series work of Pipe / Tube / Section of decoiler,

straightening, collect finished product system. These system have

continuous movement is accurate and complete ordering, the electrical

system according to strict of procedure instruction to achieve by the

hydraulic pressure system, pneumatic system and mechanism structure to

execute exactly

CUT TO LENGHT MACHINE

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CUTTER (TUBE / ROD / SECTION)

MERAJ Tube / Rod / Section Cutter Machine

Tube cutter machine to cut tube / rod / section (as per requirement)

Automatied & manual reversing of cutter after cutting tube / rod

Emergency stop

Suitable for heavy-duty cutting, featuring stable accuracy.

Automatic cooling-fluid circulation assures that cutting-faces are smooth.

Vertical sideway saw feeding provide stable and assuring long cutter

operating life.

Saw chips are treated together, allowing for easy and simple machine

maintenance.

The machine body structure is strong . Low vibration and long operating

life.

The saw can be adjusted back and forth for accurate cutting position,

ensuring extended saw-blade operating life and fast cutting.

Auto lubrication system.

CUTTER MACHINE

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HYDRAULIC POINT SHEARING

Meraj presents to you a range of most technically advanced hydraulic shearing machines with all latest features as per international standards.

The fastest & easiest way of blade clearance setting without need of feeler gauge, which helps burr-free edges

Technical Specification :

Capacity : 25mm Thickness

250mm Maximum Width

SHEARING MACHINE

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COILER (TUBE / ROD / STRIP)

MERAJ Coiling Machine Is Used To Coil Tube / Rod / Strip Of

Copper, Aluminium Etc To Becoming Coil For Further Process, Easy

Transportation, Reduce Space Required & Easy Handling.

Technical Specification:

Capacity : Pancake Coil Size from 1/8” to 3/4" Dia Tube

For Hard and Soft Annealing Tube

COILER MACHINE

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BULL BLOCK

Meraj Bull Block - Main body with base, drawing drum and drawing die box of close grain Cast Iron

Water cooling arrangement provided inside the Drawing Drum and the Die Box

Phosphorous bronze gears with high carbon axle steel worms Suitable for making Nail Wire from 8 mm or 6 mm input rods up to 2 mm

Also suitable for making Wire used to make Barbed Wire, Wire Mesh, etc.

Wet / Slip type Fine Wire Drawing Machine also available - Details on request

Technical Specification :

Capacity : Tube 20mm to 1mm Dia

BULL BLOCK MACHINE

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DEBURRING

Meraj Deburring machine mainly used to deburr and chamfer kinds of round tubes and rods. Deburring is the first step in tube preparation after the tube is cut. Deburring a tube includes squaring the end of the tube concentric to the inner and outer edges of the tube. Deburring is an essential step in any tube fabrication.

FUNCTIONS: 1. The tube diameter and length can be adjustable 2. Deburr tube ends by high-speed wire wheel 3. Easy to operate, high efficiency, good quality

Techincal Specification Capacity : 2” to 50mm &

50mm to 6mm

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HYDRO TESTING

MERAJ Hydro Testing Machine is used to test the tube through pressure.

HYDROSTATIC PRESSURE TESTING MACHINE MODEL No. MAX OD

(mm) MIN OD

(mm) MAX

PRESSURE (kg / cm2)

MAX TUBE LENGTH (Metre)

MHM 60 65 6 250 8 MHM 115 120 20 350 8 MHM 170 180 50 400 8

FEATURE :

SEAL HOLDER FRONT ANF BACK MOVEMENT THROUGHT MOTORISED

MECHANISM.FRONT AND BACK MOVERMENT CONTROLLED WITH

ELECTRICAL LIMIT SWITCH.

PNEUMATICALLY OPERATED TUBE CLAMPING UNIT

TROLLEY TYPE MOVABLE SEAL HOLDER UNIT

PNEMATICALLY OPERATED TUBE EJECTING SYSTEM

OUTER DIAMETER OF THE TUBE RANGE OF TUE CAN BE TESTED BY CHNGING

RUBBER SEAL

QUICK CHANGEABLE TOOLING WITH EASE FOR DIFFERNET RANGE OF OUTER

DIAMETER.

