Aluminium 2018 Show Newspaper by Quartz Business Media

Newspaper

The Journal of aluminium production and processing

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Digital manufacturing on the rise The aluminium industry is getting ready for digitalisation and the implementation of Industry 4.0 technologies. Those are the findings of a survey of 240 aluminium experts from 39 countries conducted on the occasion of the ALUMINIUM World Trade Fair 2018. Industry 4.0 applications are on the agenda for about 90 per cent of companies. Some 62 per cent are already developing strategies or have reached the implementation phase. The digital transformation and the path to intelligent production is one of the biggest challenges for industry, and the aluminium sector is no exception. The ALUMINIUM trade fair survey shows that the aluminium industry is already well positioned in the digital realm and reveals the ways companies are dealing with Industry 4.0 technologies. Digital manufacturing is of very highto-high significance for 85 per cent of the companies surveyed. Small companies (up to 9 employees) and large-scale industrial enterprises (5,000 employees and up) are particularly aware of the importance of digital technologies – they consider them most relevant.

processes (38%) is their key concern. The same is true in mechanical and plant engineering (35%), where networked production control (35%) also plays an important role. Companies in aluminium processing, such as those specialised in surface treatments, care about connecting with other partners (38%). Distributors feel similarly: As one would expect, they prioritise networking with customers (67%) and mobile devices (44%).

The goal: Optimising the value chain

Efficient production processes, increased productivity and enhanced collaboration within the supply chain are seen as the biggest advantages offered by Industry 4.0 applications. In addition, many of the respondents are hoping for closer relationships with partners and customers and expect faster and better connectivity with suppliers, improved customer support and faster response times, among other things.

Even though many companies are already planning and implementing projects, there is a strong need for know-how and best practices when it comes to digital manufacturing in the aluminium industry. Asked about the solutions companies are looking for right now, supply chain management was mentioned most often. There’s also strong demand for the networking of machines, robotic solutions, continued on page 3 ••

Implementation levels vary

Implementation levels at companies vary, however: while 28 per cent of respondents are still in the information-gathering phase, just as many (28%) are currently in the process of developing a digital strategy. The first projects are being realised in 23 per cent of the surveyed companies. Meanwhile, 11 per cent of respondents are already comprehensively deploying Industry 4.0 projects.

Production and R&D

Today, Industry 4.0 applications are primarily deployed in production (27%) and research & development (22%), followed by distribution (15%), logistics (13%) and the supply chain (12%). Industry 4.0 technologies are used in production control (14%), the networking of machines (“Internet of Things”, 14%) and production processes (13%). At the same time, companies are also focussed on linking up with partners (11%) and on mobile devices (11%) and cloud computing (9%). In the opinion of the respondents, networking with customers and/or external partners is getting more and more important. So far, however, only 28 per cent of the companies are systematically integrating their partners in the planning and/or implementation of their digital manufacturing strategy.

Differences by sector

When it comes to the use of digital solutions, one must differentiate between industrial sectors. The networking of machines (39%) and production control (37%) are considered most important in the production of materials and semifinished goods. By contrast, manufacturers of components for user industries say the digitalisation of individual production

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big data and online distribution processes. Manufacturers of semi-finished goods and extruded products, in particular, expressed a clear need for digital solutions. In this context, however, all of the respondents were also concerned about obstacles on the way to Industry 4.0. Digitalisation projects in the companies are currently being delayed primarily by high investment costs and too many unresolved implementation issues.

to attend the world’s largest trade fair of the aluminium industry. Spread across six exhibition halls, ALUMINIUM will showcase the industry’s complete range – from aluminium production to machines and plants for processing to finished goods and recycling. •• aluminium-messe.com

Focus on digital manufacturing

Taking place in Düsseldorf from 9 to 11 October, this year’s ALUMINIUM World Trade Fair will put a spotlight on the digital transformation and intelligent production processes. Introducing the new “Digital Manufacturing” special exhibition area, the trade fair is creating a forum aimed at demonstrating the productivity benefits provided by powerful IT solutions – from engineering software and systems to manufacturing software and machines to IT security and consulting. ALUMINIUM and its exhibitors will also provide an overview of Industry 4.0 developments at the lecture forum and in guided exhibition tours. A total of 1,000 exhibitors and 27,000 visitors from 100 countries are expected

About the survey A total of 240 industry experts from 39 countries participated in ALUMINIUM 2018’s survey “How digital is the aluminium industry already?” – including producers, processors, technology suppliers, and design and other engineers from user industries, representing small businesses, large-scale industrial enterprises and everything in-between.

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Contents 1 4 6 8 10 10 12 14 15 16 20 22 22 24 26 28 30 32 32 33 34

Digital Manufacturing on the rise Welcome to ALUMINIUM 2018 Industry Q&As New topics to meet the future Future Aluminium Forum 2019 I+ Manifesto Assan Alüminyum celebrates 30th anniversary Customised handling solutions from Combilift TOMRA to spotlight sensor-based sorting technologies Emmebi: The novelty of habit GHI supplies turnkey plants for aluminium recycling Experience-led support to the automotive industry Fontes Refractories: A key partner for aluminium smelters in the world Foil slitting and separating with documented quality Mecatherm restructures with ‘Servitisation’ Philosphy For the perfect production of aluminium cuts Aluminium and copper are still going strong in automotive manufacture Pyrotek’s insulated tabletop refractory helps reduce heat loss STAS acquires technologies from o.d.t. Engineering The State of the U.S. Aluminium Industry Innovation in the heat treatment of aluminium automotive components and monitoring challenges

35 MQP at Düsseldorf 2018 35 Products & Projects

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Editor’s welcome

ALUMINIUM 2018 – the global No. 1 meeting point for the industry

Welcome to this very special edition of Aluminium International Today: The ALUMINIUM 2018 Newspaper.

Vehicles, aircraft, buildings or packaging – aluminium is a material that has changed numerous products and industrial sectors in recent decades and will continue to change them in future. In the competition of lightweight construction and design materials, aluminium today holds a top spot as it launches an entire industry on a growth trajectory.

I was honoured to be asked by the organisers of the show, Reed Exhibitions, to provide a publication for distribution at this prestigious event.

The industry is driven by the lightweight construction megatrend, improved material properties, technical progress in the process chain like digital networking, new technologies like additive manufacturing, and increased requirements when it comes to energy and resource conservation also contribute. Time and again, the aluminium industry has enhanced the properties of its material, developed new products and optimised production processes by investing in application-oriented development. ALUMINIUM 2018 in Düsseldorf will present the advancements of the industry. From production to processing and the finished product to recycling, the show covers every facet of the industry – which is what makes ALUMINIUM so unique. I cordially invite you to get an idea of the future of aluminum and its potential, and I am delighted to welcome you at ALUMINIUM 2018.

We were inundated with content from companies exhibiting at the show and it looks like this year is set to display the most innovation across the sector we have ever seen. As the organiser of the Future Aluminium Forum, I am an advocate for promoting the benefits of smarter technology and preparing the sector for what Industry 4.0 has to offer, so it is great to see this is a main theme for 2018. There are exciting things to come and we are seeing a shift in the way aluminium is produced and the benefits value-added products provide. There are lots of ways visitors can explore the introduction of Industry 4.0 at the show, including a Guided Tour to exhibitors specialising in this area, and designated sessions in the Forum. I will be hosting the Digital Manufacturing session on Wednesday 10th October and look forward to the interesting discussions and presentations on the factory of the future. I’m excited to be visiting the show once again and seeing aluminium in all its glory! I hope you enjoy this special publication and it gives you an insight into some of the companies you can meet with and learn more about their products and services. Best regards,

Nadine Bloxsome

Olaf Freier

Hall 9 8

Casting and heat treatment, Furnace Technology

Hall 10

Hall 11 China Pavilion Norway / Iceland Pavilion Primary Pavilion Recycling Pavilion

Hall 12 ALUMINIUM Forum Career Lounge Competence Center Surface Technology matchmaking Lounge

@AluminiumToday

FLOOR PLAN OF HALLS

NORTH ENTRANCE

China Pavilion Innovation Area Welding and Joining Pavilion

Digital Manufacturing Environmental Engineering Foundry Pavilion Magnesium Area Young & Innovative Companies

Join the Aluminium International Today Group

Editor, Aluminium International Today T: +44 1737 855 115 E: nadinebloxsome@quartzltd.com

Event Director ALUMINIUM www.aluminium-messe.com

Metalworking, Digital welding, Manufacturing joining and automation Enviromental

Primary production and recycling

Engineering

Surface treatment

Semi-finished products (key focus: rolling)

Semi-finished products

12 13 Semi-finished products (key focus: extrusion)

14 6

Hall 13 Holland Pavilion Hall 14 WGM Pavilion

EAST ENTRANCE

CCD Ost Congress Center Düsseldorf as of August 2018

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Industry 4.0

Q&As Stefan Koch, Global Lead for Metals, SAP SE How important is the Industry 4.0/digital concept to aluminium manufacturing and processing?

an ideal case are directly connected to and make use of a digitally driven, profit-driven supply chain and plant and asset operations.

Digital transformation is at the heart of the entire global metals and aluminium industries. The industry is changing due to the fact that capacity is high, demand is growing as well but not at a similar pace. Aluminium companies need to find solutions to be profitable in oversupplied, competitive, and constantly changing markets. In addition, market disruptions can be caused by actions such as tariffs that require thoughtful and fast reactions. In this complicated environment, Industry 4.0 and digitalisation has become a strong lever for competitiveness and differentiation.

Has digital manufacturing become an important concept at your company? Do you have an R&D team devoted to it, for example?

Do you expect the digital concept to be embraced by aluminium manufacturers? Yes. Companies that don’t embrace digitalisation will be left behind in this hyper-competitive environment. Much like a light bulb manufacturer that refused to pivot to LED light bulbs, or telephone companies that avoided mobile but relied on landlines for revenue, the shift is not a matter of ‘if’ but ‘when’. Aluminium manufacturers of

the future are those that are leading and establishing a strong foothold in the digital transformation today.

What does your company offer its customers in terms of the Industry 4.0/ digital manufacturing concept? SAP offers a full spectrum of digital solutions to aluminium companies to master the digital revolution. Our solutions enable companies to run new sales models and omnichannel customer engagement that in

As the established leader in supporting companies to achieve their digital transformation aspirations, SAP has been digital from the beginning. SAP has always been at the forefront of the technologies that helped pave the way for today’s digital transformation. Our team is constantly pursuing the next innovation to help aluminium and global metals companies be more efficient, effective and profitable.

How has your technology evolved to embrace the digital age? SAP is continuously evolving our processes to incorporate the newest technologies. The SAP goal is to translate the latest technology innovations into the latest business processes to drive competitive advantage and the highest company business value.

Are there any negatives to the digital age? The overall impact will be very positive to the aluminium and global metals industries. The digital transformation will help aluminium companies survive the industry dynamics and compete e.g. with alternative materials which is good for the industry. There will also be more efficient use of resources like energy, which is both good for the bottom line as well as the planet. However, there will be changes that will likely impact the workforce – a transition to more knowledge-based workers vs. action-based, and the likelihood that fewer workers will be needed long-term.

What is your vision of an aluminium smelter or processing plant in ﬁve to 10 years time? Plants will have seamless, fully integrated processes that are running more or less autonomously. Plants won’t have production in one location, owned and controlled by one entity, but instead a plant will be an integration point of a network of managed resources beyond enterprise boundaries. This is a reimagining of the enterprise business model, and will offer more efficient, profitable and sustainable businesses long-term.

