Manufactured Capital
Building resilient, scalable and future-ready infrastructure
Our state-of-the-art infrastructure forms the backbone of our continued growth and success. Our manufacturing facilities, advanced machinery and robust infrastructure form the foundation of our operational excellence. We continue to strengthen these capabilities through technology upgrades and automation, enabling higher productivity, improved asset reliability and efficient operations to support sustainable growth.
Strategies Impacted
SDGs Impacted
Key Highlights, FY 2025-26
(9 domestic and 7 overseas)
certified plants*
*Consolidated
Material Topics Impacted
ISO 19443:2018 Certification
Nuclear-specific Quality Management System-Differentiator in Nuclear Business
NABL Accreditation
for Hydraulic Research Centre
Manufacturing Competence
Over the years, KBL has evolved from India’s leading pump manufacturer into a global leader in advanced fluid management solutions. Our world-class manufacturing capabilities reflect our steadfast commitment to the ‘Make in India’ and ‘Atmanirbhar Bharat’ initiatives.
We deliver high-performance solutions across diverse applications, including infrastructure, process industries, power, petrochemicals, marine & defence, nuclear applications and sustainable water management. Our focus on innovation and operational excellence, combined with initiatives such as Total Productive Maintenance, enhances efficiency, competitiveness, and sustainable growth.
Our Manufacturing Facilities
Kirloskarvadi Plant
Key Capabilities
- In-house foundry with NDT facilities
- NABL Accredited Lab
- Largest pump testing facility
- Pattern-less casting manufacturing
- Customised pump and pumping system/solution provider
Dewas Plant
Key Capabilities
- First Company in India to provide pumps with CED-coated components, which prevents from rust & enhances component life
- Producer of Energy-Efficient pumps set with IE4 & IE5 motors
- In-house High pressure moulding line (HPML Foundry)
Sanand Plant
Key Capabilities
- First submersible pump Company in India to provide CED-coated components equipped with best-in-class technology and prevent from rust and enhance component life
- Manufacturer of Energy-Efficient pumps of BIS & BEE approved models
Kaniyur Plant
Key Capabilities
- 100% women-operated manufacturing plant
- Manufacturing capability of Self priming, Mini-series & Monobloc pumps
Shirwal Plant
Key Capabilities
- SCADA based HYPN system test setup
- KirloSmart™ panel test setup
One of Asia’s Largest Hydraulic Research Centre
Kirloskarvadi houses one of Asia’s largest hydraulic research centres for testing pumps at duty conditions up to 5,000 kW and with up to 50,000 m³/hr discharge.
KBL has received NABL (National Accreditation Board for Testing and Calibration Laboratories) accreditation for its Hydraulic Research Centre Pump Testing Laboratory (HRC PTL). This accreditation is granted under the ISO/IEC 17025:2017, a globally recognised benchmark for testing and calibration of laboratory competence, uniquely positioning KBL as the only pump manufacturing company in the world to receive this recognition.
This reinforces KBL’s credibility in pump testing in accordance with stringent global quality frameworks. KBL is committed to the nation’s progress with reliable and high-quality fluid management solutions.
System Certifications
Product Certifications
- IS 9079 for Monobloc Pump Sets
- IS 14220 for Openwell Submersible Pump Sets
- IS 12225 for Centrifugal Jet Pumps
- IS 6595 for Horizontal Centrifugal Pumps
- BEE Star Rating
- FM/UL Certification for Valves
- IS 8034 Borewell Submersible Pumpset
- CE Marking for all Kirloskarvadi Pumps
- IS 210 quality and excellence in manufacturing Grey Iron Castings at Kirloskarvadi and Dewas
- Regenerative self-priming pumps (IS 8472)
- Motors for submersible pumps (IS 9283)
- IS 8418 Centrifugal Self priming
- CE Marking for Kaniyur product
Key Initiatives FY 2025-26
Our efforts are focused on restoring and sustaining basic machine conditions through TPM practices, ensuring improved equipment reliability and operational stability. Productivity enhancements are achieved through CNC programme revalidation and optimisation of cutting parameters. Workforce capability is also strengthened through multiskilling initiatives, enabling operators to handle multiple machine platforms effectively. Setup time reduction is driven through SMED implementation, while machining efficiency was further improved by optimising processes before CNC operations.
Operational efficiency is enhanced through improvements in painting processes, resulting in reduced cycle time. Machine shop productivity is also strengthened through reduction in speed losses, optimisation of setup practices and reconditioning of critical machines. Employee multiskilling was further expanded to support flexible operations across different machine types. TPM practices are implemented across critical equipment to improve reliability and performance. Additionally, value stream mapping initiatives have also helped streamline assembly flow and reduce work-in-progress lead time.
