Aluminium Extrusion Plant Project Report

Description

You can get the Project Report for setting up a Plant for Aluminium Extrusion here. Aluminium is lightweight, highly reflective, heat conductive, nontoxic, and corrosion resistance characterise this soft silver-white metal. It makes up around 1/12th of the earth’s crust, the most prevalent metallic element. It is only found in nature in combination with oxygen and other elements, never as an elemental metal. The term “aluminium” is frequently misunderstood in everyday commercial and industrial contexts to refer to an aluminium alloy rather than a pure metal. Aluminium extrusion converts aluminium alloy into objects with a defined cross-sectional profile for various applications.

Aluminium’s unique combination of physical properties is exploited in the extrusion process. Aluminium’s malleability allows it to be easily machined and cast. Still, because it has a density and stiffness one-third that of steel, the resulting products are strong and stable, primarily when alloyed with other metals. Heat has a significant role in the aluminium extrusion process. Temperature monitoring is crucial from start to finish to ensure that Aluminium alloy parameters such as tensile and yield strengths are met and affect the part’s final polish.

The billets or logs are heated to 400-480°C (750-900°F) for the aluminium extrusion process. Although the aluminium alloy is solid, it is bendable. Aluminium does not glow when heated; it appears hot or cold. Extruded aluminium is utilised for various applications, including the International Space Station components. Aluminium’s favourable features, ranging from its unique balance of strength and flexibility to its conductivity, non-magnetic properties, and ability to be recycled repeatedly without loss of integrity, enable these numerous applications. These features and properties are widely employed in the transportation, building, packaging, and electrical industries.

Why buy a project report of Aluminium Extrusion Plant?

A project report of aluminium extrusion manufacturing plant is necessary for the following reasons.

1. Helps the investor to make an investment decision in the aluminium extrusion petroleum manufacturing business.
2. Makes the entrepreneur aware of the various aspects of the aluminium extrusion business in India.
3. Helps in understanding the aluminium extrusion manufacturing process.
4. Serves as a sample report to prepare project reports for other purposes.

Market Outlook

In India, the aluminium extrusions sector has an installed capacity of roughly 550,000 tonnes per year, spread across an estimated 150 units with presses ranging from 360 T to 9000 T. In 2013, India used approximately 380,000 tonnes of aluminium extrusions. Industrial uses are fast rising, even though the building and construction market contributes 51% of demand.

Aluminium extrusions are employed in construction, transportation, electrical, machinery, and consumer durables because of their strength, flexibility, durability, and sustainability. They’re 100 per cent recyclable and don’t produce any harmful gases throughout the manufacturing process. Its use in green initiatives fuels the expansion of the aluminium extrusion market. The worldwide aluminium extrusion market is expected to increase roughly 7% during the projected period.

During the forecast period, the car industry is expected to fuel the growth of this market as we see in autos and transportation, aluminium extrusion is replacing steel. Because of its small weight is chosen over other metals, resulting in lower fuel use and greenhouse gas emissions. Furthermore, aluminium is easily recyclable and corrosion resistant, ensuring the vehicle’s long-term viability and endurance. You can take the help of our project report to understand the market potential of the Aluminium Extrusion Plant.

Also Read: Aluminium Casting Business Plan & Project Report

Market Potential

• Aluminium extrusion is the technique of melting and converting an aluminium alloy bar into a specified shape by forcing it through a cross-sectional die. Extruded aluminium offers excellent electrical and thermal conductivity and recyclability and is modified to meet the customer’s needs. The extruded pieces’ smooth and fine surface finish can also be polished, buffed, anodised, painted, or powder-coated to improve the product’s aesthetic value and attractiveness.
• Aluminium extrudes a highly desired alternative to typical aluminium goods because they are cost-effective, lightweight, corrosion-resistant, low-maintenance, and feature paramagnetic qualities. They’re used in various industries, including building and construction, transportation, machinery and equipment, consumer durables, electrical, etc.
• One of the primary aspects driving market expansion is the increased construction of green buildings. Green buildings are environmentally friendly, energy-efficient, and emit low carbon emissions, which is why they are becoming more popular throughout the world. Extruded aluminium is in high demand in the construction industry since it is commonly employed in manufacturing windows and doors in these structures. Furthermore, the expanding automobile industry is another factor driving market expansion. Extruded aluminium is low in weight.
• In automobiles, aluminium is utilised to fabricate a variety of aluminium-made parts. Furthermore, because of their high malleability, aluminium may be shaped into various shapes without using much energy, enhancing their demand for industrial applications. The global Aluminium extrusion market is expected to reach 35.47 million metric tonnes by 2026, according to IMARC Group project market research report, with a CAGR of 3.97 per cent from 2021 to 2026. The aluminium extrusion market in India is expected to rise by $2.5 billion by 2027, with a CAGR of 8.3% from 2020 to 2027.
• Even though the aluminium extrusion market saw a sharp drop in production and demand during the pandemic, the growing importance of intelligent mining and digital transformation is projected to boost the market.

