company cases about India Largest Faucet Manufacturer Transforms Production with Turnkey Low Pressure Die Casting Solution
India Largest Faucet Manufacturer Transforms Production with Turnkey Low Pressure Die Casting Solution
2026-06-09
Project Overview
Xiamen Dingzhu Intelligent Equipment Co., Ltd. was selected by India's largest faucet manufacturer — a 10,000-employee industry leader — to deliver a complete turnkey low pressure die casting (LPDC) solution. This landmark project transformed the client's production from traditional manual sand casting to a fully automated manufacturing system.
Project Scale: Complete factory-level turnkey solution
Industry: Faucet & Sanitary Fittings Manufacturing
Location: India
Client: India's Largest Faucet Manufacturer (10,000+ Employees)
The Challenge
Prior to this transformation, the manufacturer relied on manual sand casting for faucet body production, facing multiple challenges:
- Labor Intensive: Each casting operation required multiple skilled workers, creating significant labor costs.
- Inconsistent Quality: Manual processes led to variations in casting density and dimensional accuracy.
- Low Productivity: Cycle times were long and throughput limited by manual operations.
- Environmental & Safety Concerns: Sand casting generated dust, fumes, and posed risks to operators handling molten metal.
The Solution: Turnkey LPDC System
Dingzhu delivered a comprehensive factory-level transformation including:
Equipment Delivered
| Equipment | Key Specifications |
|---|---|
| Low Pressure Die Casting Machines | Fully automatic PLC-controlled, multi-station |
| Automatic Pouring & Cooling System | Precision molten metal metering with temperature control |
| CNC Trimming Stations | In-line automated gate removal and surface finishing |
Complete Turnkey Services
- Factory Layout Design: Optimized workflow from raw material to finished casting output
- Equipment Installation: Full mechanical and electrical installation on-site by Dingzhu engineers
- Operator Training: Comprehensive 3-week program covering operation, die setup, and safety
- Process Optimization: Custom die design consultation and on-site parameter tuning
- After-Sales Support: 1-year warranty with remote diagnostics and spare parts supply
Results: 300% Efficiency Improvement
The transition from manual sand casting to automated LPDC delivered transformative results:
| Performance Metric | Before | After | Improvement |
|---|---|---|---|
| Production Output (pcs/day) | Baseline | 4× Baseline | +300% |
| Direct Labor per Shift | 20-25 workers | 5-7 workers | -70% |
| Casting Yield Rate | ~75% | ~95% | +20% |
Key Benefits
1. Dramatic Efficiency Gains
Fully automatic LPDC machines quadrupled daily output while reducing labor requirements by 70%. Production that required three shifts of skilled workers now runs with a fraction of the workforce, enabling redeployment to quality control and finishing roles.
2. Superior Product Quality
Low pressure die casting delivers consistently dense, porosity-free faucet bodies with excellent dimensional accuracy. Yield rate improved from 75% to 95%, dramatically reducing rework and scrap while requiring significantly less post-casting machining.
3. Environmental, Safety & Cost Benefits
The enclosed LPDC process eliminated workshop dust, fumes, and waste sand while removing worker exposure to molten metal hazards. Combined savings — 70% lower labor, 60% less material waste, 35% reduced energy consumption — delivered rapid ROI well ahead of projections.
"Dingzhu delivered far more than machines — they delivered a complete factory transformation. Their turnkey approach made the transition seamless, and the 300% efficiency improvement exceeded our expectations."
Conclusion
This project demonstrates Dingzhu's capability as a comprehensive turnkey solution provider. By combining advanced LPDC technology with end-to-end execution, we delivered transformative results: 300% efficiency improvement, 70% labor reduction, and dramatic quality enhancement — positioning our client for sustained growth in the global sanitaryware market.