Hans Erik Vatne, Chief Technology Ofﬁcer, Hydro How important is the Industry 4.0/digital concept to aluminium manufacturing and processing? Our industry is mature and improvements in productivity and cost are thus becoming more challenging. I4.0 clearly has the potential to improve safety by removing inconvenient and dangerous work tasks through robots, reduce cost due to automation, improve productivity due to higher stability and better resource utilisation through automation and better control systems (utilising digital twins and advanced analytics).

Do you expect the digital concept to be embraced by aluminium manufacturers? Most aluminium companies are now in an exploratory phase where they test out and try to find the potentials and business cases of I4.0 and really identify what is value creating and what is hype. As an industry we have a rather high degree of manual work. This is where most work is going on.

What does your company offer its customers in terms of the Industry 4.0/ digital manufacturing concept?

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Currently we have quite good customer portals to simplify order handling and communication and modern information channels like @ShapesbyHydro.

Has digital manufacturing become an important concept at your company? Do you have an R&D team devoted to it, for example? We are working on digital twin concepts, i.e. complete digital/numerical simulation models of physical processes like a machine, electrolysis cell or a complete plant, based on a combination of: (i) Physically-based models, (ii) Advanced sensors/measurement systems (to continuously calibrate the model), (iii) Advanced analytics algorithms (statistics, machine learning, artificial intelligence). Such models are in the testing and development but have the potential to optimise electrolysis as well as more downstream manufacturing.

phase a lot of efforts were used to improve automation and the control system, including use of advanced analytics and new sensoring. Thus, the technology pilot has also become a first step towards a digital plant.

Are there any negatives to the digital age? It is obviously challenging to spend resources wisely and find the right business cases for digital projects. Further, automation and robotisation of shop-floor as well as office tasks challenges traditional tasks. So far this

is positive – creating more interesting jobs but longer term it might have consequences for the need for human labour.

What is your vision of an aluminium smelter or processing plant in ﬁve to 10 years time? The vision is clearly and autonomous cell, i.e. an electrolysis cell that is self-controlled and without need for manual intervention but this is likely to take more than 5 years.

How has your technology evolved to embrace the digital age? Hydro has recently built the Karmøy technology pilot to verify our next generation electrolysis technology. In the final project

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New topics to meet the future The transport sector and the energy transition are driving demand aluminium. The lightweight construction megatrend ensures excellent growth opportunities for aluminium as an industrial material. All around the world, the industry is making new investments to gear up for an economy that continues to boom. This positive mood is felt as well at the ALUMINIUM World Trade Fair in Düsseldorf, Germany. From 9 to 11 October 2018, the Exhibition Centre on the Rhine will again become the global marketplace of the aluminium industry. Some 1,000 exhibitors from around the world will be in Düsseldorf, the exhibition area will grow to 80,000 square metres – a clear indication of the current momentum in the aluminium industry. Spread across six exhibition halls, global players, specialists and young innovative companies will showcase the industry’s complete range – from aluminium production to machines and plants for processing to semi-finished and finished goods and recycling. Besides the aluminium key industry, the trade show and its exhibitors will focus on processes and products for the main aluminium application industries: automotive, engineering, building and construction, aerospace, electronics, packaging and railway.

New topics: Digitalisation and environmental protection

The well-known theme pavilions will serve as points of contact to lead visitors through the structured exhibition halls, including the Competence Centre Surface Technology, the Foundry Pavilion, the Primary Pavilion, the Welding & Joining Pavilion, the Recycling Pavilion and the Magnesium Area. In the new special exhibition area Digital Manufacturing, visitors will experience what Industry 4.0 means for the aluminium industry and what kinds of productivity benefits can already be achieved today by deploying high-performance IT solutions in production. Another new exhibition area dubbed Environmental Engineering will cover

water treatment, air filtration systems and oil/oil mist-vacuuming systems – and show how the aluminium industry is leading the way when it comes to emerging topics such as energy and resource conservation in one’s own production chain. An Innovation Area will display new products from different user segments, such as automotive engineering, mechanical engineering, aerospace, the building sector and additive manufacturing.

Technical education programme to deliver industry and science know-how ALUMINIUM is much more than just the world’s most important trading centre. Above all, it’s a major knowledge hub: Expert presenters from industry and science at the ALUMINIUM 2018 Conference and the ALUMINIUM Forum will discuss the principles, trends and innovations of the aluminium sector. Organised again by the GDA, the umbrella association of the German Aluminium industry, the ALUMINIUM 2018 Conference will focus on the material’s future prospects. In five sessions and 40 lectures, materials experts will explore the possibilities in the aluminiumprocessing industry and in user markets. The conference will be held at the Congress Center East; participation requires the purchase of a separate ticket. The conference will be simultaneous translated into English and German. Exhibitors themselves will take the podium at the ALUMINIUM Forum, which is part of the trade fair’s supporting programme. Over the course of the threeday lecture event, companies will introduce their innovations and successful projects in the fields of lightweight design, digitisation, surface technologies, sustainability and recycling. The admission is free for trade fair visitors.

Guided Tours

Guided Tours at ALUMINIUM 2018 offers an opportunity to get a special insight into different topics of interest. The Tour will lead you in a small group of other experts to exhibitors that have a special

Matchmaking at ALUMINIUM 2018 Trade fairs are for networking – whether it is to maintain existing business contacts or to expand one’s international network of professionals. To make this task work even better at ALUMINIUM, the free ALUMINIUM matchmaking tool allows you to get in touch with potential cooperation partners, investors, manufacturers or distributors in the run-up to the fair and arrange meetings at the event. The online ALUMINIUM matchmaking tool is available for visitors and exhibitors to search for and identify international cooperation partners to meet in Düsseldorf. Complementing the online platform, the Matchmaking

expertise in the particular subject area. The exhibiting companies will each give a short presentation of its innovations, products and services and answer questions. ALUMINIUM 2018 offers guided tours for the subjects 1 Automotive 1 Digitisation in mechanical engineering 1 Additive Manufacturing 1 Surface treatment 1 Recycling

ALUMINIUM 2018 Conference

At the ALUMINIUM 2018 Conference

Lounge in Hall 12 is the perfect place for mutually beneficial conversations.

The procedure All registered visitors and exhibitors will automatically receive an invitation to participate in ALUMINIUM’s matchmaking process. Once your profile has been activated and unlocked, you’ll be able to filter cooperation partners by country, sector, company name or product category and directly request appointments. Appointments are only generated if both parties confirm. As a special service, each participant will receive his or her personal meeting schedule shortly before the start of the trade fair. •• aluminium-messe.com

with its motto ‘Aluminium – Material for the Future’, the various applications of aluminium currently used be presented together with possible further developments that will make products in the future even lighter, nicer and more resource efficient. The Congress is planned and organized by the GDA, the German Aluminium Association. Together with representatives from the different sections of the industry, manufacturers of semi-finished products, refiners, remelters and subsuppliers, the latest innovative and future-looking solutions will be presented and discussed. The 5 sessions and nearly 40 lectures will focus aluminium markets, plant/processes/ digitalization, surface, recycling and automotive.

Tickets and program: •• aluminiumconference.de

Floorplan

ALUMINIUM 2018 will occupy halls 9 to 14 at Messe Düsseldorf which can easily be accessed from the two main entrances North and East. The halls of ALUMINIUM 2018 will be dedicated to special exhibition segments. 1 Hall 9: Metalworking, Welding & Joining, Automation 1 Hall 10: Casting and heat Treatment, Furnace Technology, Digital Manufacturing, Environmental Engineering 1 Hall 11: Primary Production, Recycling 1 Hall 12: Surface Treatment, Semifinished Products 1 Hall 13: Semi-finished Products (rolling equipment) 1 Hall 14: Semi-finished Products (extruders

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Future Aluminium Forum 2019: Applying Industry 4.0 to aluminium production Following on from the success of the inaugural Future Aluminium Forum, the Organiser’s, Quartz Business Media, are pleased to announce that the event will be moving to the Sheraton Warsaw Hotel in Poland on 22-23rd May 2019.

Future Aluminium

Aluminium manufacturers are constantly looking to improve the efficiency of their production processes and are relying upon increasingly sophisticated digital technologies to streamline their operations. In such a fast-moving world, characterised by complex Internet-based manufacturing systems, the Future Aluminium Forum 2019 is a must-attend event for aluminium professionals who want to unravel the mysteries and get to grips with the complexities of Industry 4.0. The Forum is a live discussion of the issues surrounding innovation and will endeavour

to cover all bases, including the all-important subject of machine learning, digitalisation, disruptive technologies, information sharing, process safety and control. This international technology conference will draw upon the unrivalled expertise of aluminium industry professionals, production technologists and academics, to create an event designed specifically for those seeking a greater understanding of ‘smart manufacturing’.

Who should attend?

The Future Aluminium Forum is primarily concerned with Industry 4.0 and other advanced technologies that are impacting global aluminium manufacturing. The conference focuses on ‘the factory of the future’ and linked technologies, such as artificial intelligence. It is the ideal event for senior level aluminium executives, chief technology

which will include a subscription to Aluminium International Today, the Aluminium International Today Directory, relevant news alerts and admission to the Future Aluminium Forum.

22-23 MAY 2019 • POLAND officers and specialists with an interest in the application of new technologies to the aluminium manufacturing process. The Forum’s key audience consists of those with a leading role in process technology excellence, industrial innovation, research and development, digital transformation and value acceleration, process simulation and engineering education and development.

Delegate registration now open

1 STANDARD RATE: £990pp

Exhibition

If you are interested in promoting your products and services to an international audience from across the aluminium manufacturing supply chain, then this is a unique opportunity to position your brand alongside leading experts in this field. There are very limited opportunities available and these will be allocated on a first-come-first-served basis. 1 TABLE TOP EXHIBITION SPACE £1,950 •• futurealuminiumforum.com

I+ MANIFESTO: MORE INDUSTRY. SUSTAINABLE. CREATIVE. INCLUSIVE By Maximo Miccinilli* In May 2019, the EU will hold its elections and reallocate all top EU positions in the European Commission, European Parliament, European Council and European Central Bank. As a strategic industry, we must take advantage of this new political cycle to position ourselves and bring concrete policy proposals to the table. After all, our industry has an important role to play in the future of the EU. Demand and consumption of aluminium will increase as Europe needs our sustainable metal to transition into a low-carbon society. If we are part of Europe’s future, we must also be part of the debates that will shape the policy landscape in 2019 and beyond. Our Industry Plus (I+) Manifesto, launched in April this year, is an attempt to do just that. It is driven by the need to have an inclusive and holistic discussion about a new industrial policy with a clear purpose and governance that will create the right conditions for our industries to shine and for Europe to become the world’s most sustainable and innovative economy. In the past, discussions on industrial policy were too “target-oriented”, focusing on Industrial GDP growth for example, and completely disconnected from important sectoral policies for our industry. Our I+ Manifesto is based on five simple principles and calls to action that complements the current efforts of policymakers and other platforms working on industrial policy with more specific recommendations.

Beyond the EU elections: COP21 as a positive trigger for change

Beyond the EU elections, the global COP21 climate agreement represents another turning point for all industry actors and the entire society. If Europe wants to meet its COP21 targets by 2030 and 2050, we need measurable targets with common goals for the EU and specific goals for each Member State.

