Bhoruka Fabcons

Corporate Presentation

Updated Date : February 2023

BRAND LEGACY

TCI-Bhoruka brand of companies exists since 1950’s with group revenue in excess of
Rs 6000 Cr ( USD 800 million). Bhoruka Aluminium (extrusions) since 40years and
Bhoruka Fabcons since 10yrs.

• TCI- GATI-BHORUKA group of industries

started in 1950s in transportation & logistics
segment.

• The group expanded to other segments over the

years. Logistics, Steel, Gases, Power, Real
estate and Aluminium Extrusion.

• Bhoruka Fabcons (BFPL) – BAL JV

2007- 2013 (JV)
Established in 2007 is an independent company
with complete focus on Aluminium engineering
services for downstream market.

• Bhoruka Fabcons (BFPL) becomes

independent in 2013 and begins complete focus
on downstream Aluminium market.
COMPANY OVERVIEW

VISION

To be the leading We procure aluminum extrusion, aluminium sheet metal and

other sub-assembly components.

Aluminium Downstream We perform engineering and manufacturing activities and

dispatch finished good for end application to our customers.

company in India. Extrusion Sheet Metal

POSITIONING

We engineer, We add value

COMPANY OVERVIEW

MILESTONES

2007-2012
BFPL established in 2007.
Served as a job work arm to Bhoruka Extrusions
MISSION STATEMENT

2013-2017

To provide high quality Aluminium Promotors exit extrusion business to focus on downstream vision in 2013.
BFPL expands to second unit in 2017.

products and manufacturing

services enabling our clients to 2018-2022
Partnership with Lippert Components (LCI), to manufacture coach windows in 2019.

reduce their lead time and BFPL expands to third unit in 2019.

multiple-vendor dependency. Vision for 2023 and beyond…

Approaching 10TH Year.

Technology Partnerships.
IRIS and Bonding Certifications.
Sheet Metal Setup
ABOUT US

BFPL, an ISO 9001 & EN 15085-2 certified company, has 3 manufacturing units in Mysuru in close proximity to
each other. Our expertise is in Aluminium machining, 3D Bending, Welding, Bonding and Powder Coating.

UNIT 1: Dedicated to extrusion based products

• CNC / VMC Machining
• Bending
• Welding
• Powder Coating
AREA: 14438 Sq ft

UNIT 2: Dedicated to Sheet Metal based products

• Special purpose machines
• Welding fixtures
• Bonding room
• Sheet metal fabrication
AREA: 11000 Sq ft

UNIT 3: Dedicated to Roof rails & Window assembly

• Metro coach window assembly & testing.
• Bending machine set up.
• Automotive roof rail line setup Located in Mysuru, Karnataka
150 kms from Bangalore
AREA: 12386 Sq ft
International Airport.
Certificates
ABOUT US
TEAM SIZE
90+ Full time employee, 100+ contractual employee
35 yrs. average age of workforce.
MAJOR SUPPLIERS
• Aluminium Extrusion: Bhoruka-YKK, Jindal, Hindalco, KMC, Global
• Aluminium Sheet Metal: Hindalco, Akash Aluminium
• Glass: Pan Chao China, FUSO
• Sheet metal machining: V Aim, Essen Engineering
• Liquid Painting: Carbide Care
• Anodizing: Bhoruka Extrusion, AMICO
ERP INTERNAL AUDITORS: Guru Jana & Company, Bengaluru
STATUTORY AUDITORS: Bhargava & Company
SAP ERP
BOARD MEMBERS: RC Jagadeesh (advisor), Utsav Agarwal, Prakash Chandra
MAJOR INVESTMENTS
2013-15: Extrusion Profile Machining Centres
2017-18: Welding & Bonding, Special Purpose Machines (SPMs)
2019: Railway window and Automotive manufacturing line setup
2020: In-house Powder Coating plant
2022: 5 Axis Bending Machine for 3D bending
2023 – 24 : Sheet Metal Setup (Upcoming)
FOCUS MARKET SEGMENTS

Aluminium has applications in many market segments. Bhoruka Fabcons focuses on 3 key market segments:
Metro & Railways, Automotive and EV Battery Enclosure.

RAILWAYS AUTOMOTIVE EV OTHER SEGMENT

MAJOR PRODUCTS

RAILWAYS & METRO : Sidewalls, Gangways, Windows, Driver Cabin Doors, Interior & Exterior parts.

AUTOMOTIVE: Roof-rails, Window frames, Interior & Exterior components.

EV: Aluminium Battery Enclosures, Personal mobility components.

Other Segment : Radiant Baffles (HVAC), Façade components ( Building & Construction), Deflection tubes ( Machinery).
 Revenue Data – Last 10 Years Revenue Growth (in Cr)
₹52.00

• BFPL in 10 years has served 103 customers.

