Manufacturing
An integrated malleable iron foundry in Semarang.
PT Tri Sinar Purnama has operated as an iron foundry since 1983. Production runs end to end on our own sites — pattern making, core making, moulding, melting and casting, annealing, galvanizing, machining and packing all take place in house across two production sites totalling 60,000 m², with an annual capacity of 15,600 tons and more than 1,900 employees.
The sequence below is TSP's production route for malleable iron pipe fittings and casting products, with the equipment installed at each stage.
Production sequence
| # | Process | What happens |
|---|---|---|
| 01 | Pattern Making | Tooling and patterns that define each fitting's geometry are produced in house. |
| 02 | Pattern Preparation | Patterns are mounted, checked and set up for the moulding line. |
| 03 | Core Making | Sand cores that form internal bores and cavities are produced and cured. |
| 04 | Molding Sand Preparation | Moulding sand is mixed and conditioned. Compactibility is tested every 30 minutes. |
| 05 | Molding | Moulds are formed on jolt squeeze lines and assembled with cores. |
| 06 | Melting and Casting | Iron is melted in cupola furnaces and poured into the moulds. Chemical composition is checked by spectrometer. |
| 07 | Annealing | Castings undergo annealing heat treatment. |
| 08 | Grinding | Gates, risers and parting lines are removed and surfaces dressed. |
| 09 | Shot Blasting | Castings are cleaned ahead of coating and machining. |
| 10 | Galvanizing | Hot dip galvanizing. Coating thickness is verified with an Elcometer. |
| 11 | Tapping | Threads are cut to the applicable thread standard and checked with plug and ring gauges. |
| 12 | Lathe / Machining | Turning, chamfering and union machining. |
| 13 | Drying | Products are dried ahead of final inspection and packing. |
| 14 | Packing | Packed to order specification. Leakage testing is carried out on 100% of products before packing. |
| 15 | Finished Goods Warehouse | Finished stock is held and staged for despatch. |
| 16 | Container Loading | Export orders are loaded for shipment. |
Installed capability by stage
| Stage | Capability | Installed equipment |
|---|---|---|
| Pattern Making | Patterns and tooling produced in house. | CNC & VMC ×6 · Drilling ×3 · Lathe ×3 · Grinding ×1 |
| Core Making | Core production for internal geometry. | Double Head Core ×4 · Core Furnace ×30 · Automatic Core Machine ×4 |
| Molding | Moulding, cleaning and dressing on site. | Jolt Squeeze ×57 · Shot Blasting ×6 · Grinding ×8 |
| Melting & Casting | Cupola melting with dust collection. | Cupola 8 tons/hour ×2 · Cupola 5 tons/hour ×2 · Cupola 3 tons/hour ×2 · Dust Collector ×2 |
| Annealing | Annealing performed in house. | Annealing Machine ×2 · Crane Hoist 3 MT ×2 |
| Galvanizing | Hot dip galvanizing performed in house. | Hot Dip Galvanizing Batch ×7 |
| Tapping | Threading across manual, automatic and large-size lines. | Manual Tapping ×41 · Automatic Tapping ×10 · Big Tapping ×2 · L/R Tapping ×1 |
| Lathe / Machining | Finishing and union machining. | Lathe ×31 · Tapping ×12 · Chamfering ×6 · Automatic Union ×4 · Injection Molding ×2 |
Equipment counts are TSP's installed machine inventory as stated in the company profile. Cupola ratings are the rated capacity of each installed furnace.