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Our Manifesto is very clear on the need to combine industry and climate targets within a common policy pathway, taking stock of the lessons learnt from the European Energy Package 2020 and the need to plan the transition to a low carbon economy in the next decades. As such, the Manifesto is not only part of our positioning on industrial policy but also a clear signal of the aluminium industry’s commitment to identify solutions and provide innovative technologies and new applications.

Bursting the Brussels Bubble

Our ambition with the Manifesto is bigger than just reaching established EU policymakers and candidates for the 2019

EU elections. We want to burst the so-called ‘Brussels bubble’ and create a horizontal debate with all actors that care for the future of our industries and understand their role in Europe. To reach all relevant stakeholders, we have launched a pan-European communications campaign. We created an interactive microsite where users can download the Manifesto in 10 languages, watch interviews from key actors responding to our proposals, vote on the Manifesto and share their thoughts on a renewed industrial policy. The Manifesto is truly a ‘door opener’ for us, helping us to secure meetings with important decision makers. Furthermore, we have already received over 160 responses

to our Manifesto, from individual citizens to European Commission members. Of course, we would love to hear your thoughts too. I invite you to visit our micro-site to ‘vote’ on the manifesto, provide feedback and share your thoughts on the Manifesto on social media (#INDUSTRYPLUS). Together, let’s take a stand for a stronger European aluminium industry! Manifesto Micro-site: •• european-aluminium.eu/manifesto

*Director Communications and Public Affairs at European Aluminium

Principles: 1. Complete and functioning European Single Market – that works for people, goods as well as energy – is the single most important driver of a revitalised industry. 2. Favourable and stable framework conditions are needed for companies to compete at global level, invest, innovate and digitalise, switching to the industry of the future. 3. A fair and free trade, with a modern investment policy, to ensure industry produces and operates in Europe and at the same time competes on a global level playing field. 4. High availability of skilled women and men – both apprentices and experienced workers offered life-long learning opportunities is a prerequisite for transforming our industries. 5. The European economy must rapidly transition to carbon neutrality, greater resource efficiency and circularity and more equally shared benefits of growth. Achieving this is possible through an integrated approach to industrial modernisation that harnesses all of the above, as part of the EU’s commitment to the Paris Agreement and the UN Sustainable Developments Goals.

Calls to Action: 1. Define a new European governance to coordinate industrial policies 2. Identify strategic value chains in Europe 3. Include a specific EU Industry 4.0 fund in Framework Programme 9 "Horizon Europe", focused on regional value chains 4. Establish a new EU forum allowing business leaders to contribute to determine an Industry 2050 Roadmap, in line with EU commitments under the Paris Agreement 5. Make it attractive for industry to invest in Europe

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Assan Alüminyum celebrates 30th anniversary Assan Alüminyum, one of the three largest aluminium foil producers in Europe, continues to expand in the flat rolled aluminium industry, while keeping its focus on becoming more environmentally sustainable in all of its processes. The company produces new projects that reduce its waste and its energy consumption significantly each year. It has acquired a renewable energy power plant two years ago, in order to reduce its carbon footprint. The in-house recycling facility also contributes to the company’s sustainability strategy. Celebrating the 30th anniversary of its establishment this year, Assan Alüminyum, a subsidiary of Kibar Holding, has become one of the fastest growing flat rolled aluminium producers in Europe, with its installed capacity now reaching up to 300 thousand tons per year. The company exports to more than 70 countries and four continents, mainly to West Europe and to North America.

Short-term investments completed Assan Alüminyum has installed two new casting lines in record time that have started production in the first half of last year, and a state-of-the-art foil mill, which

has started production at the end of 2017. Five new coil and six new foil annealing furnaces and a world-class, high-precision grinding machine are also part of the completed investment. A highprecision coil-to-coil aluminium slitting line has also been installed and complements the high-capacity coil coating line. With these new expansions, the company now has 19 continuous casting lines and 10 foil rolling mills. Especially with the addition of the new foil rolling mill, the company is now able to concentrate more on high valueadded flexible packaging products. The General Manager of Assan

Alüminyum, Göksal Güngör, who is also currently serving as the President of Global Aluminium Foil Rollers Initiative (GLAFRI) notes: “We firmly believe that aluminium, with its superior qualities such as lightness, excellent barrier properties, flexibility and durability, will play a key role in the future of many other industries. Therefore, while we monitor the current situation of global trade closely, we see this as temporary and continue to invest in the bright, sustainable future that our industry promises the world. Our 1500 dedicated employees are the ones who give us the strength to expand further with no hesitations.” The company offers its products to a variety of sectors such as packaging, distribution,

construction, consumer durables, automotive and HVAC.

Striving to become more global Assan Alüminyum has recently established its fully owned subsidiary, Kibar Americas, in Chicago, Illinois, through which the company aims to serve its North American customers. While through Kibar Americas, Assan Alüminyum currently provides services such as sales, supply chain, before and after sales technical support, it is also evaluating opportunities to grow in the North American market in the medium term. Güngör states: “We differentiate ourselves through our core values of reliability, flexibility and innovation. With our global culture, we work closely with our business partners, providing them with creative, tailor-made solutions, to become their localised solution partner. Hence our motto: Creating the Future Together, as our team is only complete when our business partners are also part of it.”

A new large-scale investment being planned out In addition to its recently completed investments, the company is currently planning a large-scale investment, consisting of a direct chill (DC), hot rolling facility. The negotiations are ongoing for this investment project, which is estimated to have a total value of 900 million dollars and to accommodate approximately 650 additional employees. This new facility aims to serve strategic industries, such as defense, aerospace, marine and other transportation and specialised packaging. The investment also includes an integrated port and R&D Center. With the ability of producing high-grade alloys, the company will be able to create further added-value through high performance products. •• Booth: 11E60

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Customised handling solutions from Combilift

Combilift is a regular exhibitor at the Aluminium show, and this Irish materials handling specialist’s stand is always packed with the latest innovations. Celebrating its 20th anniversary this year, Combilift is showing a selection of its ever-growing products, including live demonstrations, in Hall 13, Stand N16, at Aluminium 2018. Combilift developed the world’s first multidirectional all-wheel drive IC engine

powered forklift in 1998 and has since developed over 30 other models which are all designed for the safe space saving and productive handling of a wide range of products - long and bulky loads, pallets as well as out of gauge loads and containers. Over 40,000 units have been exported to around 85 countries and Combilift recently opened its new €50 million, 46,500 sq. m. facility which will enable it to double current

production within the next five years. All Combilift products are tailor made to customer requirements and the portfolio not only includes the original and groundbreaking multidirectional trucks but has now expanded to include pedestrian stackers, 3 and 4 wheeled sideloaders, articulated trucks for very narrow aisle operation, stand on trucks which are very popular with stockholders, and straddle carriers and mobile gantries. Recent focus has been on the expansion of the company’s pedestrian range, which was first introduced five years ago. There is growing demand for walk behind forklifts to replace ride-on models wherever possible as these can substantially increase safety, particularly in production areas where other employees are present. A major feature of the Combi-WR and Combi-CS range is the multiposition tiller arm, developed and patented by Combilift. This incorporates push button rotation of the rear wheel parallel to the chassis for placing and picking in the aisle. The operator can therefore remain at the side of the truck rather than at the rear as is the case with other pedestrian stacker trucks. This improves forward visibility and reduces the risks of incidents in narrow aisles as the operator is not positioned between the racking and the truck. Exhibits also include models from the original C-Series, which comes with lift capacities from 2t up to 25t. The electric version of the Combi-CB compact counterbalance design forklift with 4-way

ability is also now available with capacities of up to 4t. The Combi-MR combines the capabilities of a reach truck with the versatility of multidirectional travel and this standon reach truck (a sit-down option is also available) offers extreme manouevrability in confined spaces, enabling operation in reduced aisle widths for increased storage capacity. It is characterised by its unique steering function; the joystick enables seamless switching of the direction of travel and allows the operator to perform compact turns. Combilifts are available with a wide array of options, attachments and a choice of diesel, LPG or electric power. These versatile and long life workhorses can be used outside for offloading incoming products, they can deliver material directly to production or extrusion lines and store finished products in the warehouse – making them ideal solutions for the diverse requirements of the aluminium sector. “Due to the extent of our product offering we can never show all of our models, whatever size of stand we have”, said Combilift MD Martin McVicar. “But the exhibits give a good overview of the possible and varied applications. We are continually adding to our range and we look forward to showing visitors what’s new since the last Aluminium event.” •• Booth: 13N16 •• combilift.com

+353 47 80500

combilift.com

VISIT US @STAND 13N16

MATERIAL HANDLING SOLUTIONS FOR YOUR INDUSTRY Combilift is the leading supplier of customised handling solutions with guaranteed improved storage capacity, safer product handling and increased productivity.

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Newspaper

TOMRA to spotlight sensor-based sorting technologies at ALUMINIUM 2018 TOMRA Sorting Recycling will show how X-TRACT and LIBS technologies can help increase the worldwide supply of aluminium at the same time as enhancing sustainability TOMRA Sorting Recycling will showcase its sensor-based sorting technologies at Aluminium 2018, the world trade fair and conference, at Messe Düsseldorf, Germany, from 9th to 11th October. TOMRA’s exhibition stand will spotlight the company’s X-TRACT machine, which separates valuable materials from metal waste, and its stateof-the-art LIBS technology, which accurately sorts and separates different aluminium wrought alloys. Aluminium 2018 is expected to attract more than 27,000 visitors from 100 countries and will share latest insights into everything from aluminium production to processing, finished goods and recycling. TOMRA can be found on Hall 11, stand no. 11|54. The company’s technical experts will be available during all three days of the event to answer visitors’ questions. TOMRA’s participation at Aluminium 2018 highlights how the company provides technical solutions to two of the industry’s biggest challenges: with global production of aluminium pushed to an all-time high because of the increasing need for light metals for energy transition and transportation, recycling can help meet demand for the material; and with intensifying pressures for sustainability, recycling improves resource conservation. Frank van de Winkel, TOMRA Sorting Business Development Manager Metals, said: “High levels of aluminium production plus the high accuracy of modern alloy-sorting techniques

make it more and more worthwhile to unlock the value from secondary materials that would otherwise be lost. What’s more, re-using scrap metal is an environmentally-friendly practice which demonstrates the industry’s commitment to sustainability. For these reasons we’re looking forward to discussing our technologies at Aluminium 2018 with refiners and remelters.” TOMRA’s X-TRACT separates heavy metals from aluminium alloys with such high precision - irrespective of the materials’ size, moisture, or surface pollution level - that it achieves aluminium purities of 98-99%, even from a varied mix and with small grain sizes. This technology employs an electric X-ray tube so that broad-band radiation can penetrate the material to provide spectral absorption information. This data is then

measured with a highly sensitive X-ray camera to identify the atomic density of the material, regardless of its thickness. Material is sorted into high- and low-density fractions, with TOMRA’s DUOLINE® sensor technology using two independent sensor lines with different spectral sensitivities. TOMRA’s LIBS-based sensor sorting technology extends the options for the use of scrap- and secondary-aluminium. By employing a dynamic laser which can monitor the entire width of the belt, this has the unique advantage of eliminating the complex and costly need to separate materials into single lanes. This enables the sorting and separation of different aluminium wrought alloys with unprecedentedly high levels of efficiency, achieving sorting accuracies of 99% purity (or

greater) with high throughputs of three to seven tons per hour. Aluminium 2018 will also be an opportunity for recyclers, smelters and remelters to learn how TOMRA customises technical solutions to fit customer requirements. The combination of stateof-the-art technologies and personalised technical support explains why TOMRA has become one of the leading suppliers of sorting units in Europe, Asia and the USA. Over 60 TOMRA units have been sold worldwide for the separation of different scrap sources, such as taint tabor from (old) sheet scrap, extrusion profile scrap, used beverage-can scrap, and production scrap and new scrap from manufacturing waste. •• Booth: 11I54

