According to insights shared by Mr. Manish Jain, COO, ITL Industries Ltd., the metal sawing industry has witnessed a remarkable transformation over the last four decades. What once depended on manual chisels, hammers, and slow cutting methods has evolved into highly advanced NC-controlled circular sawing technologies capable of delivering superior speed, precision, and productivity. With the rapid expansion of the automobile and engineering sectors, modern manufacturers now demand higher efficiency, close tolerances, improved material yield, and lower operational costs. Today’s sawing technologies are playing a vital role in supporting automation and precision manufacturing across India’s industrial landscape.
From Manual Cutting To Bandsaw Technology
Nearly 40 years ago, large billets and blooms were cut manually using chisels and hammers, while smaller bars were processed through shearing machines or power hacksaws.
Though bandsaw machines were available during that period, their performance remained limited due to the use of carbon steel blades, which suffered from low cutting rates and repeated blade joint failures.
A major breakthrough came with the introduction of Bi-Metal HSS Bandsaw Blades. Their strong back material allowed higher blade tension and better beam strength, resulting in faster cutting speeds, improved dimensional accuracy, and enhanced tool life. Cutting rates for medium alloy steel increased significantly to nearly 40–50 sq. cm per minute compared to only 10–15 sq. cm using conventional methods.
CNC Revolution Increased Demand For Efficient Sawing
As CNC machining centers became the backbone of automobile component manufacturing, the demand for efficient raw material cutting solutions increased rapidly. To keep CNC production lines running at full capacity, manufacturers required multiple bandsaw machines for continuous feeding of cut components.
This increased dependence on bandsaws created several challenges, including high floor space consumption, manpower requirements, maintenance costs, and operational inefficiencies. For nearly a decade, many industries relied heavily on outsourced cutting vendors to meet growing production demands.
Rise Of NC Circular Sawing Machines
The next major transformation emerged from Japan with the development of Throw-Away Cermet Thin Kerf TCT Circular Saw Blades. Combined with advanced NC Circular Sawing Machines developed by companies like NISHIMAX, TSUNE, and AMADA, these technologies offered extremely fast and precise cutting performance.
However, the imported machines were expensive. Between 2000 and 2006, Taiwanese manufacturers introduced comparatively affordable alternatives, followed by Indian manufacturers who developed cost-effective machines specifically suited for Indian raw materials and operating conditions.
Among the pioneers, ITL Industries Ltd. played a significant role in indigenizing NC Circular Sawing technology with several application-oriented modifications.
Reducing Tool Cost Changed Industry Economics
Initially, industries hesitated to invest in NC Circular Sawing Machines due to higher tooling costs compared to traditional bandsaws. Continuous research and development by Indian machine manufacturers eventually helped reduce tool costs from nearly 6 NP/sq. cm to about 3 NP/sq. cm by 2008.
This development completely changed the economics of metal cutting. One NC Circular Sawing Machine could replace nearly five bandsaw machines, drastically reducing floor space, manpower dependency, maintenance issues, and rejection rates. Improved cut quality and close length tolerances also enhanced material yield by minimizing cutting allowances.
Advanced Solutions For Precision Manufacturing
Today, circular sawing technology is widely used for cutting bars up to 200 mm diameter. Indian manufacturers now offer machines with capacities ranging from 50 mm to 200 mm to suit diverse industrial requirements.
To further optimize productivity, specialized CFC/CnC-Dr Machines capable of Cutting, Facing, Chamfering, and Central Drilling in a single setup have also been developed. These machines are highly beneficial for producing pipe bushes, shafts, and other precision engineering components.
Focus On Sustainability & Reconditioning
Continuous efforts are also being made to reduce tooling costs and support sustainability initiatives. In collaboration with Japanese technology partners, TCT saw blade reconditioning centers have been established to enable multiple re-sharpening cycles of saw blades.
After reconditioning, tooling costs can reduce by nearly 50%, while simultaneously supporting foreign exchange savings and carbon credit objectives.
Future Of Metal Sawing In India
Modern NC Circular Sawing Machines are proving highly effective for processing stainless steel, bearing steel, super alloys, and other exotic materials widely used in automotive, aerospace, and engineering industries.
With increasing focus on automation, productivity, and precision manufacturing, advanced sawing technologies are expected to play an even bigger role in shaping the future of India’s engineering and metalworking sectors.