Thaai Casting Limited is establishing a new manufacturing facility in the Chennai industrial region dedicated to gear shaping and high-precision machining. The project involves an investment of INR 1 billion, with commercial operations scheduled to begin in January 2026. Machinery for the facility has already been procured from Austria.
The 3-acre site in Sriperumbudur will produce gear parts for wind turbines, with processes such as gas nitriding applied to enhance durability of windmill gearboxes. Initial revenues from wind components are expected in late FY26, with annual contributions projected at INR 400–450 million from FY27. Thaai Casting has secured long-term, exclusive supply agreements for wind segment components with Winergy, a German supplier of wind drivetrain solutions, components, and services.
Supporting facilities are also being expanded. A 1-acre nitriding site, set to initially operate at around 30 percent utilisation, is being built to house six furnaces by early 2026. The gas nitriding process is supported by a SCADA system for real-time monitoring, integrated alarm systems, digital flowmeters, and an ammonia cracker to ensure consistent quality. The existing site includes a furnace capable of handling up to 13 tons in a single batch. The company’s third furnace was inaugurated at its subsidiary, Thaai Induction and Nitriding, earlier in the year in the presence of Tomas Van den Abeele, Head of Global Procurement, Flender, along with the Flender team.
Alongside wind-related operations, Thaai Casting continues to invest in broader machining capacity. The company is also procuring Starrag Dörries VT 28 single-column vertical turning lathe for machining planetary carriers, and has completed installation of heavy equipment including a new TOYO 1000T die casting machine and additional gear shaping units, which are undergoing testing and validation.
As of 30 September 2024, Thaai Casting reported an order book of INR 3.87 billion with an execution timeline ranging from 60 to 80 months. Recent additions include an order of INR 1.27 billion for supply of automotive and non-automotive products, and another order valued at INR 124.3 million from building and construction sector partners. The two recent orders bring the total order book to INR 5.26 billion
Thaai Casting was established in 2011 and specialises in high-pressure die casting and precision machining for both ferrous and non-ferrous materials. It supplies components such as engine mounting brackets, transmission mounts, and steering parts to automotive manufacturers. The company also offers advanced surface treatments including induction hardening and gas nitriding. Its end customers include Hyundai, Kia, Maruti Suzuki, PSA Group, Ashok Leyland, Tata Motors, Mahindra, Toyota, GEV Wind Power, Adani Wind, and JCB.
The company’s existing machining capabilities include CNC lathes and vertical machining centres with 4th-axis capabilities for non-ferrous parts, as well as vertical turning lathes, horizontal machining centres with pallet changeover, and cylindrical grinding for ferrous components. Induction hardening is applied across automotive, aerospace, oil and gas, railway, and medical applications.
The company also confirmed that machinery being installed for the wind vertical could support aerospace production, and that the company has registered as a defence parts vendor. Prototype work for defence customers is underway, with further progress expected in the coming year.
Thaai Casting Limited is headquartered in Sriperumbudur, Tamil Nadu, and operates across automotive, wind energy, defence, and advanced engineering sectors.