THIS IS POTENTIAL WAITING TO HAPPEN. LET TOMRA’S X-TRACT HELP YOU FIND IT. DUAL PROCESSING TECHNOLOGY HIGHEST QUALITY OF SECONDARY MATERIAL IN METAL APPLICATIONS LARGEST INSTALLED BASED WORLDWIDE Contact us for more information: TOMRA Sorting GmbH · +49 2630 9652 0 · info@tomrasorting.com

www.aluminiumtoday.com

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Newspaper

Emmebi: The novelty of the habit “Two things condition us that are absolutely opposed the one to the other: Habit and novelty”. It is a maxim by French writer Jean de La Bruyère which, however, seems to suitably describe passion for industry at Emmebi, a company which has achieved international excellence in generating technologies for the finishing, packaging and handling of aluminium profiles. This is the ‘habit’ which, for over 50 years, has characterised the coherence of its totally ‘made-in-Italy’ professionalism. Every machinery, as a matter of fact, is the technological outcome of sophisticated Emmebi prototypes, devised to adapt to whatever production environment, besides being planned, produced and installed in an utterly personalised way, based on every single customer’s requirements in terms of space and function. Furthermore, over-

the-phone customer service and spare part provisioning guarantee continual plant monitoring and punctual intervention worldwide, whenever needed. The “novelty”, instead, comes with the words of evolution, both structural – with a 3,000 sq. metre extension of its production facility, to become operational by the end of the year -, and commercial, with the strategic increase of its foothold in the German, Australian and US markets, thanks to new, in-the-van installations, in prestigious companies such as Berlinbased AWB (basket warehouse and package warehouse), Ozzie Capral (extrusion plant automation) and Californian Sierra Aluminium (a complete system for automating two extrusion presses).

Specifically, the American supply includes a fully automatic system of stackers with scrap lines, a basket handling system designed to move baskets from ageing ovens by means of conveyors and of an automatic crane, a bridge crane for an extrusion basket warehouse to optimise stoking, production and packing or for stacking larger quantities of rack units, taken from multiple entry points. And, also, a de-stacker to remove profiles from the extrusion basket and to then feed the packing line, packing lines to form master bundles, wrapped with stretch film, with automatic wood insertion, a bridge crane to close the basket loop and move empty baskets back to the stacking area. Emmebi’s propensity for automation

had already materialised in 2016 when the revolutionary ‘WeStore’ system was started up, devised together with OMAV, a leading firm in the field of industrial plant building. The solution placed on the market has allowed for the complete supply of automated warehouses, inclusive not only of product range completeness, but even of full production process optimisation: From extrusion presses to packing, while perfecting their handling and operational logistics. Another novelty, in line with the company’s evolutionary prospects, consists in Emmebi being able to automate a complete extrusion plant with bridge cranes for basket conveyance, basket equipment, oven loading and unloading, de-stacking equipment, packing and warehouse for baskets, dies, packages and profiles. ‘Novelties’ for certain, but that over the years have become a ‘habit’, since evolution has always been carefully studied albeit kept steady, in line with the firm’s original corporate spirit, «the one that puts human relations first with respect to managerial administration – explains Commercial Director Elena Mauro – namely preserving a ‘family’ size and keeping growth both within reasonable and progressive terms, thus enabling us to manage work without enduring the emotional impact of our markets. It seems that the words of another French author are being echoed, those of Raymond Radiguet, when he stated that ‘it is not in novelty but in habit that we find our greatest pleasures’. That pleasure which at Emmebi is called – and rightly so– being proud of one’s own story, product quality, and of the worth of one’s work. •• Booth: 14E10

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FULL RANGE EQUIPMENT FOR EXTRUSION PLANTS

Fully automatic systems for extrusion plants to handle flows of material, from the ageing oven to the storage area, including Stacker/De-Stacker, Basket Handling Systems, Packing Lines and Automatic Storage Systems with the newly-born company named WeStore.

M A D E I N I T A LY

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www.emmebi.net

Automatic Storage Systems owned by Emmebi and Omav

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INNOVAL TECHNOLOGY THE UNIQUE DANIELI RESOURCE FOR ALUMINIUM PROCESS & PRODUCT KNOW-HOW

Innoval Technology: high-quality consultancy and technical support to investors, manufacturers and end-users of aluminium rolled, extruded and cast products. A UK-based multidisciplinary team to optimize your processes and improve your products.

> > > > >

Process improvement Materials development Product and process training Strategic support Best practice

Innoval Technology 15 successful years of industry support THE ONLY ROLLING COURSE DEDICATED TO ALUMINIUM

OVER 90 MILL COOLING SYSTEMS OPTIMISED WORLDWIDE

FASTER PROCESS OPTIMISATION: ROLLING PROCESS TOOLKIT

REDUCING THE RISK: USING INDUSTRY EXPERTISE IN PLANT DESIGN

This unique training course has been running successfully for more than ten years with delegates from over 70 companies worldwide.

Superior mill cooling and coolant control leading to improved profile and flatness of rolled sheet.

A suite of mathematical models make it possible to 'see inside' a working process and obtain parameters which are physically impossible to measure.

Involving a technical team with world-class industry expertise means a new plant has the best possible start.

INNOVAL TECHNOLOGY 'Aluminium Process & Materials Expertise, Product & Process Training'

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Danieli Headquarters 33042 Buttrio (Udine) Italy Tel (39) 0432.1958111

1914 / 2014 DANIELI CENTURY

DANIELI THE RELIABLE INNOVATIVE PARTNER TO BE FRONT RUNNERS

www.danieli.com

30/08/2018 12:00:06

INNOVAL TECHNOLOGY THE UNIQUE DANIELI RESOURCE FOR ALUMINIUM PROCESS & PRODUCT KNOW-HOW

> > > > >

Process improvement Materials development Product and process training Strategic support Best practice

Innoval Technology 15 successful years of industry support THE ONLY ROLLING COURSE DEDICATED TO ALUMINIUM

OVER 90 MILL COOLING SYSTEMS OPTIMISED WORLDWIDE

FASTER PROCESS OPTIMISATION: ROLLING PROCESS TOOLKIT

REDUCING THE RISK: USING INDUSTRY EXPERTISE IN PLANT DESIGN

This unique training course has been running successfully for more than ten years with delegates from over 70 companies worldwide.

Superior mill cooling and coolant control leading to improved profile and flatness of rolled sheet.

A suite of mathematical models make it possible to 'see inside' a working process and obtain parameters which are physically impossible to measure.

Involving a technical team with world-class industry expertise means a new plant has the best possible start.

INNOVAL TECHNOLOGY 'Aluminium Process & Materials Expertise, Product & Process Training'

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Danieli Headquarters 33042 Buttrio (Udine) Italy Tel (39) 0432.1958111

1914 / 2014 DANIELI CENTURY

DANIELI THE RELIABLE INNOVATIVE PARTNER TO BE FRONT RUNNERS

www.danieli.com

30/08/2018 12:00:06

Newspaper

GHI supplies turnkey plants for aluminium recycling The Global Aluminium Scrap Recycling Market is rapidly growing, and most researches point out to the continuity of this trend. Due to the requests for equipment of a different kind that GHI has been recently receiving, the company has used its broad experience to develop complete plants for the aluminum recycling industry, always aiming to help their customers finding out the best solution for them. GHI provides tailor-made, flexible, ecofriendly and scalable turnkey plants. The equipment supplied includes the state-ofthe-art technology, which means a high degree of automation to increase productivity and security in the plant and a system to manage the manufacturing process enabling the control and the continuous improvement. Furthermore, a corrective, predictive and preventive maintenance is achieved thanks to the 4.0 technology. The usual scrap aluminium recycling plant includes, but is not limited to, the following equipment: 1 Tilting Rotary Furnace: It recovers aluminium from low-grade scrap and produces significant lower contaminant waste than traditional models. Its geometry eases the emptying and dross cleaning. Furthermore, the salt slag can be recovered by means of subsequent melting process in this furnace. GHI has built furnaces of this type with a capacity up to 65 tons of liquid aluminium.

As auxiliary equipment, skimming machines, scrap loaders and fume collection systems can be provided. 1 Cooler System: Recycling companies can improve their recovery rate by rapidly cooling the salt slag produced by the Tilting Rotary Furnace in the Cooling System. This technology allows to cool up to 12.000 kg per hour. 1 VORTEX Melting Furnace: GHI has designed a specific furnace to allow recycling companies to get the most aluminum out of melt fine-grade scrap, such as chips or UBC. It includes an agitation system that can be either electromechanical or electromagnetic. This system generates a vortex in which the load is poured. The capacity of these furnaces goes up to 100 tons. 1 Decoating and drying system: The metal losses from the fine-grade scrap melting process can be reduced by removing both organic and inorganic contaminants prior to introducing the scrap into the melting furnace. This can be achieved by a decoating and drying system. 1 Reverberatory Holding Furnace: The molten aluminium is held and alloyed in these furnaces. Its shape and its open front allow access to the entire chamber easing the skimming process. Moreover, recycling companies can improve the quality of the aluminium by means of the porous plugs fitted in these furnaces that homogenise

the composition and the temperature of the metal. They may include a weighing system, molten aluminium bath level control, among other features. 1 Ingot casting machine: It allows to produce aluminum ingots in a fast and continuous way, guaranteeing that all ingots are uniform in quality, weight and dimensions. 1 Transport ladles: To avoid the energy consumption and metal losses resulted from re-melting ingots, GHI provides transport ladles for molten aluminium. These ladles allow the molten metal to be delivered to plants located several hundred kilometers away from the recycling plant. GHI conceives its equipment from the design phase for its integration with the 4.0 technology. This technology goes beyond simply analysing data and variables, it uses the data to turn it into improvements for the clients which result in benefit for them in terms of productivity, safety and energy

consumption. An example of this technology is the first “Smart Plant” installed by GHI in Europe. This plant collects and sends over 2.000 variables per second that are analysed by the 4.0. Engineering team. Furthermore, the continuous development of intelligent algorithms by the company, leads furnaces to become self-correcting machines. GHI has 80 years of experience in design, engineering, manufacturing, procurement, supply, erection testing and commissioning of industrial furnaces. The first relevant furnaces for the aluminium Industry were manufactured in 1955 for the Spanish smelter of Alcan (Canada). From that date on, GHI has manufactured a high number of installations for meltingholding, thermal treatment and heating. Specifically, more than 8.000 installations globally from which more than 1.000 equipment are in the aluminium industry. •• Booth: 10F50

Excellence in Strip Processing Technologies Since 1955.

Quality meets Innovation.

