The interaction with Mr. Yatinder Suri provides insights into the stainless steel industry, including raw material sourcing, manufacturing processes, sustainability, and emerging trends. It highlights innovations and strategies for growth while offering valuable advice for new entrants.

Can you share a brief overview of your experience in the stainless steel manufacturing industry? What initially drew you to this field?

My journey in stainless steel began at the Ferro Alloys Steel Division plant in Nagpur, which featured state-of-the-art alloy and stainless steel-making equipment, supported by a top-notch team of technocrats and a well-equipped chemical and testing laboratory. The plant aimed to serve the engineering and automotive industries with high-quality, clean forging-quality steel and substitute imports of high-end alloy steels for the forging sector. Additionally, it focused on developing a robust export market for stainless steel long products in Europe and the USA.

While at Tata Motors, recruited from campus at IIT Kharagpur, the Director and GM often said that those leaving Tata Motors would end up working with companies serving Tata Motors. This prophecy came true for me, as I joined an industry supplying quality alloy steels to forgers whose products were used in Tata trucks—symbols of trust and performance. The modern manufacturing facilities and the uniqueness of special steels attracted me to this field.

How do you ensure the quality and sustainability of raw materials used to manufacture stainless steel?

The guiding principle is simple: purchase raw materials from reputable suppliers. Low-cost, unreliable sources are strictly avoided. Early on, stainless steel scrap was unavailable domestically, so we relied on imported shredded and heavy scrap combined with ferroalloys in the Electric Arc Furnace (EAF).

For optimal operations, refractories for EAF, continuous casting tundish, Ladle Refining Furnace (LRF), Argon Oxygen Decarburization (AOD), and heat treatment furnaces must come from trusted manufacturers. Ferroalloys, graphite electrodes, and liquid argon should also be sourced from reputable suppliers. A captive oxygen and nitrogen plant ensures reliability, while strong cash flow management maintains timely payments and long-term supplier relationships, which are critical for seamless plant operations.

What challenges do companies face in sourcing raw materials?

The major raw materials—stainless steel scrap, ferro chrome, ferro silicon, copper, ferro manganese, and nickel—present distinct challenges. While most are available domestically, stainless steel scrap is often imported due to limited domestic availability. India’s recycling industry is in its infancy but gaining support from the government, with new centers emerging for organized scrap collection and processing.

Initiatives like JSL’s buyback of sorted stainless steel scrap from customers are innovative steps. Reliable production planning and cash flow management are critical to ensuring uninterrupted operations and maintaining strong relationships with suppliers.

What are the key steps involved in the stainless steel manufacturing process?

The process includes:

• Receiving customer orders.
• Production planning.
• Raw material procurement and inspection.
• Melting scrap in EAF.
• Refining in AOD to create the required stainless steel grade.
• Final refining in LRF or VOD.
• Continuous casting.
• Billet, bloom, or slab inspection.
• Reheating in a furnace as per rolling plans.
• Rolling into the desired size or section.
• Heat treatment and inspection before dispatch.

What are the most critical factors to consider during the manufacturing process to ensure high-quality stainless steel?

Production teams must be informed about customer requirements, including chemical compositions, gas levels, and physical properties. Transparent communication and thorough training ensure adherence to Standard Operating Procedures (SOPs). Continuous casting is a critical stage requiring experienced operators for a smooth surface finish and defect-free macrostructure. A well-trained team minimizes inspection time and ensures timely delivery of high-quality products, which fosters repeat business and customer satisfaction.

How has technology impacted the manufacturing process in recent years?

Emerging technologies have reduced production cycle times and improved quality. For example, preheating scrap charges with hot exhaust gases and integrating liquid ferrochrome from in-house plants save energy and reduce CO2 emissions. Automated IT-driven systems in some European companies eliminate human intervention in production planning, ensuring consistency and efficiency.

What recent innovations have significantly impacted stainless steel manufacturing?

The advent of AOD in the 1980s revolutionized stainless steel production by enabling the use of high-carbon raw materials in EAFs, followed by carbon reduction in AOD. This process drastically reduced costs and made stainless steel more accessible, leading to significant growth. Innovations like LRF, VOD, and EMS further diversified grades and applications, ensuring stainless steel’s continued growth as a versatile and fast-growing metal.

What steps are taken to minimize the environmental impact of stainless steel manufacturing?

Using recyclable stainless steel scrap reduces CO2 emissions significantly. Many European manufacturers rely on over 90% recyclable raw materials. Renewable energy sources, such as hydro, wind, and solar, are increasingly used alongside carbon capture technologies. The focus is on achieving high-capacity utilization and energy efficiency to lower the carbon profile.

What current trends are shaping the stainless steel market?

Trends include sustainable manufacturing, advanced technology adoption, and increased demand in construction, automotive, and medical sectors. Government initiatives like the stainless steel quality control order have set standards, aligning the domestic industry with global benchmarks.

What sectors or industries are driving the most demand for stainless steel products?

Key sectors include:

• Construction and Infrastructure: Bridges, roofing, and decorative elements.
• Automotive and Railways: High-speed rail, metro projects, and electric vehicles.
• Kitchenware and Appliances: Hygiene-focused cookware and utensils.
• Process Industry: Chemical, food processing, and pharmaceutical applications.

What advice would you give to someone entering the stainless steel industry?

The Indian stainless steel market offers vast opportunities driven by strong demand and government support for domestic manufacturing. New entrants should focus on technological innovation, quality, and building sustainable processes to gain a competitive edge.

What has been your most rewarding experience in this field?

Leading the Indian subsidiary of Outokumpu was a standout experience. It allowed me to introduce specialty stainless steels, promote sustainable manufacturing, and bring advanced grades to India. Building Outokumpu into a trusted brand in India through innovative products and exceptional customer service remains a treasured accomplishment.