LENGTH SETTING FOR DIFFERENT LENGTH OF TUBE CAN BE SET B QUICK

CAN BE OPERATED IN AUTO AND MANUAL MODE

COMPLETE AUTOMATIC TUBE TRANSFER PROCESS CONTROLLED BY PLC

PRESSURE SENSING AND TRANSMITTED BY ELECTRONIC PRESSURE

TRANSMITTER

TUBE RESTING STAND WIH PNEMATICALLY OPERATED LOADING SYSTEM

FOR TUBE TRANSFER

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STRECHER

MERAJ HYDRAULIC STRECHING MACHINE FOR TUBE, ROD AND SECTION IS

USED TO STRETCH WITH DIFFERENT LENGTH TO EQUAL LENGTH AND FOR

STRAIGHTENING IT.

FUNCTION :

ADVANCE TECHNOLOGY WHICH CUTS THE COST

HYDRAULIC STRETCHING, STABLE QUALITY

PLC AUTOMATIC CONTROLLED, EASY TO OPERATE

ACCURACY

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PILGER MILL (Supplied by Meraj Engg.)

Two Roller Ring Die Pilger Machine Is The Technical Equipment That Is Uses

Ring-Die To Reduce Diameter If Carbon Steel And Non-Ferric Steel Seamless

Tube Largely Or Rightly And Its Advantage Is It Can Do Cold Rolling, Roll The

Billet Directly, Operate Simply And With High Precision

Model & Specification

LD8-15

LD15-30

LD15-60

LG-30H

LG-60H

LG-80H

LD-120

OD of Blank

Tube（mm） 9-17 17-34 17-64 22-55 83 50-102

64-127

Wall Thickness of Blank

Tube（mm） 1.8 2.5 4 6 7 10 7

Max. Length of Blank Tube Length(m) 4 5 5 6 5 6.5 7

OD of Finished Tube(mm) 8-15 15-30 15-60 15-40 30-60 40-80

60-120

Wall Thickness of Finished Tube(mm) 0.1-1 1.1-2 0.2-3 0.4-5 1-6 1-8

0.25-6.5

Max. Length of Finished Tube(m) 8 15 15 15 15 15 15

Speed of Operating

Frame（Time/Min) 70-140

65-110 40-80

60-120 60-80 60-80

30-100

Weight(ton) 8 15 35 22 50 80 100

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CONTINUOUS EXTRUSION (Supplied by Meraj Engg.)

COPPER CONTINIUOUS EXTRUSION PRODUCTION LINES

INTRODUCTION

The production line by feedback machines. Anti-oxidation cooling system,

take up of five major component line. Material choose up-casting on the

production of oxygen-free copper rod, the surface the copper rod was clean

cannot used copper rod cleaning system.

Copper rod by the release, the straightening directly into the continuous

extrusion machine, after extruding to strip products, at this time product

have high temperatures, so in the exit of extrusion machine have an anti-

oxidation plant and cooling system, through meter calculator plant and

other equipment of the production line producing copper strip.

The process is simple, low investment and production site of small, saving

energy and labor, the low cost of production, manufacturers welcomed.

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BASIC CONFIGURATION

Feedstock payoff

Feedstock straighten unit

Feeding cut device

Hydraulic and lubricate system

Continuous extrusion machine

Cooling system (including the anti-oxidation system)

Take up regulate plant

Take up stand

Electric control system

Bailing press

FEATURES

Raw material specifications for the reunification of the raw rod, so

material will be easy for ready

The length of continuous production, high efficiency

As the extrusion process is heat distortion, the product does not

require annealing, energy saving signification, good flat.

Transform products only change a mold, fast and convenient.

Especially suitable for small batches, producing more varieties.

Get good mechanical properties and micro organizational structure,

the conductivity will good for products.