Visit us in Düsseldorf October 9 – 11, 2018

Since 1955, our name has been synonymous with premium equipment and technical solutions which set benchmarks for the metallurgical industry with a focus on:

Stand 11C20

• Strip processing lines • Specialty processing equipment • Coil handling equipment • Modernisation of existing processing plants

BWG Bergwerk- und Walzwerk-Maschinenbau GmbH Mercatorstr. 74 –78 · 47051 Duisburg, Germany Phone: +49 203 99 29-0 · Fax: +49 203 99 29-400 E-Mail: info@bwg-online.de

Technology made in Germany. Since 1955.

www.bwg-online.de

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We combine solid engineering experience, know-how and innovative solutions for the benefit of our valued customers.

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Alusalt : Rapid payback salt slag reprocessing plant.

TARDIS Gen II Dross Presses: Most popular dross processing machines. Highest overall metal recoveries.

Tilting Rotary Furnaces (TRF): Multifuel, oxy-fuel, robust & reliable. ALTEK provides unrivalled process knowledge.

Onspec: Molten metal analysis, continuous feedback on melt chemistry.

Electromagnetic Furnace Stirrers: Bottom OR side mounted (see picture) air-cooled & best metal circulation.

Steel Alloy Castings: Ingot Sow Moulds, Dross pan sets & slag containers.

www.altek-al.co.uk T: +44 (0) 1246 38 37 3 (UK) T: +1 484-713-0070 (US) E: sales@altek-al.com

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Experience-led support to the automotive industry With many OEMs turning to lightweighting in order to reduce their CO2 emissions or incorporate battery technology into their vehicles, aluminium automotive sheet and extrusion suppliers are experiencing a huge increase in demand. Innoval Technology (Innoval) is ideally placed to help both OEMs and their suppliers make the move to aluminium. Innoval has decades of experience in the field of aluminium automotive sheet and extrusions, with the direct participation by Innoval Technology’s staff in the development and industrialisation of much of the automotive sheet and extrusion technology in use today. Their deep knowledge of rolling and extrusion, together with the understanding of end-user requirements, enables cost effective and innovative technology solutions throughout the entire supply chain. Innoval Technology, part of Danieli, provides high quality consultancy,

technical support and training to investors, manufacturers and end-users of aluminium across the broad range of industry sectors. At Aluminium 2018 Innoval will be taking bookings for their new Aluminium Automotive Sheet training course. It will take place on 6-8th November 2018 (2.5 days) at Innoval’s offices in Banbury, UK. Anyone interested in automotive applications of aluminium wrought products should consider enrolling on the course. The course is specifically designed for companies new to making or using aluminium automotive sheet. It will help the development of a thorough understanding of this important product from both a metallurgical and engineering process point of view. This will enable the understanding of the root cause of process and product problems, and will provide the essential knowledge to improve processes and to develop better product performance. The course, which has been developed

and will be delivered by technical specialists with expertise in automotive sheet, will cover the following topics: 1 Background to the use of aluminium in automotive applications 1 Equipment needs and supply chain considerations 1 Metallurgy basics and AA5000-series alloy properties and their control 1 Surface control and lubrication 1 Vehicle manufacture 1 AA6000-series alloy properties and their control 1 Surfaces and corrosion 1 Testing requirements and OEM qualification The Aluminium Automotive Sheet training course is suitable for Senior Managers and Technical Specialists and incorporates a visit to Jaguar Land Rover’s manufacturing facility at Castle Bromwich. The Aluminium Automotive Sheet training course is just one of the many

training courses provided by Innoval. Our most popular and successful course, the Aluminium Rolling Technology Course, has been running for over 14 years. During this time delegates from 74 different companies in 35 countries have attended the course. For the first time, due to increased demand, there will be two Spring rolling courses next year. These week long courses will take start on 25th February 2019 and 13th May 2019. Innoval will be co-exhibiting with parent company, Danieli, at Aluminium 2018. Registration forms for all the Innoval training courses will be available on the Danieli booth (13M12) at the show. If you have a process improvement or product development project you’d like to discuss with Innoval’s aluminium experts, please visit the Danieli booth where the Innoval team will be happy to meet you. •• innovaltec.com •• Booth: 13M12

FONTES REFRACTORIES: A key partner for aluminium smelters in the world FONTES REFRACTORIES is a company specialised in the manufacture of refractory products for industrial sectors, and particularly for the primary aluminium industry FONTES REFRACTORIES belongs to SGI group, located in Mons (Belgium). Since 30 years, SGI has been developing a refractory branch. This last one proposes to its clients a global offer with high grade products and services, thanks to the complementarity of all the subsidiaries. Located in Revel, a small town in the SouthWest of France, Fontes Refractories is the only french companies to produce Ordinary Refractory Bricks with High Quartz content : BRO HQB. Indeed, thanks to specific natural raw material extracted from its own quarries, Fontes’ BRO HQB bricks have very interesting physicochemical properties, such as an intrinsic resistance to corrosion by cryolite and liquid aluminium. Thanks to these specific characteristics, Fontes’ BRO HQB bricks are high-end products for electrolysis cells linings in primary

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aluminium sector. The company's origins stretch back to 1810. The company was family-owned company, specialised in the production of heavy clay products for construction. Many quarries in the surroundings villages successively supplied raw materials to the production plant. This business lasted right through to the late 1950s. In 1960, during researches to find a new quarry, significant raw silico-alumina deposits have been discovered in Vaudreuille. Then, the company started to specialise in the manufacture of refractory products intended for various industries and the housing sector. In only few years, Fontes Refractories products showed their really good qualities in electrolysis cells linings from Aluminium Pechiney (AP) technology. Fontes Refractories’ BRO HQB Bricks have received AP accreditation for 25 years, but they are also renowned in multiple technologies used worldwide. That’s why FONTES REFRACTORIES products were used in

numerous smelter constructions projects around the world, such as Aluminium Dunkerque in 1983, Aluminio Argentino in 1998, Aluminium Bahrain in 2003, or more recently, Ma’aden in 2011-2012. Since the construction of these smelters, Fontes Refractories has supplied BRO HQB bricks fro maintenance of the facilities. Obviously, since the 60’s, FONTES REFRACTORIES became a key partner for its customers.This strong partnership is based on company’s strong value proposition based on quality and availability of the products, large range of available sizes and respect of delivery times but also on a high level of service like reactivity in case of short delay, and dedicated commercial staff. In seeking to provide the best possible products to meet the most stringent specifications, FONTES REFRACTORIES has developed an embedded computerised quality control system from quarried raw materials through to the finished product. The quality control systems at each stage in the manufacturing process provide a

guarantee of the level of quality required by its customers. All manufacturing and quality datas are computerised directly on the production line in order to provide customers with full traceability of their products. Thanks to all this manufacturing and quality controls, and with a production capacity of 16,000 tonnes per year, Fontes Refractories is able to supply electrolysis lining bricks for new plants, as well as regular and ad hoc maintenance of refractory lining in existing facilities. Currently, the company is working on many research and development projects, such as new qualities of BRO with higher alumina contents, larger bricks size to meet new challenges smelters are asking for: longer lifetime of pots, higher voltage, faster maintenance and liningconstruction… With all this improvements, Fontes Refractories will remain a long-term partner for smelter all around the world for many years. •• Booth: 11I40

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Foil slitting and separating with documented quality

Eddisons Cases_AIT FP 17/08/2018 14:56 Page 1

E: sales@eddisonscjm.com T: +44(0)1724 334411 W: www.eddisonscjm.com

Used Equipment For Sale?

Eddisons CJM are specialists in the Valuation and Sale of used Aluminium Processing Equipment n

Casters, Rolling Mills, Extrusion Presses, Slitters, Cut to Length Lines, Coil Coating & Painting Lines

Qualified Professional Valuers and Experts in the Global Marketplace n Competitive Fees n We can sell your used equipment

For a free confidential initial discussion without obligation, contact Charles Moses FRICS T: +44 (0)1724 334411 M: +44 (0)7831 854971 E: charles.moses@eddisonscjm.com Instructed by a Retained Client, France

High Quality Powder Coating Line For Aluminium/Steel Coil

n Approx 10,000 tonnes per annum output on Aluminium Coils n 2 Powder Coating Cabins for Rapid Colour Change n Max Width 1550mm n Thickness 0.8mm – 2.0mm n Coil Weight: 10 tonnes n Speed: 7.5m/min n Also suitable for cold rolled and Galvanised Steel Strip n Footprint: Approx 80m x 15m x 6m high Available Mid 2018 Fully operational & can be seen working

Location: Saint-Chamond, near Lyon, France Viewing: By appointment with Eddisons CJM

Eddisons CJM, Dunlop Way, Scunthorpe, DN16 3RN, UK

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Instructed by Pracal Srl, Italy

2014 Continuous Coil Coating Line For Aluminium Strip n n n n n n n n

Plain colours and decorative (eg wood grain) finishes Strip Width: 600 – 1320mm Strip Thickness: 0.20 – 0.70mm Coil Weight: 9 tonnes Line Speed: 15-40m/min Paint Types: Epoxy, Polyester, Pvdf and other paints with a PMT of 232 – 260ºc Installed Electrical Power: 130kW Installed Thermal Power: 680,000 Kcal/hour

Can be seen working Early Inspection Recommended

Location: Pollo, Italy Viewing: By appointment with Eddisons CJM

Within the production of Aluminium foils for demanding applications, finishing processes such as doubling, slitting and separating of the foil are of utmost importance for the quality of the finished products. The processing of the most diverse web-shaped materials has been the key competence of Kampf Schneid- und Wickeltechnik GmbH & Co. KG for almost 100 years. Especially in the production of Aluminium foils and strips, the machines of KAMPF convince with solid mechanical engineering and best process control. Many hundreds of satisfied customers are the best references for this. Slitting accuracy, consistent excellent winding quality and reproducibility of product properties are most important factors for profitable foil production together with high productivity and sustainability in the production process. KAMPF’s Duplomat, Sepamat and Unial machines are therefore the first choice of market leaders in foil producers. Very sensitive, state-of-the-art control systems enable the processing of the thinnest foils even with difficult material specifications. An intuitive machine monitoring system for controlling the machines is available to the operator. The HMI offers not only the use of preset routines by means of an extensive recipe memory, but also the possibility of operating the machine individually and with adapted process parameters. Extensive reporting options serve to document the product history and are part of the basic configuration of every machine. KAMPF also offers its customers many optimised solutions in the machine environment. Already at an early stage, KAMPF took up the diverse customer requirements and realized the potential of automated and networked processes. The new “Automation” department develops individual automation concepts closely integrated with the machine design. The specialists are involved right from the start of the project. In this way, the customer receives high-quality machine automation systems that can also be integrated into an existing customer infrastructure. For example, adapted handling systems for loading and unloading the machines ensure a smooth production process alongside the machines. KAMPF has, at the same time as developing the automation solutions, dealt with the topics of digitisation and networking. As part of the “Converting 4.0” project, the@vanced, an integrative platform for networking machines and components was developed. Users are thus in a position to initiate improvement measures based on the evaluated realtime data and thus optimise the entire production. An example of a successful integration of KAMPF machines and high-end analysis systems is the combination of Sepamat machines with pinhole detector systems from E.D.S., srl. Here, the wishes of the end customers are implemented in an exemplary manner. On the one hand, the film manufacturer can document the quality of the produced foils for the end customer in full. On the other hand, the operator receives detailed information about the winded foils in real time. The system detects and locates holes smaller than 10µm even at the highest machine speed. A special software analyses the data and supports the operator in eliminating sources of pinholes in upstream processes. •• Booth: 13J40