Machine reliability and availability are improved across operations through focused efforts to reduce breakdowns and strengthen preventive maintenance systems. Structured preventive and autonomous maintenance practices are implemented to sustain equipment health and ensure consistent performance. Energy efficiency was further supported through targeted energy conservation initiatives, contributing to overall operational sustainability.
Process and product improvements are undertaken to enhance reliability and quality across operations. Design and process modifications are implemented in pumps to prevent water ingress and reduce test bench rejections, along with enhancements to ensure effective retention of critical components. Statistical process control tools, including X and R charts, are introduced in the machine shop to monitor process trends and enable timely preventive actions. Additionally, advanced testing capabilities are strengthened through the implementation of a direction identification unit in motor testing panels, ensuring correct rotational direction in single-phase products and minimising quality defects.
Embedding Sustainable Manufacturing
KBL continues to strengthen its commitment to sustainable manufacturing practices. In recognition of these efforts, the Company has been awarded with CII GreenCo Certification for its facilities, reflecting excellence in resource efficiency, environmental management and green initiatives across operations.
KPML Motor Division
- KBL Dewas
- KPML Stamping Division
- KBL Kirloskarvadi
- KEPL
- KBL Sanand
- KBL Kaniyur
Enhancing Green Manufacturing:
- Implementation of energy-efficient technologies such as IGBT-based furnaces, static technology-based stabilisers, inverter-driven 5-star air conditioners, upgraded compressed air piping systems and VFDs for motors and machines
- Adoption of 13.5 MWp Renewable Energy through Open Access Solar Power Purchase Agreements (PPA)
- Strengthening emission control by installing RECDs on older DG sets
- Enhanced water management through rainwater harvesting and water recycling initiatives
- Sustainable maintenance practices, including predictive and preventive maintenance to reduce energy losses, along with systematic leak detection for air, oil and water systems
- KBL Sanand plant implemented reusable collapsible metal pallets for material transport from suppliers to reduce use of plastic, wood and corrugated paper
- Sustainability and energy efficiency initiatives were strengthened through multiple interventions across operations at the Dewas plant. LPG usage at the canteen was replaced with PNG, and LED lighting was installed in key areas to reduce energy consumption. HVLS fans were introduced to improve energy-efficient ventilation, while process optimisation measures in the CED plant, including equipment replacements and system rationalisation, contributed to cost savings and improved efficiency
- Advanced solutions such as the installation of an Active Hybrid Harmonic Filter (AHF) panel at the furnace and the deployment of VFDs for dust collector ID fans further enhanced energy savings and operational performance
Digital Manufacturing
At KBL, digital manufacturing is leveraged to enhance operational efficiency, improve process visibility and enable data-driven decision-making across shopfloor operations. The Company has been progressively integrating digital tools and systems to streamline production planning, monitor machine performance, and optimise resource utilisation.
Through the adoption of advanced analytics, real-time monitoring and automation, KBL is strengthening its manufacturing agility and responsiveness. These initiatives are enabling improved productivity, better quality control, and reduced downtime, while supporting KBL’s journey towards smarter and more connected manufacturing operations.
Installation of New Machines and Systems
KBL has enhanced its manufacturing capabilities through continuous modernisation and process improvements. Automation through PLC and SCADA-based systems was introduced for performance testing, improving accuracy, reliability and data-driven decision-making. Infrastructure upgrades, including utility line installations, compliant power backup systems and advanced painting facilities, strengthened operational resilience and ensured adherence to regulatory standards. Advanced multi-axis machining systems have been introduced to improve precision and efficiency in critical component manufacturing. Material handling infrastructure has also been strengthened to support safe and efficient movement of heavy components.
Process improvements, such as mechanisation of manual operations, upgradation of testing equipment, and adoption of specialised tools in assembly lines, contributed to higher productivity, improved quality and reduced manual effort. Further, investments in modern infrastructure, including high-density storage systems, enabled better space utilisation and streamlined material handling. The installation of advanced safety systems enhanced overall plant safety and risk mitigation. Collectively, these initiatives supported cost optimisation, improved operational efficiency, enhanced product quality, and strengthened workplace safety across facilities.