₹40.32
• Revenue growth from 12Cr in FY16 to ~50Cr in FY23.
₹28.44
• Aluminum Processing has increased from 350 tons to 910 tons. ₹26.39 ₹27.30
₹24.88

₹10.67 ₹17.39
₹12.33

FY 15 FY 16 FY 17 FY 18 FY 19 FY 20 FY 21 FY 22 FY23

Revenue Data – FY 22-23

50.23 910 40
Total Revenue Metric Tons Active
(in Cr) Al Processed Customers
Infrastructure
 MANUFACTURING INFRASTRUCTURE
CNC MACHINING

CNC- COMET
VMC
MAKE: EMMEGI, ITALY
MAKE: HURCO
▪ Profile capacity (max) : 7000mm x 300mm
▪ Bed Length: 7000mm, working area up to 6m ▪ Working surface: 762mm x 406mm
▪ Table Load (max): 340 kg
▪ Automatic Tool Feed

CNC- CLASSIC MAGIC

AUTOMATICA
MAKE: EMMEGI, ITALY
MAKE: EMMEGI, ITALY
▪ Dual Head cutting machine, Angle 22.5deg to 90deg.
▪ Bed Length: 6000mm.. ▪ Cut length (min/max): 50mm ~6000mm
▪ Bed Length: 6000mm
▪ Automatic Feed
MANUFACTURING INFRASTRUCTURE
SPECIAL PROCESS - BENDING

BFPL has expertise in 3D Aluminium Bending. We house a 5 Axis Bending machine to cater to complex bending
requirements.

SPECIFICATION:

• Fully Automatic operational capability.

• Min radius of R60mm up to Max radius of R700mm can be

achieved.

• 6m maximum profile length with 65mm push diameter.

• 15 Bend programs (30 optional ) available.

• CW and CCW Bending options

• 3D parts simulation

• Multi-sequence bending capability for up to 5 parts with

common bend radius and diameter.

• 4 stacking option to load different radius tools.

• Material type: Aluminium, MS, SS

5 AXIS BENDING
MANUFACTURING INFRASTRUCTURE
SPECIAL PROCESS - WELDING

BFPL has expertise in Aluminium Welding and holds EN 15085-2 Class I Certificate. We specialize TIG Welding
process for Aluminium and Steel.
MANUFACTURING INFRASTRUCTURE
SPECIAL PROCESS – POWDER COATING

BFPL has an in-house powder coating facility – Chromium and Non Chromium base

SPECIFICATION:

• Fully Automatic Plant, 1ton/ shift capacity.

(varies with profile)

• All RAL, NCS & Custom colors possible

• In-house testing facility

• 3500 x 800 x 1100mm- Tank Size

• Hexavalent Chrome 6 Tank process

• Hexavalent Chrome with Henkel (Germany) PT

process.

• 3500 x 1100 x 150mm Booth Opening

• Wagner Make Guns

• 100 Pre-set gun programs for quick setting based on

component shape and size.

• 147m long close loop conveyor with 25 Kg max load.

MANUFACTURING INFRASTRUCTURE
SPECIAL PROCESS – GLUING & WINDOW ASSEMBLY

BFPL has a controlled gluing/bonding facility. Bonding

process is used to bond the glass to the window
assembly.
• The bonding process is widely used in the E-loco driver side window product
assembly. These product goes through a 7 days curing process post gluing
activity.

BFPL has an in-house assembly line set-up for railway

body side windows.
• Equipped with testing facility along with required fixtures.

• Window assembly uses Rubber gasket of HL3 compliance.

• DGU glass used with different performance requirement according to client

needs.

• Aluminium frame with anodizing and PC is primarily used.

WINDOW ASSEMBLY
MANUFACTURING INFRASTRUCTURE
OTHER EQUIPMENTS

UNIT 1
Machining Equipment: Finishing Equipment:

Bending Equipment:

Welding Equipment:
Punching Presses - 80 Ton

UNIT 2
Machining Equipment: Special Purpose Machine (SPM)

Welding Equipment:

UNIT 3

Automotive Roof Rail Production

MANUFACTURING FACILITY (sq ft)
Window testing & assembly
UNIT 1 UNIT 2 UNIT 3
PRODUCT
METRO & RAILWAY
PRODUCTS
METRO & RAILWAY

Bhoruka Fabcons has 10+ years of expertise in the metro & railway domain. We have manufactured various Aluminium
interior products catering to 1160+ cars at sites world wide.

