Our manufacturing set-up is tooled for in-house machining of critical parts like Crankcase, Connecting rod and dynamic balancing of Crankshaft and Motor pulleys etc. Flexible & optimized manufacturing set-ups are proven for quick set-up changes to prioritize any model based on customer requirement, in product range of 1 cylinder to 12 cylinder compressors. Our pre-treatment shop covers 100% stress relieving & phosphating of each Crankcase while our machine shop is equipped with the latest CNC machines like HMC & VMC, Balancing machines, VTL and in-line quality gates to generate records. Our assembly line is equipped with torque tools to deliver a precise range of torques and quality gates at various locations generate real time quality data.

KPCL has developed manufacturing infrastructure to accommodate manufacturing of 1 CNG Compressor per day. On an average we are looking at an output of 300 Compressors annually. Our manufacturing shed has two bays with crane capacity of 50 tons – 2 Nos and 20 tons – 2 Nos. We have an unique CNG testing bed facility where we can test CNG packages from 200 to 3600 SCMH capacity with suction pressure of 3 kg/cm2G to 40 kg/cm2G and discharge pressure upto 255 kg/cm2G. We have CNG storage capacity of 7000 water liters (2000 ltrs -2 Nos & 3000 ltrs – 1 Nos) where we can test four motor driven packages/two engine driven packages at a time. This test bed facility is a closed loop system consisting of multistage Pressure reduction scheme which reduces pressure from 255 kg/cm2 G to desired suction pressure and piping is looped with heat tracing to maintain desired suction temperature as per client requirement. Our CNG motor driven and engine driven compressor packages are tested in full load condition and all the parameters are recorded. Various alarm and trip condition are also being tested to ensure the working of safety interlocks. KPCL’s Gas Compression facilities are also part of this large set up and a prime requirement which we have added to this has been in house Radiography Room / Shot Blasting and Specialized Painting Room. This ensures that products can be tested and manufactured upto world class standards. In addition to this we are now planning to offer packages to client, so that they can inspect the packages from remote  by just sitting in their office during this Covid-19 period.

In-House Technology and Infrastructure

KPCL has one of the most modern screw cutting plant in the world today . We manufacture  state of the art air ends  designed with the help of SRM and City University – undisputed  pioneers and leaders  in screw profile  design . Highly sophisticated fully automatic screw milling and grinding machines produce screw rotors  in temperature controlled conditions to extremely close tolerances .These rotors are checked with the latest rotor profile CMM machines to ensure our screw compressors exceed our customer’s quality expectations.

We have one of the most modern machine shop in the country. Our shop is equipped with numerous horizontal and vertical CNC machining centers, SPM , VTL , boring, grinding and general purpose machines  to produce the high quality components  required in the manufacture of piston , screw and centrifugal air ends. In fact we are the only compressor manufacturer  in India machining API 672 centrifugal impellors with dedicated 5 axis milling machines. Our in house capability includes machining high speed gear boxes for these  centrifugal compressors

We have our own foundry dedicated to the manufacture of highly intricate castings used for in house consumption . Thus facility along with our NABL approved laboratory and  heat treatment facility gives us the flexibility to meet customized requirements specially for oil and gas , nuclear and defense customers.

The highest quality standard product are assembled  under supervision of expert team in our lean assembly shop.