From greenfield anodizing plant setup to production optimisation — 45+ years of hands-on expertise in sulphuric anodizing, hard anodizing, and powder coating line design. The only consultant in India who runs an active anodizing plant — Spectra Metal Shield.
Specialised consulting for anodizing, hard anodizing, and powder coating facilities across India.
Complete design and commissioning of sulphuric acid anodizing lines — layout, tank sizing, rectifiers, and operator training.
Learn more →Technical consulting on hard anodizing processes — bath chemistry, temperature control, current density, and quality benchmarks.
Learn more →Architectural-grade anodizing for facades, curtain walls, and fenestration — Class 1/Class 2 coatings, colour consistency across batches, IS 1868 / BS 3987 compliance.
Learn more →Design of pre-treatment stages, spray booths, curing ovens, and conveyor systems for aluminium profiles and extrusions.
Learn more →Audit of existing lines for throughput gaps, rejection causes, and chemical cost reduction opportunities.
Learn more →End-to-end project management for new facilities — site evaluation, equipment selection, and vendor coordination.
Learn more →Hands-on floor visits for process troubleshooting, quality issue resolution, and team upskilling.
Learn more →
45+ years working directly in aluminium surface treatment — in actual plants, not boardrooms.
A proven track record taking projects from concept to running production, across varied scales.
Spectra Metal Shield keeps our knowledge current — every recommendation grounded in live operations.
As a proprietorship, you work directly with Balasubramanian Iyer — no junior consultants or middlemen.
Understand your requirements, process scope, production targets, and site constraints in a direct conversation.
On-site visit to evaluate space, utilities, water, power, and workflow — the foundation of a good plant layout.
Layout finalisation, equipment selection, vendor coordination, installation supervision, and commissioning.
Process tuning, quality troubleshooting, and operator training even after the plant is running.
Calculators, sourcing guides, and technical references — built from 45 years of hands-on plant experience.
Since 1983, Balasubramanian Iyer has worked exclusively in aluminium surface treatment — first in architectural and decorative anodizing, delivering gloss, matt, and satin finishes for architects, fabricators, and curtain wall contractors, then expanding into hard anodizing for defence applications and industrial clients including Hawkins and TTK Prestige.
He has personally overseen plant setups and production troubleshooting across India, and continues to operate Spectra Metal Shield as an active hard anodizing unit. He also supplies specialist anodizing chemicals — colouring salts, stabilizers, sealing salts, and etching finish chemicals — directly to Indian plants. When you engage Saravana Consultancy, you deal directly with him.
Our own hard anodizing plant — proof that our consulting is rooted in active production. Every process recommendation we make has been validated on our own equipment, with our own teams, on real jobs. We don't just advise. We operate.
Hard anodizing unitSelected projects — 1983 to 2016.
Typical greenfield anodizing plants take 8–14 months from site evaluation to first commercial run. Hard anodizing units add 1–2 months for chiller and bath cooling commissioning. Saravana Consultancy has commissioned 10+ plants on this timeline across India.
Hard anodizing plant capex ranges ₹2–6 crore for 50–200 m²/day capacity, depending on bath count, rectifier sizing, and chiller requirements. The dominant cost variables are current density target (typically 2.5–3.5 A/dm²) and required coating thickness (25–75 µm).
Both. Production optimisation audits run 5–15 days on-site and produce a prioritised action plan. We have reduced rejection rates by 40–60% on multiple plant audits across India.
MIL-A-8625 Type III for wear-resistant hard coats (25–75 µm), MIL-A-8625 Type II for sulphuric/decorative work (5–25 µm), and BS 3987 / AAMA 611 for structural architectural anodizing.
Yes — we conduct site visits across India for greenfield projects and audits. Same-week availability for urgent troubleshooting issues; standard visits scheduled within 2–3 weeks.
Available for projects across India. Site visits can be arranged at your facility.
Hard anodizing unit