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Mechatherm restructures with ‘Servitisation’ Philosophy Mechatherm have had great success supplying casthouse technology around the world during the last 25 years. Many of these projects have been major capital plant installations ranging from single furnace installations to complete casthouse process solutions. Mechatherm recent contracts include casthouse furnaces and ancillary equipment for the ALBA pot line expansion in Bahrain, melting and holding furnaces for Granges Americas in Tennessee USA, Tilting Rotary Melting Furnace for Kuusakoski in Finland & Holding Furnaces for Logan, Kentucky USA. During the recent industry downturn where many aluminium producers stopped all major investment in new capital plant projects. Many companies struggled to maintain growth and in many situations companies had to make significant cutback to staff, budgets and investment. Mechatherm were no different to this and it was a case of survival. During this downturn Mechatherm undertook a management leadership training program and as part of this we adopted and integrated the ‘Servitisation’ working model throughout the company. The overall goal for this was to offer a FirstClass service to our customers and engage the entire business in this process. We united the service department

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and sales department to work as a single team working together with our strategic customers to offer a complete service package. Our engineering teams have become client focused working closely with the account manager to manage the customer relationship. We have seen major improvements operating in the manner on recent contracts. The levels of Servitisation include the traditional Product Provision, Aftersales and Advanced Services. The aftersales servicing, spares, repairs and condition monitoring has provided an ongoing revenue source that will be critical during future industry downturns. The advance services are still being developed and are being based on performance of our equipment and are very much customercentric and relationship focused. A Customer Relationship Management system has been fully implemented to manage and analyse customer interactions and data throughout the customer lifecycle, with the goal of improving customer service relationships and assisting in customer retention and driving sales growth. Feedback from our customers is taken very seriously and is key to measure our performance as a service provider. Integrating Account Managers and customer satisfaction surveys will improve this overtime.

Mechatherm have recently opened a branch office in Dubai to help in the servicing of the many furnace installations we have completed in the Gulf region. This shows our commitment to many customers in this area to give them the best and most efficient local service. We will also be considering opening other branch offices in our key market global areas over the forthcoming years. The capital Sales team is managed by Stuart Allen and the Service team is managed by Mark Allen.

Stuart Allen, Director of Sales commented “The future is looking very bright for Mechatherm and we have recently recruited many new staff as the company looks to continue its growth over the next few years. Our current projections are very encouraging for the next two years that will see us at £30 million turnover giving us continued profitable sales growth. We are continually developing and innovating new furnace concepts and the capital sales team focus is very much on the recycling of aluminium.” •• Booth: 10H12

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For the perfect production of aluminium cuts: The horizontal saw from Mössner When it comes to processing aluminium, the topics are always: speed, precision and minimizing material loss. Given that, as a sawing expert and manufacturer of specifically high-performance special machines, in which bandsaws and robots are applied, Mössner has started concentrating on these topics from early on and has developed excellent solutions. The special machines for the processing of aluminium bars to produce aluminium cuts with maximum precision and extraordinary performance are in operation worldwide. With the Mössner horizontal saw it is possible to cut up to 6000 cm2/min aluminium, depending on saw band and alloy. The machine is versatile and efficient and is able to produce plates from aluminium slabs in various sizes. In combination with a vertical saw, cubes and cuboids are also no problem. When it comes to workpiece sizes there are hardly any restrictions. Mössner customises the machine depending on customer’s workpiece size. Due to the modular construction of the tables, they can easily be adapted to slabs of different sizes. The Mössner horizontal saw is available in two different versions. The bandsaw is equipped with a firmly installed feed table and the saw moves on the traveling axis. Due to a special clamping concept, the bottom plate can be cut from the raw slab at first - a procedure only Mössner offers in this way. The result of this process is even less waste and more output. The other variant is equipped with a firmly installed bandsaw and the feed table moves

on the travelling axis. The slab is placed on the feed table, the saw is automatically set to the programmed height. The feed table moves through the saw according to adjusted feed rate, depending on slab width. This version is particularly suited for the mass production of aluminium plates, and in combination with a milling machine, for the production of plates with mirror milling of surface and foliation. An additional automated transport of plates, enables easy removal of plates from sawing machine via crane and vacuum lifters and automated transport to the milling machine. The sawing machine is a further result of the close collaboration between Mössner and customers. Many years of experience and extensive know how in constructing special machines are supported by targeted investments in research and development. A year ago, a new and highly modern assembly hall of 2.100 square meters was put into operation at Mössner. In the new hall for the assembly of large machines, additional 440 square meters office space was integrated on two floors, for the research & development department - key word industry 4.0 – and for further conference rooms. The new multifunction sawing system and the new hall are two examples and an expression of Mössner’s innovative strength. Growing orders and high customer satisfaction are the result. •• moessner-kg.de •• Booth: 9G10

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The horizontal saw offers new perspectives for the perfect production of aluminium cuts.

The Mösser multifunctional sawing system is a combination of a horizontal and vertical sawing centre. It enables the sawing of aluminium slabs without having to turn the material. Due to the special clamping situation, it is possible to operate in a very narrow tolerance band. This innovative clamping system enables the trimming of the bottom of the block first and the immediate transport of the cuts out of the system. By using the NC saw band rotation, it is

possible to cut 90° and slanted angles. The August Mössner GmbH + Co. KG develops and builds special machines with the focus on bandsaws and robots. Thereby, tasks in sawing, cutting, milling and testing are carried out precisely and highly efficient. The company operates as service provider with a technically high manufacturing expertise in customized products and solutions. Mössner is a globally operating medium-sized company.

With Air Products’ patented Transient Heating burner, you can achieve more even heating throughout your reverb furnace, eliminate cold zones, and maximize melt rates. How? It is the only smart burner technology in the world using a sensor-driven control strategy to direct energy down toward the melt; sequentially to all areas of your furnace. This innovative technology can help you realize: • Up to 40% increased productivity • Up to 40% improved fuel efficiency • Up to 20% higher metal yield Give us a call today to get even more out of your reverb furnace! +44 800 389 0202

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Aluminium and copper are still going strong in automotive manufacture For the development of the world’s aluminium industry, automotive manufacturing is pointing the way ahead today. While the use of aluminium car bodies used to be associated only with historic race cars for many years, a turnaround was perceived when Audi’s A8 with Space Frame entered series production in 1994. However, it took almost another 20 years before aluminium, with its unsurpassed lightweight design properties, prevailed in volume manufacturing over steel and other lightweighting materials such as plastics and carbon fibre. Although of course, it needs to be recognised here that no material simply replaces another – the key to success lies in the optimum choice and combination of materials, tailored to a given application. The optimum performance of metallic materials is obtained by appropriate heat treatment. In the evolution of new aluminium alloys and associated thermal processing methods including technologies for recycling, we are now witnessing a dynamism that would hardly have been expected 20 or 30 years ago. This is where OTTO JUNKER, with over 90 years’ experience in furnace manufacture, proves a competent partner to the semifinished products industry, tiered suppliers, and automotive manufacturers. While the company covers virtually the full range of metals with its induction melting systems, its thermoprocessing equipment focuses entirely on the heat treatment of aluminium and copper. This includes, e.g., solutions for the production of extruded aluminium profiles for crash management systems, which involves the heating of aluminium billets in a JunkerDynamicHeater® system (JuDy). Also in the portfolio are heat treatment and ageing furnaces for alloy wheels, brake callipers and other discrete items. In this context, the walking-beam conveyor system has established itself due to its significant advantages (e.g., energy efficiency, protection of the material) over other conveyor concepts (e.g., roller hearths). The most vigorous uptrend in recent years is apparent in the field of strip flotation furnaces for aluminium auto body sheet (ABS). Consistent with market growth, OTTO JUNKER has dedicated a substantial portion of its research and development activities to the strip flotation furnace with adjoining

Strip flotation furnace system embodying OTTO JUNKER’s cooling strategy (HiPreQ®)

quench. The company has been able to build on its extensive experience with aircraftgrade aluminium here. Apart from their sheer impressive length – which in the case of a strip flotation furnace may attain as much as 100 m – these lines embody a vast know-how. Particularly in the field of cooling technology, OTTO JUNKER has set new standards with its HiPreQ® mist quench for the ABS grades used in automotive production. This was achievable thanks to the company’s own Technology Centre at its Simmerath headquarters site, which is equipped with advanced pilot equipment. In North America alone, demand for ABS is forecast to grow from 300,000 t in 2015 to over one million t in 2020. An essential factor explaining the brisk demand for, and high acceptance of, aluminium is the material’s recyclability and the fact that the energy input needed in recycling is substantially lower than that required for smelting the primary metal. It takes about 15,700 kWh of electric power to produce one tonne of primary aluminium.

With this amount of energy, an electric car consuming just over 15 kWh/100 km on average, such as BMW’s i3 model, could travel more than 100,000 km. Recycling aluminium, however, requires only 5% of the energy demand that goes into its primary production, so the material here sheds some of the negative image it owes to its environmental performance in smelting. Accordingly, for this recycling application OTTO JUNKER offers suitable gas-heated melting furnaces capable of holding up to 120 tonnes. On recycling lines designed specifically for beverage cans, which are preceded by paint stripping equipment, the pyrolysis gases emitted are used for heating the entire process. The paint-stripping step is designed to minimise the loss of material by burn-off, thus ensuring a maximum recycling yield. Along with aluminium, copper is an important material to the automotive engineer. As the demand for electrical components rises and vehicles increasingly go electric,

the need for plug connectors, lead-frames, etc., is growing as well. But while copper is used in its uncoated state in electronics, it is becoming increasingly important in automotive production that copper should be coated to limit the impact of environmental factors. With its hot-dip tinning line for copper strip, OTTO JUNKER offers a solution to this requirement for the automotive industry and its suppliers. Intensive efforts are also being made at the level of digitalisation as part of the commitment to advance heat treatment technology to an “Industry 4.0” standard. A first mobile application providing broad functions – from materials tracking, quality systems and process monitoring through to plant operation and maintenance – was recently launched by OTTO JUNKER. As for artificial intelligence, its use will still require major development steps, to be sure. But initial progress has been made here as well. In closing, it can be stated that new solutions and applications relying on aluminium and copper materials continue to enjoy brisk demand. Ample testimony of this will be in evidence at the ALUMINIUM trade fair in Düsseldorf. Be there – and see for yourself! •• www.otto-junker.com •• Booth: 10E42