Products surface smooth and stable

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MAIN TECHNOLOGY PARAMETER O COPPER & ALUMINIUM EXTRUSION

MODEL TJ300/

90 TJ350/

200 TJ400/

250 TJ400/

280 TJ550/

450 TJ600/

450 LJ300/ 110

LJ350/ 200

SCOPE OF PRODUCT

SOLID COPPER FLAT

ALUMINIUM TUBE / FLAT

WHEEL DIAMETER

285mm 340mm 400mm 400mm 550mm 580mm

285mm

340mm

POWER OF MAIN MOTOR

90kv 200kv 250kv 280kv 450kv 450kv 110kv 200kv

MAX ROTARY SPEED OF WHEEL

13 r/min

13 r/min

10 r/min

12 r/min

8 r/min 8 r/min 16 r/min

16-26 r/min

OUTPUT CAPACITY

400 kg/h

400-800 kg/h

400-1300 kg/h

400-1300 kg/h

800-2500 kg/h

1200-4000 kg/h

110 kg/h

400-750 kg/h

CROSS SECTION OF PRODUCT

15-150mm2

150-600 mm2

250-2200 mm2

25-2200 mm2

380-3700 mm2

450-5000 mm2

15-150 mm2

45-300 mm2

MAX WIDTH OF PRODUCT

35 mm 700 mm 130 mm 150 mm 205 mm 260 mm

30 mm

70 mm

MIN THICKNESS OF PRODUCT

1.2 mm 3 mm 4 mm 4 mm 6-8 mm 8-10 mm

1.2 mm

2 mm

FLASH <3 <5 <5 <5 <5 <5 <1 <1

AREA OF PRODUCTION LINE

6mx30m

8mx30m

10mx40m

10mx40m

10mx40m

10mx40m

6mx30m

8mx30m

DIAMETER OF RAW

Ø12.5 + 0.2 mm

Ø16 + 0.2 mm

Ø20 + 0.2 mm

Ø20 + 0.2 mm

Ø22 + 0.2 mm

Ø25 + 0.2 mm

Ø9.5 + 0.2 mm

Ø15 + 0.2 mm

HARDNESS OF PRODUCT

HB68-70

TENSIL STRENGTH OF ROD

< 170 N /mm2

< 90 N /mm2

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EXTRUSION PRESS (Supplied by Meraj Engg.)

The process of extrusion is simply forcing a billet of metal through a shaped

die to produce a continuous length of constant section similar to the die

profile. The extrusion of copper really initiated the extrusion process as a

high production process.

There are two basic extrusion processes , Direct extrusion and indirect

extrusion. Direct extrusion is by far the most widely used process. Indirect

extrusion more efficient and produced higher quality products.

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MATERIALS AND SECTIONS

All metals and alloys can be extruded. Extrusions can be solid or hollow.

Extrusions can be tapered or stepped by manupulating the die during the

extrusion process.

EQUIPMENT/ PROCESS

Extrusion presses are generally hydraulically operated and the process is

generally completed in a horizontal elevation. Hot metal extrusion involves

preheating the billet prior to extrusion to reduce the work required to

extrude the section.

EXTRUSION PRESS

Meraj Engineering also supplies various type of

furnace such as:-

ANNEALING FURNACE (Electric & Oil)

MELTING FURNACE

POT FURNACE

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Contact Details :

ADDRESS

L – 6129/2, 4th

PHASE, GIDC, VAPI,

PIN – 396195, DISTRICT - VALSAD,

GUJARAT, INDIA

PHONE 091 260 2452454 / 2452312

MOBILE 091- 9377717273 / 9328026055 /

9824132776 / 9725777899

EMAIL merajengineering@gmail.com

merajengineering@in.com

WEB www.merajengineering.com

NOTE:-

The manufacturer always performs product improvements to achieve

the best possible. All specifications, dimensions and design

characteristics shown in this catalogue are subject to change without

notice. (Products specifications are based on the actual machines)