MERAJ ENGINEERING

Solution For Metal Industry

MERAJ
ENGINEERING
Solution for Metal Industry

MANUFACTURER, SUPPLIER AND

EXPORTER OF
SECTION, TUBE, ROD, COIL
&

SPECIAL PURPOSE MACHINERIES

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 MERAJ ENGINEERING
Solution For Metal Industry

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
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 Less down time

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 Automatic Tube Discharge at Front Frame.

 MERAJ ENGINEERING
Solution For Metal Industry

MODEL NORMAL MAX. MAX. LENGTH OF PULL FORCE

OD (mm) PRODUCT (Meters) (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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Solution For Metal Industry

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) Max Dia Max. Wall Min. Wall Speed
Range mm mm Thickness Thickness
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 MIN WIDTH MAX THICKNESS MIN THICKNESS

WIDTH mm mm mm 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 Min. Dia Max. Dia Max Wall Motor

Mo. mm mm Thickness 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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Solution For Metal Industry

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
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CUT TO LENGHT MACHINE

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Solution For Metal Industry

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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Solution For Metal Industry

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

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SHEARING MACHINE
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Solution For Metal Industry

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 MIN OD MAX MAX TUBE
(mm) (mm) PRESSURE LENGTH
(kg / cm2) (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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Solution For Metal Industry

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- LD15- LD15- LG- LG- LG- LD-
15 30 60 30H 60H 80H 120
OD of Blank 50- 64-
Tube（mm） 9-17 17-34 17-64 22-55 83 102 127
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 60-
Tube(mm) 8-15 15-30 15-60 15-40 30-60 40-80 120
Wall Thickness of 0.25-
Finished Tube(mm) 0.1-1 1.1-2 0.2-3 0.4-5 1-6 1-8 6.5
Max. Length of
Finished Tube(m) 8 15 15 15 15 15 15
Speed of Operating 70- 65- 60- 30-
Frame（Time/Min) 140 110 40-80 120 60-80 60-80 100
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Weight(ton) 8 15 35 22 50 80 100
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Solution For Metal Industry

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

TJ300/ TJ350/ TJ400/ TJ400/ TJ550/ TJ600/ LJ300 LJ350/
MODEL 90 200 250 280 450 450 / 110 200
SCOPE OF ALUMINIUM
PRODUCT SOLID COPPER FLAT TUBE / FLAT
WHEEL 285mm 340mm 400mm 400mm 550mm 580m 285m 340mm
DIAMETER m m
POWER OF 90kv 200kv 250kv 280kv 450kv 450kv 110kv 200kv
MAIN MOTOR
MAX ROTARY 13 13 10 12 8 r/min 8 r/min 16 16-26
SPEED OF r/min r/min r/min r/min r/min r/min
WHEEL
OUTPUT 400 400-800 400- 400- 800- 1200- 110 400-750
CAPACITY kg/h kg/h 1300 1300 2500 4000 kg/h kg/h
kg/h kg/h kg/h kg/h
CROSS 15- 150-600 250- 25-2200 380- 450- 15- 45-300
SECTION OF 150mm2 mm2 2200 mm2 3700 5000 150 mm2
PRODUCT mm2 mm2 mm2 mm2
MAX WIDTH 35 mm 700 mm 130 mm 150 mm 205 mm 260 30 70 mm
OF PRODUCT mm mm
MIN 1.2 mm 3 mm 4 mm 4 mm 6-8 mm 8-10 1.2 2 mm
THICKNESS OF mm mm
PRODUCT
FLASH <3 <5 <5 <5 <5 <5 <1 <1
AREA OF 6mx30 8mx30 10mx40 10mx40 10mx40 10mx4 6mx3 8mx30m
PRODUCTION m m m m m 0m 0m
LINE
DIAMETER OF Ø12.5 + Ø16 + Ø20 + Ø20 + Ø22 + Ø25 + Ø9.5 + Ø15 +
RAW 0.2 mm 0.2 mm 0.2 mm 0.2 mm 0.2 mm 0.2 mm 0.2 0.2 mm
mm
HARDNESS OF
PRODUCT HB68-70
TENSIL
STRENGTH OF < 170 N /mm2 < 90 N /mm2
ROD
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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 :
L – 6129/2, 4th PHASE, GIDC, VAPI,

ADDRESS 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)
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