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Pyrotek’s insulated tabletop refractory helps reduce heat loss Pyrotek’s base-insulated tabletop refractory for vertical direct chill (VDC) billet casting reduces heat loss and maintains dimensional stability throughout casting tables. “This is a robust solution for VDC billet casting customers,” says Jonathan Klesch, a global product manager for Pyrotek. “We use an innovative refractory and integrate an insulation layer to provide long service life while reducing heat loss across the table.” With this new technology, a micro-porous board is added to the base of refractory shapes, improving the thermal performance. Casthouses can potentially lower furnace temperatures by reducing the temperature gradient across the length of the table. Klesch says one of Pyrotek’s core competencies is manufacturing refractory shapes. It produces components for major casting equipment manufacturers and those who rebuild VDC billet casting tables. “We are constantly in search of improving performance and embarked on this product development project to reduce heat loss in billet casting tables without compromising the integrity of the assembly,” he says. Pyrotek’s refractory is a thermally shockresistant material that is nonwetting to molten aluminium. When compared with a traditional fused silica refractory, the density is lower and strength is higher. This improves both thermal performance and fracture resistance. Field testing has demonstrated a 25 percent reduction in tabletop metal structure temperatures compared to another product on the market. This translates to an estimated 8 percent reduction of heat loss using the base-

insulated design. Trial testing also revealed that a competitor’s product was two-and-a-half times more likely to crack after 600 casts. The smooth surface created by a unique surface treatment system minimizes mechanical attachment of skull and improves wear and erosion resistance. It also had 11 percent lower thermal expansion, reducing stress that developed in the mastic joints between components and led to less maintenance during tests. Pyrotek makes a variety of precast components used to distribute molten metal to mould positions in VDC billet casting tables. These components are pre-fired and ready to use. Along with base-insulated tabletop refractory, Pyrotek offers monolithic and shellinsulated tabletop refractory. Pyrotek offers all products needed to operate and maintain VDC billet casting tables, including thimbles, transition plates, mastics, gaskets and seals, flow-control products, coatings and lubricants and casting accessories. •• www.pyrotek.com •• Booth: 11E30

STAS acquires technologies from o.d.t. Engineering For another year, STAS will be present at Aluminium 2018 in Düsseldorf, Germany, the largest show of its kind in world of aluminium. A team of experts will be present at booth 10D50 to promote some its most recent product developments and exchange with the global aluminum community on the current and future trends of the industry. 2018 is an important year for the Canadian company. Among other important achievements such as the commissioning of dozens of equipment units for the line 6 at Alba (Bahrain), STAS recently (April 2018) formalised the acquisition of technologies from the Australian company o.d.t. Engineering specialised in the design and supply of casting and material handling equipment and production consumables for aluminum and magnesium cast houses. The company enjoys an enviable reputation for design innovation, efficiency and quality fabrication and is, like STAS, a family-owned company. The sale and transfer of the purchased assets include the capacity, without limitation, to operate the business exclusively worldwide and brand the name o.d.t. Engineering, with the exception of repair and spare parts. Assets purchased include several technologies such as ingot casting and stacking lines (ICS) for aluminium and magnesium (ingot weight range between 6-25kg), sow casting and stacking lines (SCS), as well as complementary products such as cast-iron wheels, moulds, plans, designs, drawings and any Intellectual Property rights pertaining to all previous items. STAS is now engaged in the marketing, sales and fabrication of new equipment related to the acquired technology as well as any equipment upgrades with the support of key o.d.t. personnel. With this strategic move, STAS further establishes its position as a world-class, full-stack supplier of innovative equipment for the aluminum sector and paves the way for new business opportunities to come. ‘’What we want is to be able to offer integrated, robust and agile solutions to global producers from the potroom to the end of the casting line, and thus respond to the demand from many customers to be a ‘one-stop shop’ and simplify operations and service’’, explains Louis Bouchard, Executive President at STAS, who took over his new role last year after 15 years with the company. Since the late 1980’s, STAS’s mission is to partner with

its customers from the aluminium industry to help them achieve their production goals with various equipment and solutions for the cast house as well for the electrolysis, carbon and crucible shop areas. ‘’With o.d.t. technologies now listed in our global product catalogue, our company vision to become an inevitable supplier for anyone involved in the aluminum production chain is now more real than ever before’, says Bouchard. ‘’For our employees and collaborators, this is a natural extension to what we can already design, produce and deliver as aluminium professionals. We see many opportunities and we will work hard to integrate the two organizations into one successful, integrated business model’’. With a global team of + 180 employees – including more than 60 new employees who joined over the last year - and a vast network of agents and partners located around the globe in strategic locations -, STAS is clearly giving itself a boost with this acquisition and has big plans for the future. New technologies such as the Billet Surface Inspection system (BSI 3D) and the Pot Ramming Machine, both in-line with the latest 4.0 industry standards, have already experienced commercial successes and can compete with any other similar technologies in their respective product line. To ensure future growth and to be ready for the future, the company’s Technology & Innovation team is also partnering with different producers to develop tools and solutions to bring the industry to the next level i.e. through automated, smart and connected machines applying the same guiding principles that led to company to where it is today: innovation, simplicity of design, quality and a focus on the long term benefits and the added value that technology can bring to the production of aluminum. STAS has been providing engineering innovations for nearly 30 years with superior product quality and leading-edge technology. Their team of experts and international agents are dedicated to providing best-inclass customer solutions for the aluminium industry and will continue to enhance and expand their products with the passion and dedication their customers have come to expect. •• stas.com •• odt.com.au •• Booth: 10D50

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The State of the U.S. Aluminium Industry The Aluminum Association is working closely with its membership to advance the interests of the domestic aluminium industry during a time of opportunity and uncertainty. The association is also working with our government and global counterparts to ensure that complex, globally integrated supply chains are not needlessly disrupted while we address the very real challenge of Chinese aluminium overcapacity. From global trade to automotive issues, the industry continues to pursue its mission through the association promoting the production and use of aluminium as the sustainable material of choice. Global trade remains a top priority for President Donald Trump and his administration nearly halfway through his presidency. The president has for decades believed in using aggressive action to achieve better trade deals for American workers. And the U.S. aluminium industry has been a particular focus of this approach, most notably with the Section 232 tariffs on most aluminium imports entering the US. Earlier this year, the industry successfully pursued antidumping and countervailing duty action against illegally subsidized aluminium foil coming from China. A similar effort on common alloy imports from China is underway. Meanwhile, the Trump administration is working to renegotiate the North American Free Trade Agreement (NAFTA) with Canada and Mexico and is pursuing tariffs on a range of imports coming from China. The president’s various trade actions over the last year have sparked some concern of an escalating “trade war” that could have unintended consequences. For the aluminium industry, the administration’s across-the-board Section 232 tariffs have caused market uncertainty and disrupted vital, integrated supply chains like the North American aluminium market. The Aluminum Association appreciates and shares this administration’s desire to strengthen the U.S. manufacturing base. However, we continue to advocate for targeted trade enforcement and a move toward government-to-government negotiations on Chinese overcapacity. On the non-trade front, the industry continues its work through the association’s Aluminum Transportation Group (ATG) to promote aluminium as a key material for carmakers to meet customer and regulatory demands for increased safety, performance and fuel economy. We also continue to grow our advocacy footprint by building our Political Action Committee.

Time for Action on Chinese Overcapacity

Nearly a year after he launched Section 232 national security investigations on imported steel and aluminium, President Trump announced a 25 percent tariff on most steel and a 10 percent tariff on most aluminium entering the United States. As of August 2018, every country – except for Argentina and Australia – is subject to the 10 percent aluminium tariff. Key trading partners like the European Union, Canada and Mexico were granted temporary exemptions while officials met to hammer out a deal. However, the Trump administration allowed those temporary exemptions to expire on June 1. The Aluminum Association believes across-the-board tariffs do not address the fundamental problem of massive aluminium overcapacity in China. The domestic aluminium industry is growing, but subsidized production in China, which is leading to unfair and illegal trade practices, threatens the industry’s continued health. As the leading voice for the U.S. industry, the Aluminum Association continues to call for permanent, quota-free tariff exemptions for all countries designated as market economies and for a move toward immediate government-to-government negotiations with China to address the trade-distorting practices that drive structural aluminium overcapacity. To this end, the U.S., European, Canadian, Japanese, Brazilian and Mexican aluminium associations penned a letter to G20 leaders to reiterate the call for a global forum on aluminium overcapacity. And in advance of the G7 meeting in Montreal this summer, the U.S., Canadian, European and Japanese associations met to discuss the overcapacity challenge and create a working “plan of action” for a sustainable industry. With so much focus on international trade and a consensus that Chinese aluminium overcapacity is distorting the global market, now is the time for targeted action and an even stronger commitment from the G7 and the G20. Learn more about what the association is doing at www.aluminum.org/timeforaction.

A Win for Rules-Based Trade

While the Section 232 discussion dominated most of the trade news on aluminium, the association’s Trade Enforcement

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Working Group was wrapping up its antidumping and countervailing duty (AD/CVD) case on aluminium foil from China. The AD/CVD case was the association’s first trade case of its kind and concluded with a unanimous finding from the U.S. International Trade Commission (ITC) that subsidized production of aluminium foil in China was harming domestic foil producers. As a result, the Commerce Department issued unfair trade orders on aluminium foil imports from China imposing antidumping duties ranging from 49 to 106 percent and countervailing duties ranging from 17 to 81 percent. Aluminium foil production in the United States supports more than 20,000 jobs and $6.8 billion in economic activity. However, artificially low-priced aluminium foil from China has flooded the market in recent years and caused companies to cut back production and close U.S. factories. The ITC’s decision has led to reinvestment and new growth in the domestic foil sector. Since preliminary subsidy margins were announced last July, imports of Chinese aluminium foil into the United States have dropped more than five-fold. We have also seen investments in foil production from member companies like JW Aluminium and Granges. The Aluminium Association believes in strong trade enforcement and that targeted actions like these can have a great effect on markets that are being unfairly impacted by illegally subsidized production. The Commerce Department’s targeted action to level the playing field was a big win for U.S. aluminium foil producers and rules-based trade. However, the situation in the foil market is symptomatic of the larger issue of Chinese aluminium overcapacity. Toward the end of 2017, the Commerce Department self-initiated an AD/CVD investigation on imports of common alloy sheet from China. The agency again found imports from China are being sold at less than fair value (or “dumped”) in the United States and announced preliminary antidumping duties of 91 percent on imports of common alloy aluminium sheet from China as well as preliminary subsidy margins that range from 31 to 113 percent. The Commerce Department is slated to make a final decision in the case later this year. Both the aluminium foil case and common alloy sheet case underscore the Commerce Department’s commitment to combatting unfair trade and creating a level playing field for domestic aluminium producers. This strategic trade enforcement is what the industry needs to remain competitive and healthy.

Auto Drives Aluminium Demand

It may be a multi-material world, but aluminium is the rising material of choice for automakers -- offering the fastest, safest, most environmentally friendly and cost-effective way to boost fuel economy and cut total carbon emissions. Reducing vehicle weight—without reducing vehicle size or compromising safety — will be vital as automakers develop next generation cars and trucks. And automotive aluminium continues to be a big driver for domestic industry growth, with member companies investing more than $2.6 billion since 2013 to help meet demand. Following a midterm review, the Environmental Protection Agency (EPA) and the National Highway Transportation Safety Administration (NHTSA) in August released a final Notice of Proposed Rulemaking (NPRM) on vehicle fuel economy standards. The Safer and Affordable Fuel Efficient Vehicles Proposed Rule for Model Years 2021-2026 suggests eight possible scenarios ranging from a “preferred option” of freezing current standards at 2020 levels through 2026 to increasing standards by between two and three percent during that time period. The NPRM also challenges whether the state of California should maintain its waiver authority under the Clean Air Act to regulate air pollution more aggressively than the rest of the country – making litigation between the state of California and the federal government on this issue likely. Even the administration’s “preferred option” of flat lining the standards still envisions a 4.3 percent mass reduction of the fleet by 2025 (compared to 5.7 percent in the more aggressive

Obama-era standards). Much of this mass reduction will require the increased use of aluminium to achieve. The association supports fuel economy standards that continue to increase year-over-year, a negotiated outcome between California and the federal government maintaining one national program for fuel standards, and continued regulatory certainty to encourage continued investment by automakers and suppliers in the United States. Throughout the process, we have emphasized that reducing vehicle mass with more aluminium is one of the top strategies for automakers to safely and affordably drive fuel economy improvements.