Delhi, India
RS11 - 162 Cars

Montreal, Canada
AT REM- 184 Cars
Lucknow, India
Delhi, India 80 Cars
BT 16 -40 Cars

Mumbai, India Chennai, India

MML3 – 64 Cars 40 Cars

Queensland, Australia
300 Cars
Bangalore, India
ELOCO – 217 train set

Perth, Australia Sydney, Australia

24 Cars 270 Cars
PRODUCTS
METRO & RAILWAY

Bhoruka Fabcons manufactures various interior and exterior parts. Our products are majorly extrusion and sheet
metal based.

Roof Arch Profile and Rain Gutters Gangway Frames

Cover Brake
Threshold Plate
Module UNDER SEAT CABINET DOOR POD FRAME EMERGENCY LADDER
Saloon Window (Door Area)
Assembly
Driver Cabin
Window Assembly
Emergency Ladder

Draught Screen
Mounting Bracket
Door Pillar Frame
BLOWER DUCT DOOR PILLAR AIR DIFFUSER PANEL
Sidewall
Sidewall (saloon area)
(interior area)

Blower Duct
Floor Profiles

Under Seat Cabinet LOCOMOTIVE WINDOWS SIDE WALL GANGWAY COMPONENTS

PRODUCTS
METRO & RAILWAY- SIDE WALL

Side Walls of metros, made from various grades of sheet metal requires multiple process. Bhoruka Fabcons
manufactures complete Aluminium side walls catering to several metro projects.

Typical Sheet metal sizes:

Alloy:
Generally, alloy grade used in sheet metal is the 5XXX series namely
5052 and 5754.

Post operations:
• Laser cutting
• Gluing/bonding
• Welding
• Painting
SHEET METAL SIDE WALL
PRODUCTS
METRO & RAILWAY- WINDOW

Windows frames of car body side also use Aluminium. Bhoruka Fabcons has partnered with Lippert components
to manufacture, assemble and test windows in-house.

Window frames are extensively made of Aluminum extruded profiles.

Each profile differs based on the end application and from OEM to OEM.

There includes critical post operations on extruded profiles:

1. Cutting
2. Slotting
3. Milling
4. Bending
5. Welding
6. Anodizing
7. Assembly of frames with glass and other sub-components.
8. Testing

ALUMINIUM WINDOW & FRAMES

PRODUCTS
METRO & RAILWAY- GANGWAY

Gangways interconnect two cars. Bhoruka Fabcons manufactures gangway components and profiles for
customers.
The alloy used for gangways differ based on the end application and the
type. Gangway profiles with complicated 3D bending attracts 6061 and
6063 alloy with T4 condition.

Some common profiles used are:

The most critical machining activity is bending.

BFPL has a 3D bending capability with its 5 Axis bending machine.
Bending radius ranges from R70mm to R700mm.

GANGWAY PROFILES
PRODUCTS
METRO & RAILWAY- THIRD RAIL

Bhoruka Fabcons also caters to the ‘Power and Infrastructure’ vertical for third rail electrifications as world’s
transit authorities are switching to steel capped Aluminium conductor rails thereby creating demand for
Aluminium extrusions in Third rail applications.

A third rail/ conductor rail is a method of providing electric power to trains

through a conductor placed alongside tracks.

THIRD RAIL APPLICATION

PRODUCTS
METRO & RAILWAY- CUSTOM PRODUCTS

Bhoruka Fabcons has an in-house design & new product development team which caters to custom/R&D product
development according to end applications of the client.

Our Scope:

• From concept to validation, BFPL team has taken

the entire scope. Currently this product is validated
and is in active manufacturing.

• Complete Aluminium make with 18kg gross weight

of the ladder assembly.

• Extensive finite element analysis combined with

physical testing was conducted for validation of the
product.

• Less than 3min needed to operate and assemble

the unit by single person in.

• The main structure and platform is made of

Aluminium grade 6063 T6, the steps is made of
aluminum grade 6005 T6.

EMERGENCY EVACUATION LADDER

CUSTOMERS
METRO & RAILWAY

WHO ARE THEY ?

Our customers are majorly

Rolling stock OEMs and Tier-1
Manufacturers (Non-gov).
PRODUCT
AUTOMOTIVE
PRODUCT
AUTOMOTIVE- ROOF RAIL

Bhoruka Fabcons has expertise in manufacturing high quality

Aluminium roof rails with 3D bending requirements.

Dedicated manufacturing line

Dedicated line for continuous production. Our setup

includes a series of special purpose machines,
fixtures, buffing and linishing setups.

Special purpose bending machine

Aluminium roof rails requires 3D bending to gain

curvature of profile for fitment and aesthetics. SPMs
are custom designed according to each roof rail
design.

