What we do

Aluminium surface treatment consulting — from concept to commissioned plant

Every engagement is handled directly by Balasubramanian Iyer. 45+ years of hands-on experience, 10+ plants set up across India.

Anodizing plant setup aluminium
01
Plant setup

Anodizing plant setup

Complete anodizing plant commissioning from the ground up — tank sizing and layout, rectifier selection, sulphuric acid anodizing process setup, and operator training. We have done this 10+ times across India.

Line layout & design Tank sizing & material selection Rectifier specification Chemical process setup Operator training Commissioning support
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Hard anodizing process aluminium
02
Process consulting

Hard anodizing

Hard anodizing demands precise process control — bath chemistry, temperature, current density, and agitation all interact. We bring hard anodizing expertise that textbook consultants simply cannot offer — because we run an active hard anodizing plant ourselves.

Bath chemistry setup Temperature & cooling design Current density optimisation Coating thickness control Quality testing protocols Troubleshooting support
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Powder coating line aluminium profiles
03
Plant setup

Powder coating lines

Powder coating line design for aluminium extrusions — pre-treatment systems, spray booths, curing ovens, and conveyor layout. A line is only as good as its pre-treatment, and we design both together.

Pre-treatment line design Spray booth specification Oven sizing & airflow Conveyor system layout Recovery system design Commissioning support
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Production optimisation aluminium plant
04
Optimisation

Production optimisation

If your anodizing plant has high rejection rates, inconsistent quality, or rising chemical costs — a structured audit usually finds the root cause fast. We deliver a clear, prioritised improvement plan, not a generic report.

Full line audit Rejection root cause analysis Chemical cost review Throughput improvement Process parameter review Written improvement report
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Greenfield aluminium plant project India
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Project management

Greenfield plant projects

Setting up a greenfield anodizing plant in India involves dozens of interdependent decisions. We manage the full project — site evaluation, equipment selection, vendor coordination, and commissioning — so nothing falls through the cracks.

Site evaluation Utility planning (power, water) Equipment vendor selection Civil works coordination Installation supervision Trial production support
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On-site consulting aluminium surface treatment
06
On-site

On-site consulting

Some problems need eyes on the floor. On-site anodizing process training, troubleshooting, and bath analysis — we visit your facility, diagnose the issue directly, and fix it with your team.

Process troubleshooting Quality defect diagnosis Operator training Bath analysis Documentation review Follow-up support
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Structural anodizing architectural aluminium facade
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Architectural finishing

Structural anodizing

Architectural-grade anodizing for facades, curtain walls, fenestration, and cladding. Class 1 (25 µm) and Class 2 (10 µm) coatings with colour consistency across batches that arrive on site months apart — the problem that defines structural work.

Class 1 & Class 2 setup Colour consistency protocols Sealing quality control Large-part rack design IS 1868 / BS 3987 / AAMA 611 Batch traceability
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Not sure which service you need?

Tell us where you are in your project — we'll point you in the right direction. No obligation, no sales pitch.

Get in touch Call +91 77984 83087
Common questions

Frequently asked questions

What services does Saravana Consultancy offer?

Seven core services: anodizing plant setup, hard anodizing plant setup, powder coating line design, structural anodizing consulting, production optimisation audits, greenfield plant projects, and on-site process consulting.

What is the typical engagement length?

Greenfield plant projects run 8–14 months. Production audits run 5–15 days. On-site consulting is typically 1–4 weeks per visit. Initial scoping calls are usually 30–60 minutes.

Do you handle equipment procurement or only consulting?

Both — full turnkey procurement for greenfield projects (tanks, rectifiers, chillers, ventilation), or consulting-only mode where you procure based on our specifications.

What is the difference between standard and hard anodizing setup?

Standard sulphuric anodizing (Type II) operates at 18–20°C with simpler chillers and 1.0–1.5 A/dm² current density. Hard anodizing (Type III) requires 0–5°C bath temperature, larger chiller capacity, and 2.5–3.5 A/dm² current density.

Can you help reduce rejection rates on an existing plant?

Yes — production optimisation audits typically reduce rejections by 40–60% by addressing chemistry drift, current distribution, rinse contamination, fixturing, and operator training gaps.