Advancing Aluminium

Despite continued global trading challenges, the U.S. industry has an opportunity to play a larger role in the nation’s manufacturing growth. In April, the association released a new economic impact study that shows increased direct aluminium jobs over the past several years – more than 162,000 workers across the country. And preliminary data shows aluminium demand in North America totalled 27.2 billion pounds in 2017 – the eighth year of consecutive demand growth and a record since tracking began in the 1960s. To help meet this record demand, association member companies have committed or completed more than $2.6 billion in U.S. plant expansions since 2013. Moreover, this investment will create more than 2,000 permanent American manufacturing jobs and strengthen the industry’s overall competitiveness. Our members are investing not only in facilities to meet current and projected demand, but also in innovative technologies to keep North American aluminium competitive. Most recently, member companies Alcoa and Rio Tinto announced a new joint venture – Elysis -- to create carbonfree aluminium. This revolutionary process produces oxygen and replaces all direct greenhouse gas emissions from the traditional smelting process. Alcoa, Rio Tinto, the Governments of Canada and Quebec, and Apple have invested a combined $144 million in research and development on this technology and plan to distribute it in 2024. The North American aluminium industry has made significant strides in recent years to limit the environmental impact of producing aluminium, and Elysis is the latest example of how innovative technology can drive future sustainability gains.

In other news

In 2013, a bipartisan group in the United States Congress formed the Congressional Aluminum Caucus. The caucus serves as a forum to raise awareness of the U.S. aluminium industry and every aspect of the metal’s production and use – from mining to manufacture to recycling. As it adds new members, the caucus remains an invaluable resource for the industry both inside and outside the Beltway -- sending letters on key issues, hosting briefings for members, and amplifying industry messages on Capitol Hill. With global trade high on the White House’s priorities list, the caucus has been able to voice concerns and raise questions on behalf of the industry to key government officials. Meanwhile, the Aluminum Association has worked to update some of the publications in its bookstore, including our “Rainbow Sheets” for the latest in alloy and temper designations as well as the latest Aluminum Statistical Review. In response to the Section 232 tariffs, the association developed a special report, the “U.S. Aluminum Import Monitor,” which provides members the most recently released U.S. import data specific to aluminium products covered under the Section 232 remedy. As the tariff process unfolds, the association is closely monitoring company requests for exemptions from both Section 232 and Section 301 (targeted at China) tariffs. As a membership benefit, the association maintains a document tracking the thousands of tariff exclusion requests for dozens of types of aluminium products. Association members have access to this tracking document. To cap off an eventful year, the association was recognized as one of the National Association of Manufacturers’ (NAM) Council of Manufacturing Associations’ (CMA) “10 Best Manufacturing Associations to Work For.” And we are looking forward to hosting out annual member meeting in Washington, D.C. on October 1-3. •• aluminum.org/join

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Innovation in the heat treatment of aluminium automotive components and monitoring challenges By Dieter Conrads (BSN Thermprozesstechnik GmbH) and Carola Konitzer (Phoenix™ GmbH) In the automotive industry, the trend towards lightweight construction continues and, with the increasing development of high-strength aluminum alloys, it is constantly finding new application areas. In engine technology, these materials have replaced steel in many places. The heat treatment equipment required for this purpose must meet the high standards of automotive production. Not only does low cycle times and high process reliability play a role here, but last but not least, the everincreasing demands on quality assurance and their seamless traceability must be integrated into ongoing processes. BSN Thermprozesstechnik based in Simmerath has broken new ground in the heat treatment of engine blocks, cylinder heads and similar components made of aluminum with the innovative concept of multi-level rotary hearth furnaces for solution annealing, quenching and subsequent artificial aging.

ThermalView Plus Software displaying the full process profile trace

Sketch of the Phoenix™ heat protection principles

Sketch of a rotary Furnace plant with quench bath

These rotary hearth furnaces allow, in contrast to other furnace concepts, the required reproducible individual treatment of the components. Due to the central robot loading and unloading and the associated elimination of charging racks, (the grippers place the component directly on the respective receiving places in the oven), the costly return transport of these transport aids is eliminated and efficiency increases. Due to the special air flow a uniform and fast heating of all parts is provided. This means that all components can be heated with exactly the same parameters without mutual interference. Despite the success of the furnace technology, a problem arises. How can you measure the product temperature in such a rotary furnace in a meaningful way and comply with process standards? The furnace itself, like all industrial furnaces, is equipped with temperature sensors for regulation. But these sensors do not give any indication of what really happens internally or on the surface of the product. Previously, the actual product temperatures were measured using trailing thermocouples that had to be routed

through the furnace. Naturally, this is not possible with this special oven design because the thermocouples would wind up. Conventional measuring systems require too much space to provide the required thermal performance. Phoenix™, manufacturer of temperature profiling systems, has tackled this particular problem. In close cooperation with BSN, systems have been developed that can be integrated into the process without any loss of time. The Phoenix™ systems work according to the “hot box” principle. A data logger, protected by a heat protection container, is driven through the furnace and collects data at up to 20 measuring points. Thermocouples, which are attached to or inserted into the product, record the actual product temperatures and store them in the datalogger. The evaluation software ThermalView Survey or Plus generates a complete report and gives you an idea of the respective temperatures at a glance. The difficulty arises from the conflict between limited space and demanding heat protection performance. It must also be ensured that the heat protection container is adapted to the component in such a way that the robot can still grasp it automatically. Thus, the production is not disturbed and the measurements can be performed reproducibly at any time without loss of production time and capacity. The collected data reflects accurate and meaningful values. Such profile data provides validation to the end customer that the product meets target quality standards. The Phoenix™ heat protection containers work using one of two principles:

Prepared Aluminium part fitted with the Phoenix™ profile system

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1. Water-cooled containers - In these containers the data logger is protected in a waterproof housing. The heat protection performance is achieved by evaporating water. The size of the tank must be adapted to the respective process duration. 2. Heatsink Technology - Here is the heat protection provided by the insulating material and a heat sink surrounding the data logger. The heat sink is filled with a special salt that absorbs the heat and liquefies at temperatures of 58°C. The water-cooled containers are the means of choice here, as they are ideal for these applications due to their more compact design. In several concepts, rotary hearth furnaces were implemented for solution annealing, water quenching or air quenching and subsequent artificial aging. Engine blocks were milled out so that the heat protection container found sufficient space inside and also the thermal load capacity for the relatively long process was not exceeded. The system with the data logger in the container does not protrude beyond the external dimensions of the component. The gripper takes the prepared block (the thermocouples were placed in advance in the relevant places) and puts it, without interrupting production in the oven chamber. The furnace run with temperatures around 550 ° C and a process time of several hours is recorded, the block is removed and left in the quench bath. In the water, the container fills up again preparing it for the next hot aging furnace. Thus, longer process times are no problem and the automatic assembly makes it very easy for the user to measure regularly and reproducibly according to quality specifications and standards. But not only the process reliability and quality of the products plays a big role. Equally important are the efficiency of the furnace and the optimization of the operating costs. All this is directly related to the correct setting of the ovens. The aim of every furnace measurement is to bring the energy and the quality of the products into balance, so that both are in an optimal relationship. This is exactly what the Phoenix™ temperature measurement systems and industrial ovens from BSN stand for. BSN and Phoenix™ are exhibiting at the upcoming Aluminum trade fair from 09.-11.10.2018 in Düsseldorf. Visit us. BSN •• bsn-therm.de •• Booth E61 Phoenix™ •• Phoenixtm.de •• Booth H17

Component and Phoenix™ system being loaded into furnace by gripper

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Innovative casthouse solutions

MQP at Düsseldorf 2018 MQP is a UK based company operating on a worldwide basis. Its mission is to provide products to the aluminium industry that improve quality, increase production efficiency, reduce costs and minimise environmental impact. Innovation and excellence is fundamental to MQP’s way of thinking and this is reflected in its range of products. At Düsseldorf 2018 we will be highlighting the following products on our Stand; 1 Optifine -high performance, industry proven, grain refiner that allows

standard TiBAl to be replaced at up to 80% lower addition rates (see graph). Successful grain refinement is achieved without the addition of unwanted borides. Opticast- unique grain refinement optimisation system used in conjunction with Optifine at Customer cathouses. A fully operational system complete with electrolytic polishing and anodizing of samples will demonstrated on the Stand. Optifilter -three chamber, in-line, filter unit incorporating ceramic foam, grain refiner and efficient cyclone.

Optifine achieves the required grain refinement (dotted line) at much lower addition rates (red plot) than standard grain refiner (blue plot)

Successful cooperation for almost 20 years

Three stage Optifilter unit

KAMPF Sepamat with E.D.S. pinhole detection

Ideal for casthouses with frequent alloy changes or low volume operations. A full-size industrial trial unit will be on show and information on modelling work being carried out for MQP at Brunel University available. 1 Batchpilot-innovative, casthouse proven, automated system for measuring transfer and furnace metal weight installed in several casthouses worldwide. An operational video will be shown on the Stand. 1 Refinal-range of cost effective, environmentally friendly, fused fluxes for reducing alkali metals and inclusions. New and improved aluminium product packaging will be shown.

Transmitter Web to be inspected

•• Booth: 11G31

Receiver

Products & Projects

Transmitter

Aluminium cold-rolling mill by Fagor Arrasate increases and diversiﬁes Iberfoil’s production

Hazelett casting process selected for JW Aluminum expansion

Fagor Arrasate has installed an aluminium coldrolling mill in the Iberfoil Aragón plant in Sabiñánigo, which is capable of processing 850 m/ min with a belt width of 1680 mm, which will enable the company to increase production and enter new sectors. The company belongs to the Alibérico group and has entrusted Fagor Arrasate with the extension of its Huesca factory with the incorporation of this mill. It will triple its production and extend the range of thicknesses that can be processed, thus diversifying its portfolio of products and allowing it to focus on new markets. In addition, Fagor Arrasate has installed a slitting line in the Iberfoil plant capable of operating at 150 m/min.

Hazelett Corporation confirms that the Hazelett®Twin-belt Continuous Casting Process will be utilised for the JW Aluminum expansion. “This new facility will be a model for the most costeffective and energy efficient sheet production in North America,” said Mr. David Hazelett, President. “And, it will significantly ease the projected shortage of aluminium coil in the United States.” The Hazelett®Model AS2000 casting machine being supplied is capable of producing 2000 mm wide strip at approximately 50 metric tonnes per hour. Alloy capabilities include 1XXX, 3XXX, 5XXX, and 6XXX series.

The premium combination for productivity, quality and efficiency ■

Full integration

■

Automatic data exchange

■ C omplete analysis and

reporting Flexible design with - four Sepamat machine sizes - two pinhole detector models

■

■ 4.0 ready with

13 J40 Visit us at: www.kampf.de www.eds-srl.it

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ALUMINIUM Materials handling andɅliftingɅsystems

Storage systems

Centrifugal blowers

Ship loaders/unloaders

Bath and carbon recycling plant systems

Dense/solid phase and other conveyingǾsystems Potfeed e.g. HyperDense Phase SystemsǾ(HDPSTM) Dosing devices

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Pot process control systems Electrolysis handling equipment Carbon: rodding and anode handlingǾsystems; baking furnace liftingǾsolutions

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