Highest quality checks

From raw material to finished product, each step of
the process goes through quality checks to ensure
highest quality end product.
PRODUCT
AUTOMOTIVE- ROOF RAIL

As a tier-2 supplier, we have supplied over 10+ Lakh Aluminium Roof Rails serving over 5+ Lakh passenger
vehicles.
• Roof Rails are offered with options of Mill finish, Powder coating and Anodizing.
• We can cater to 3D bending requirements for roof rail curvature using special purpose bending machines.
• Capacity to manufacture 50,000+ Roof Rails per month.

Our Roof Rails Serve

NISSAN KICKS MARUTI XL6 NISSAN TERRANO RENAULT DUSTER

HYUNDAI VENUE MARUTI BREZZA RENAULT KIGER RENAULT TRIBER

PRODUCT
AUTOMOTIVE- WINDOW FRAMES

Bhoruka Fabcons supplies various Aluminium window frames for the commercial vehicle segment. Our scope
extends to manufacturing other Aluminium interior and exterior parts.

Commercial Bus

• All bending and welding requirements of window

frames are in-house.

• Window assembly including powder coated/

anodized window frames and all child parts offered.
POWDER COATED FRAME INTERIOR PARTS

Commercial Vehicle

• Commercial vehicle side windows and back windows

offered with options for mill finish, powder coating
and anodizing.

• Design can be customized as per client

requirements.
MILL FINISHED FRAME ASSEMBLED FRAME
CUSTOMERS
AUTOMOTIVE

WHO ARE THEY ?

Our customers are majorly

Automotive OEMs and Tier-1
Manufacturers.
PRODUCT
EV
PRODUCT
EV- BATTERY ENCLOSURE

Bhoruka Fabcons has a NPD team for design and a

dedicated to manufacturing line Aluminium battery
enclosures.

DEDICATED LINE WITH 15,000

PRODUCTION CAPACITY OF EV BATTERY CASES PER MONTH

WHY CHOOSE US ?
▪ We have expertise in working with Aluminium extrusion and sheet metal
profiles.

▪ We assist our client right from the design stage and help customers adapt their
enclosure design according to manufacturing feasibilities.

▪ Our NPD team works alongside clients to manufacture enclosures which confirms
with the AIS 156 regulations.

▪ We assist in prototype development before scaled production.

PRODUCT
EV- MOBILITY & ACCESSORIES

Bhoruka Fabcons has also executed projects in the

e-mobility segment.

▪ E Rickshaw
Our NPD team reverse engineered a SS chassis to an all Aluminium
chassis for an E-rickshaw manufacturer.

▪ E-Scooters
We developed several Aluminium components and parts for a e-scooters.
Developed an entire prototype for one of our clients.

▪ Accessories
We developed and manufacture custom accessories for the mobility
segment. Products such as luggage carries are an example.

EV PROTOTYPES
CUSTOMERS
EV

WHO ARE THEY ?

Our customers are majorly

Startups & Companies in the
EV ecosystem.
PRODUCT
OTHER SEGMENTS
PRODUCT
RENEWABLES

Solar: Wind Turbine:

We have catered to mounting structure and sub-components of floating Heat Sinks, Motor components and other profiles is under scope.
solar that are aluminium make to aid light weighting.

FLOATING SOLAR COMPONENTS WINDMILL TURBINE COMPONENTS

PRODUCT
HEALTHCARE & HVAC

Medical Equipment: HVAC:

We design and manufacture new profiles and sub assembly components for R&D Radiant Cooling baffle is one of the component manufactured for Infosys to bolster
and commercialized medical devices for our clients. efficient cooling and reduce carbon foot print.

MEDICAL EQUIPMENT COMPONENTS RADIANT COOLING BAFFLES

PRODUCT
B&C AND TEXTILE

Building & Construction: Textile:

We have expertise in Architectural bending. We cater to large bending profiles for We manufacture machine components for machines in the textile industry.
architectural facades. Other products include window frames, door frames and
shutter systems.

ARCHITECTURAL BENDING
HEAT SINKS PARTS FOR
AUTO DOFFER MACHINE

SHUTTER SYSTEMS
CUSTOMERS
OTHER SEGMENTS

WHO ARE THEY ?

Our customers are majorly

OEMs and Tier-1 companies.
THANK YOU

THINK
ALUMINIUM…
Connect with us today!
THINK
BHORUKA FABCONS !
a ONE STOP SOLUTION for your Aluminium products.
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Telephone: 0821 – 2415290 / 2510351

Address:

Unit 1: #427E, Hebbal Industrial Area, Mysore - 570016

Unit 2: #427/1, Hebbal Industrial Area, Mysuru - 570016

Unit 3: No.360, Hebbal Industrial Area, Kasaba Hobli, Mysuru - 570018