Heavy Industrial Plant Infrastructure
Built over four decades of engineering legacy, our specialized manufacturing plant in Machhe Industrial Estate, Belagavi, operates complete end-to-end production lines engineered for safety and scale.
Operational throughput supporting bulk B2B batch orders for DA and RG cylinders.
Raw material security utilizing IS 6240 and IS 15914 micro-alloyed steel.
Volumetric expansion testing up to 250 kgf/cm² under direct BIS inspection.
High-volume supply track record delivered to IOCL, BPCL, and HPCL.
6-Stage In-House Production Process
BTPS enforces complete in-house manufacturing control from raw steel coil inspection to final dispatch, eliminating third-party quality risks across our 1,000,000 annual cylinder output.
JSW Prime Steel Sourcing
Exclusive procurement of deep-drawing coil steel from JSW Steel compliant with IS 6240 and IS 15914 specifications.
Shearing & Deep Drawing
Automated hydraulic blanking and deep-drawing presses ensuring uniform wall thickness (4.0mm to 5.6mm).
Automatic SAW / MIG Welding
Circumferential seams welded using high-precision Submerged Arc Welding (SAW) for zero-porosity structural joints.
Normalizing & Stress Relieving
Full thermal normalizing and stress relieving in computerized batch furnaces to restore microstructural ductility.
Porous Mass Integration (DA)
In-house formulation and baking of proprietary Monolithic Calcium Silicate porous mass (90–92% porosity, ≥22 kgf/cm² crushing strength).
100% Hydrostatic & Leakage Testing
Mandatory 100% volumetric expansion testing (up to 250 kgf/cm²) and pneumatic bubble leak testing before final zinc metallizing and dispatch.
Monolithic Calcium Silicate Porous Mass Baking Infrastructure
Dissolved Acetylene (DA) cylinder safety depends entirely on internal porous mass stability. BTPS operates dedicated in-house mass filling and curing ovens to produce a monolithic calcium silicate porous structure.
The baked monolithic mass achieves 90%–92% porosity and a minimum compressive strength of 22 kgf/cm². Saturated with pure Acetone (CH3COCH3) solvent and built with a certified 11% safety space, our DA vessels eliminate free acetylene gas pockets.
DA Safety Accessories Integration
- IS 3224 Valves: Precision forged brass valves with standardized outlet threads.
- 100°C Fusible Plugs: Dual fusible safety plugs fitted on welded shell heads melting at 100°C (+4°C/-2°C).
- Zinc Metallizing: Grit-blasted surface treatment followed by thermal zinc metallizing and heavy industrial enamel painting.
- PESO Validation: Shell design and mass integration approved under Government of India safety laws.
JSW Prime Steel Metallurgy & Heat Treatment
IS 6240 Standard Deep-Drawing Steel
Utilized for IS 7312 Dissolved Acetylene cylinders and standard IS 3196 Part 2 Refrigerant Gas cylinders. Procured directly from JSW Steel with certified carbon and manganese chemistries to guarantee uniform wall draw during hydraulic cup forming.
Used in 5.6L to 68L Standard RG & DA SeriesIS 15914 High-Test Micro-Alloyed Steel
Engineered exclusively for High Test (HT) Refrigerant Gas cylinders. Micro-alloyed steel additions allow thin-wall light-weight vessel designs while safely sustaining 70 kgf/cm² hydrostatic test pressures for R-410a, R-32, and R-290 gases.
Powers 70 kgf/cm² HT Series CylindersTesting Laboratory & Volumetric Expansion Rigs
Our Belagavi plant operates dedicated destructive and non-destructive testing rigs to ensure zero-defect pressure containment prior to BIS officer lot clearance.
Volumetric Expansion Hydro-Test Rigs
Automated water-jacket testing rigs subject shells to proof pressures up to 250 kgf/cm² to measure permanent volumetric expansion, ensuring zero plastic strain.
Pneumatic Leakage Immersion Tanks
100% of finished cylinders fitted with valves undergo pneumatic bubble leakage testing at 12 to 40 kgf/cm² under complete water immersion.
Radiographic X-Ray & Burst Testing
Destructive hydraulic burst tests and 100% non-destructive radiographic weld inspection verify structural seam soundness and ductility.
Infrastructure & Process Engineering Guidelines
Factual guidelines regarding plant location, automated welding technology, and raw material steel procurement standards.
Where is the primary BTPS manufacturing plant located?
Where is the primary BTPS manufacturing plant located?
The primary BTPS manufacturing facility is located at Plot Nos. 138-B, 140 to 143, Machhe Industrial Estate, Jamboti Road, Machhe, Belagavi 590014, Karnataka, India. The plant houses our deep drawing presses, automated SAW welding lines, stress relieving furnaces, and porous mass baking infrastructure with an annual capacity of 1,000,000 cylinders.
How does BTPS ensure weld seam structural integrity during high-speed production?
How does BTPS ensure weld seam structural integrity during high-speed production?
Circumferential seams are welded using automated Submerged Arc Welding (SAW) systems with strict voltage and speed controls. Every batch undergoes non-destructive radiographic X-ray inspection, full thermal normalizing stress relief, and 100% hydrostatic expansion pressure testing before receiving final clearance.
What raw material steel standards govern BTPS cylinder production?
What raw material steel standards govern BTPS cylinder production?
BTPS procures prime steel coils exclusively from JSW Steel. Dissolved Acetylene (IS 7312) and Standard Refrigerant Gas cylinders use IS 6240 steel, while High Test (HT) Refrigerant cylinders utilize micro-alloyed IS 15914 steel to safely withstand 70 kgf/cm² hydrostatic test pressures.
What certifications and quality approvals govern the Belagavi manufacturing plant?
What certifications and quality approvals govern the Belagavi manufacturing plant?
The Belagavi manufacturing facility operates under an ISO 9001:2015 Quality Management System certified by TÜV SÜD (Certificate No. 99 100 23469). Production lines carry official Bureau of Indian Standards (BIS) product certification marks for IS 7312 and IS 3196 (Part 2), alongside high-pressure approvals from PESO / CCOE, Government of India.