Forged Grinding Ball Mini-Plant

Turnkey mini-plant for producing forged and rolled balls for mills

• Modern Technologies Modern Technologies is an engineering company specializing in developing its own low-cost technology for producing forged grinding balls 80mm and up in diameter. We do not buy expensive billets - we make them ourselves.

How the process works

The billet is heated in an induction unit, then goes to forging, and after forming is sent for water cooling.

Full production cycle: Scrap metal processing (cost: $200/t) Adding ferroalloys to achieve the required metal properties Melting in an induction furnace Billet forming on a line with molds Precise billet cutting Induction heating before forging Processing on forging presses Controlled cooling Filtration system for cleaning process media Quality control laboratory

• BILLET PRODUCTION IN THE MOLD Producing forged balls 80mm and up in diameter: an innovative, cost-effective technology. Our company offers an advanced technology for producing forged balls 80mm and up in diameter, combining high efficiency with significant cost savings. Key advantages of the technology: 1. A unique billet production method - a low-cost way of making billets for subsequent forging has been developed. 2. An automated process - billets are cut, heated through an inductor, and the entire system can be fully robotized. 3. Substantial savings - with forged balls selling on the market for $1,000 to $2,000, our technology lets us produce them for no more than $600 apiece (including materials and all labor).

Production capacity:

• Production volume: 200⁠-⁠300 to 1,000 tonnes a month at a single plant.
• Turnkey supply: the complete equipment package (including the filtration system, inductors, and more), with installation, delivery, and start-up, is priced at around $1 million.
• Fast payback: the plant’s payback period is under 1 year. This solution is ideal for companies looking to optimize the cost of producing forged balls without losing quality, with room to scale.

Billet production in the mold

The entire production line can be: Fully automated, ensuring stable parameters and high efficiency.

Cost and market analysis for forged ball production: Production cost:

• Cost of scrap metal: $200 per tonne.
• Including ferroalloy additions: $300 per tonne. Even on the most conservative estimates, the total cost of finished forged balls comes to about $500 per tonne. Market situation:
• The average market price for forged balls 80mm and up in diameter ranges from $900 to $1,100 per tonne.
• We offer a price of $800 per tonne, giving a significant advantage over average market values. While keeping product quality competitive, our pricing lets us stay well below the market level while maintaining stable production profitability.

Production capacity:

• Base output: 200⁠-⁠300 tonnes of product a month.
• Expanded option: up to 1,000 tonnes a month Power consumption:
• Installed equipment capacity: ≈800⁠-⁠1,000 kW.
• Average consumption in operation: ≈600 kW.
• Monthly power consumption at 300 tonnes of output: ≈300,000 kWh.

Staff (for producing 300 tonnes/month):

• Operators: 2 people per shift.
• Foreman: 1.
• Process engineer: 1.
• Electromechanic: 1.
• Lab technician: 1.
• Warehouse keeper: 1.
• Accountant (outsourced): 1. Total for two-shift operation: 8⁠-⁠10 employees.

Economic indicators (at 300 tonnes of output a month):

• Selling price: $800 per tonne.
• Monthly turnover: 300 × 800 = $240,000.
• Production cost: $500 per tonne.
• Production costs: 300 × 500 = $150,000.
• Gross profit: $90,000 a month.
• Net profit after tax: $70,000⁠-⁠80,000. Project payback period:
• Turnkey plant cost: $1,000,000.
• Average monthly net profit: ≈$75,000.
• Estimated payback period: 12⁠-⁠14 months.
• At a selling price of $900 per tonne: payback shortens to under 1 year.

Expansion prospects (up to 1,000 tonnes a month):

• Monthly turnover: 1,000 × 800 = $800,000.
• Production costs: $500,000.
• Gross profit: $300,000 a month.
• Payback period for the large complex: under 10 months.

Our advantages:

• Full cycle from scrap metal to the finished ball
• Low production cost
• Minimal staffing
• High margin
• Fast payback
• Turnkey for $1,000,000

Technical and economic indicators:

• Output: 300⁠-⁠500 tonnes of finished product a month.
• Investment required: $1,000,000.

Main process stages: Billet preparation: Cutting metal bar stock into sized billets using a saw. Heating: Fast, efficient induction heating of the billets to forging temperature. Forming: Forging the billets to give them the required shape and mechanical properties. Heat treatment: Quenching and tempering (heat treatment) with subsequent controlled cooling to achieve the specified hardness and strength. Quality control: Checking the finished product’s parameters against the standards.

Finished billets:

Finished billets