Product Uses

• Window and door frame systems, prefabricated houses/building structures, roofing and exterior cladding, and curtain walling are just a few applications for aluminium extrusions in the construction industry. Extrusions are also utilised in constructing road and rail cars, aircraft structures, and marine vessels.
• Extruded aluminium is also used for various applications, including the International Space Station components.
• Aluminium profiles are by-products that are typically used in structural applications. Construction, architectural, and industrial profiles are the three types that can distinguish based on their intended application.
• Construction profiles: This shape has a strong bending and torsional rigidity despite its low net weight—frames for solar panels, structures for working platforms and scenarios, and so on.
• Architectural profiles: The surface finish is critical for this application. Architectural shapes are used to create window, door, and curtain wall frameworks.
• Industrial profile: Aluminium profiles are employed for several purposes where stiffness or surface quality are not as crucial, but a combination of both, as well as other material qualities such as conductivity, give this by-product a wide range of industrial applications. Cable channel systems, heat sinks, air conditioning, cabinets and furnishings are just a few examples.

Raw Material for Project 

Cylindrical Aluminium Extrusion Billet, Fuel, and Water are essential raw materials for the aluminium extrusion project process. Apart from that, only packing materials are needed.

Points included in the project report of Aluminum Extrusion Plant

The project report of Aluminum Extrusion Plant covers the following topics.

Process of Manufacturing

Extrusion is the technique of forcing aluminium alloy material through a die having a particular cross-sectional profile. A substantial ram pushes the aluminium through the die and emerges from the die aperture. It appears in the same shape as the die and is hauled out along a runout table when this happens.

If you are interested in understanding the manufacturing process of the Aluminium Extrusion Plant, then you should go through our project report.

STEPS IN THE ALUMINIUM EXTRUSION PROCESS

Step 1: Prepare the extrusion die and transfer it to the extrusion press.

A round-shaped die is first fabricated from H13 steel. Alternatively, if one is already accessible, it is retrieved from a warehouse such as the one seen below. To help maximise the die’s life and maintain even metal flow, it must warm to between 450 and 500 degrees Celsius before extrusion. After warmed up, can insert the die into the extrusion press.

Step 2: an Aluminium Billet is Preheated before Extrusion

The billet is then carved from a lengthier log of alloy material into a solid, cylindrical block of Aluminium alloy. It’s preheated to 400-500 degrees Celsius in an oven to make it pliable but not molten enough for the extrusion procedure.

Step 3: Billet are Transferred to the Extrusion Press

The billet is mechanically transported to the extrusion press once it has been warmed. A lubricant (or release agent) is applied before it is loaded onto the press. The release agent is also used to the extrusion ram to prevent the billet and ram from adhering together.

Step 4: The ram pushes the Billet Material into the container

The malleable billet is now put into the extrusion press to give a hydraulic ram pressure of up to 15,000 tonnes. The billet material is forced into the extrusion press container while the ram applies pressure. The substance extends to fill the container’s walls.

Step 5: Through the Die, the Extruded Material Emerges

The alloy material is now being forced against the extrusion die to fill the container.

The Aluminium material has nowhere to go but through the opening(s) in the die when constant pressure is applied.

It emerges in the shape of a fully completed profile from the die’s opening.

Step 6: Extrusions are guided along with the runout table and quenched

A puller grabs the extrusion after emerging from the press, which leads it along with the run out table at the same speed as it exits the press.

The profile is “quenched,” or uniformly cooled as it goes along the run out table by a water bath or fans above the table.

Step 7: Shearing Extrusions to Table Length

A hot saw shears an extrusion once it reaches its full table length, separating it from the extrusion process. Temperature plays a crucial influence in every phase of the process.

Even though the extrusion was quenched after entering the press, it has not yet reached its complete cooling temperature.

Step 8: Extrusions cooling at room temperature

Table-length extrusions are mechanically transported from the run out table to a cooling table after shearing; the profiles will remain until room temperature comes. After that, it is stretched.

Step 9: Extrusions are stretched into alignment with the help of stretcher

Some natural twisting has occurred in the profiles, which needs to be addressed. They are transported to a stretcher to correct this.

Each profile is mechanically grasped on both ends and pulled until it is entirely straight and meets the requirements.

Step 10: Finish Saw used to cut into length

The table-length extrusions are transferred to the saw table once they have been straightened and properly work-hardened. They are sawed to pre-determined measurements, ranging from 8 to 21 feet. The characteristics of the extrusions match the T4 temper at this point. They can then be moved to an ageing oven to be aged to the T5 or T6 spirit after being sawed.

Profiles can be heat treated after being extruded to improve their qualities. They can then be heat treated and various surface treatments to enhance their look and corrosion resistance.

Also Read Article on : Copper Powder Making Project Business Plan.

Costing of Setting up of Plant

Before investing in Aluminium Extrusion Plant, you must study the project report, and it will be beneficial for you.