Karad Projects and Motors Limited (KPML)
Key Highlights
- KPML Stamping Division received the “Zero PPM Award” from an EV automotive customer for two consecutive years, reflecting its consistent focus on quality and defect-free delivery
- KPML Stamping Division is honoured with the “Winning Together Award” for successfully developing a Single Impeller Pump for healthcare applications, showcasing its commitment to innovation and customer collaboration
- KPML Component expanded manufacturing capabilities for drive unit assemblies and established in-house production capacity for DBxe shafts, enhancing overall operational efficiency and strengthening self-reliance
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- KPML Motor division enhanced submersible turbine pump manufacturing capacity by optimising existing infrastructure without the need for new construction, enhanced renewable energy adoption through the installation of additional solar panels
- KPML Motor division expanded the product portfolio to cater to healthcare applications and strengthened project execution capabilities through the manufacturing of specialised stators for key initiatives
- KPML Motor division further improved quality and productivity through the installation of new machinery across critical manufacturing lines
- KPML Motor division successfully commercialised submersible turbine pumps as an import-substitute product developed domestically for the first time, while also establishing a robust supply chain to support their production and delivery
- KPML Component division achieved the highest-ever monthly dispatch of kits, including a record dispatch of DBxe kits, demonstrating strong operational performance and delivery capability. Additionally, enhanced productivity in Montanari shaft keyway manufacturing through the implementation of a hydraulic multi-station clamping fixture
- Karad Projects and Motors Limited - Foundry Division (formerly, The Kolhapur Steel Limited), is a state-of-the-art, modern steel foundry established in Kolhapur, Maharashtra, India, in 1965. The foundry produces high-integrity steel castings to various national/international standards and specifications. The product range covers Carbon steel, Alloy Steel, Duplex steel, Super duplex steel, Stainless steel and Nickel-based alloys for various industries like Oil, Gas, Power generation, Mining, Engineering, Sugar, etc.
- KPML Foundry division achieved cost savings in pattern manufacturing and machining through effective outsourcing strategies, while maintaining 100% quality standards. Successfully developed and supplied trial export orders to international customers, demonstrating strong capability in meeting global requirements
System Certifications:
Kirloskar Corrocoat Private Limited (KCPL)
Manufacturing competencies
- Process expertise – Batch manufacturing
- Technology know-how – Anti-corrosion glass flake coating material manufacturing for various equipment, like pumps, tanks, vessels, structures and customer-provided equipment
- Product specialisation – Anti-corrosion glass flake coating
- Regulatory compliance – ISO certifications
- Qualified manpower
Key capabilities
- Total installed capacity – 230.1 KL / 276.12 MT
- Various mixers like electric, pneumatic and vacuum of different capacities
- Fume extraction & scrubbing system
- Cold storage for storing the RM & FG
- Lab testing equipment for checking liquid properties of coating material
- Air handling unit (AHU) for controlled storage manufacturing & testing
Kirloskar Ebara Pumps Limited (KEPL)
Key Achievements
KEPL achieved several key manufacturing milestones during the year, reflecting improvements in efficiency, productivity and reliability. A machining process for steam turbine nozzle rings was successfully established on the newly installed multi-axis SHW machine, resulting in a significant 40% reduction in cycle time. Additionally, machining of the 80X50 KB3S pump was successfully developed on a Double Column VMC using CAM and a special angle head, enhancing precision and process capability.
The SCADA system at the turbine division was successfully tested, strengthening monitoring and control systems. Operational efficiency was further improved with the doubling of output in the impeller cell, while equipment reliability saw a substantial enhancement, with Mean Time Between Failures (MTBF) improving from 74 days to 281 days.
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The integration of a turbine test bed equipped with a SCADA system further enhances testing capabilities, ensuring reliability and quality in turbine performance evaluation. The boiler has been upgraded to increase superheated steam temperature by 40°C, improving process efficiency. PU flooring has also been implemented in the light pump machining shop to enhance workplace conditions, safety, and operational effectiveness.
Awards & Accolades
- Gold Award (highest category) in the CII Business Excellence Maturity Assessment for Kirloskarvadi, KEPL and KPML Plants
- TPM Excellence Award from the Japan Institute of Plant Maintenance (JIPM)
- 18th State Energy Conservation Award under the “Automobile & Engineering” category, awarded by the Maharashtra Energy Development Agency (MEDA)
- Platinum award in the Restorative category and the Gold award in the Renovative category in the Kaizen competition presented at the 52nd CII National Kaizen Competition
- 1st Prize for Excellence in Safety Practices at QCFI – Safety Convention
- Gold trophy for TQM case study along with the Quality Culture initiatives at QCFI – Kaizen, TPM/TQM, MUDA Convention (Vadodara Chapter 2025)
- Two Gold Awards at the QCFI Coimbatore Chapter
- Meritorious Award from the Indian Society for Quality (ISQ), underscoring its strong performance and excellence in quality initiatives
- Manufacturer of the Year Award by Pump Industry Awards for the Fourth Consecutive Year.
- KPML Stamping Division is awarded with “Winning Together Award” for developing single impeller Pump for Healthcare Application
- KEPL is awarded with CII GreenCo silver rating
