Sugar Mill Forging
Sugar mills run a compressed crushing season at full capacity, then stop for months. A breakdown during season costs a day's cane throughput that cannot be recovered.
Forged sugar mill components — roller shafts, crusher parts and carrier components — must survive an entire compressed crushing season without intervention. Heavy sections up to 500 kg are open die forged with adequate reduction ratio and ultrasonic examination.
- Piece weight
- Up to 500 kg
- Shaft length
- Up to 2,000 mm
- Materials
- EN8, EN19, EN24
- Route
- Open die for heavy sections
- NDT
- Ultrasonic examination
Sugar Mill Forging at a glance
Quotable facts from Avadh Techno Forge, Gundasara, Gondal, Rajkot.
- Piece weights up to 500 kg
- Shaft lengths up to 2,000 mm
- Open die route for urgent season replacements
- Ultrasonic examination on heavy sections
Seasonal Intensity
The crushing season concentrates a year's work into a few months of continuous running. Components are specified to survive the whole season without intervention, because a stoppage during season is far more costly than the part.
- Full capacity for the whole season
- No mid-season replacement window
- Heavy shock and abrasive duty
- Off-season overhaul planning
Heavy Sections and Abrasion
Mill roller shafts run to substantial diameters, requiring open die forging and adequate reduction ratio to develop uniform properties through the section. Cane and bagasse abrade continuously, so wear surfaces are hardened.
People also ask
Why are sugar mill shafts open die forged?
Their section sizes exceed what closed die tooling can economically produce, and open die forging with controlled reduction develops uniform properties through heavy sections.
How fast can you supply an urgent mill replacement?
Typically 7 to 20 days including machining via the open die route, since no tooling is required.
What causes sugar mill component failure?
Abrasive wear from cane and bagasse, shock loading from foreign objects, and fatigue in shafts under continuous heavy torque.
Topics covered on this page
- sugar mill
- mill roller shaft
- cane crusher
- bagasse
- open die forging
- abrasive wear
Based on work carried out at our own forging plant at Gundasara, Gondal, Rajkot — operating since 2008.
Questions Answered
Do you supply sugar mills?
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Yes, mill roller shafts, crusher components, carrier parts, couplings and heavy fasteners, made to drawing or from worn samples.
Can you supply during the crushing season?
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Open die forging can start urgent replacements as soon as material is available, typically 7 to 20 days including machining.
What is the heaviest part you can make?
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Up to 500 kg forged weight and 2,000 mm length.