• Labour, water and electricity, natural gas, mould costs, maintenance costs, scrap costs, additional processing costs for aluminium billets, rent costs, equipment depreciation, financial costs, management costs, and one set of aluminium extrusion production lines are all included in the price of setting up an aluminium profile factory.
• Because the parameters of the extrusion line you need to employ are determined by the size of the generated aluminium profile, when different types of aluminium extrusion machines are used, the length of the aluminium extrusion produced varies.
• The extrusion press’s tonnage capacity will increase as the size of the aluminium profiles increases.
• The size of the extrusion mould is established in production based on the shape and size of the section of an aluminium profile and whether the extrusion mould is a flat die or a porthole die.
• When the mould size is known, may calculate the extrusion machine’s tonnage capacity.
• Here is an estimate of how much it would cost to start a new aluminium extrusion factory.
• 600T aluminium extrusion press, billet heating furnace with hot log shear, mould heating oven, cooling bed and run out table, puller and ageing furnace, the approximated estimated cost is 250,000.00-500,000.00USD based on various brands of extrusion machine and auxiliary equipment.
• Based on various brand extrusion machines and ancillary equipment, the projected cost of an 800T aluminium extrusion press, billets heating furnace with hot log shear, mould heating oven, cooling bed and run out table, puller and ageing furnace is approximately $300,000.00-600,000.00USD.
• Based on several brand extrusion machines and ancillary equipment, the estimated cost is approximately 400,000.00-750,000.00USD for a 1000T aluminium extrusion press, billets heating furnace with hot log shear, mould heating oven, cooling bed and run out table, puller and ageing furnace.

Explanation

• The above explanation is only the cost of the aluminium extrusion production. We must include the cost of shipping and the fees of installation and commissioning.
• The gas connection and installation, the environmental impact assessment, the operating forklift and aluminium billets cost (outsourcing), and the working fund will all be considered when building a new plant.
• For one aluminium extrusion production line, one shift employee will be at least five people, and two shifts-3 shifts will be 10-15 people.
• As a result, establishing a single aluminium extrusion factory will cost approximately USD 350,000.00.
• This aluminium extrusion production line is just for mill finish aluminium extrusions. We’ll need melting and casting equipment to create aluminium billets ourselves.

Machinery And Equipment Required

The following types of equipment are present in a complete aluminium profile production line. You can get detailed information about the plant and machinery involved in aluminium extrusion by downloading the project report in PDF format by paying a nominal fee.

• Aluminium melting workshop
• Aluminium melting furnace
• Casting platform
• Billet cast mould
• Billet cutting machine
• Homogenising furnace
• Workshop for aluminium extrusion
• Aluminium extrusion press
• Aluminium billets heating furnace
• Mould heating oven
• Cooling fan
• Cooling bed and run out table
• Extrusion line cutting saw
• Ageing furnace
• Shape correction machine
• Aluminium profile anodising workshop
• Water chilling unit
• Colouring machine
• Refrigeration unit
• Heat exchanger
• Filter press
• Lifter
• Aluminium profile brushing machine
• Aluminium profile polishing machine
• Sandblasting/shot blasting machine
• Aluminium profile electrophoresis coating workshop
• Electrophoresis equipment
• Aluminium profile powder coating workshop
• Powder-coated equipment
• Aluminium profile mould workshop
• Nitriding oven
• Machining Centre
• Lathe
• Milling machine
• Wire cutting
• Electric spark
• Mould quenching furnace
  

Laboratory Equipment 

• Spectrometer
• Hydrogen meter
• Metallographic equipment
• Laboratory equipment, consumables
  

Packaging Equipment

• Wrapping machine aluminium profile
• Film applicator machine aluminium profile
• Hot shrink packaging machine aluminium profile
• Automatic bagging machine aluminium profile.

Facilities for environmental protection and other ancillary equipment and wastewater treatment equipment

• Dust removal equipment
• Crane
• Water pump
• Cooling Tower
• Forklift
• Air compressor
• Boiler
• Equipment for distributing electricity
• Moulds and consumables
• Extrusion die and tooling
• Release oil
• Felt strip
• Hydraulic oil
• Cutting oil
• Mould repair tools Etc.
  

BASIC SERVICES NEEDED

• Factory and office building
• Electric power equipment
• Transformer station
• Transformer station to an electric control box
• Electric control box to machine
• Water supply
• Water pump
• Pure water treatment
• Cooling tower
• Reservoir
• Boiler
• Piping: from boiler and reservoir to equipment
• Air supply
• Air compressor
• Piping： from an air compressor to equipment
• Oil supply
• Feed pump oil
• Oil storage tank
• Piping： Pump to equipment
• Foundation for:
• Melting furnace, casting machine
• Extrusion press & handling system.
• Anodizing treatment tank construction.
• Wastewater treatment construction
• Moving & shifting vessel
• Truck
• Lift hooker
  

FACTORS THAT AFFECTS QUALITY

The following aspect will affect the output of the extrusion line.

• Aluminium alloy
• The billet’s quality
• The thickness and size of the profile
• Extrudable conditions
• Lot quantity for each die
• Die design ability

Conclusion

In short, we would like to assure you that the Project Report of Aluminium Extrusion Plant covers various aspects of the business, which will be beneficial for you. Our advice is to download and study the project report in pdf format.