Different alloys have become the answer for a wide variety of applications for traditional industries, such as the construction sector, seeking to develop increasingly demanding and sophisticated products required by the automotive and aerospace sectors. For a number of years industrial manufacturers have been investing considerable resources into redefining materials for forming structural components, substituting traditionally used steel with the aluminum, thanks to the high workability and extensive possibilities offered in aluminum extrusion, where molding the mechanical features of the end product are concerned. Reducing the weight of a vehicle and increasing the characteristics of resistance and shock absorption is not only advantageous to the environment, but also provides improved safety features.
A growing demand for increasing volumes of manufactured products is facing European and US extruders who, with the exception of some larger, well-known groups, are mostly brave small companies with limited resources. Therefore, they have very little room for error. Aluminum Insights, is one of these courageous front runners. Based in Syracuse (IN), its 76,000 square foot manufacturing facility begins with a high-efficiency 2,920 ton extrusion press and extends through an array of CNC fabrication and kitting operations to deliver assembly-ready parts at their customers’ line-side kanbans. The extrusion plant ordered during winter 2020, after detailed technical discussions, Aluminum Insights was fully convinced by Presezzi Extrusion’s high performance/cost ratio solutions, which were supported by recent references for similar lines from other top-level US customers. The additional plusses of the Presezzi Extrusion Group proposal were the quick local response and service capabilities (thanks to Presezzi Extrusion Norh America) that eventually led this important order to be assigned to Presezzi Extrusion Group.
In October 2021 Presezzi Extrusion team along with the Board Members of Aluminum Insights have performed the Factory Acceptance Tests on the new indirect extrusion press. During the test the press and all the downstream equipment was inspected, and some cycle performed along with technical team of Aluminum Insights to meet all contractual milestones before shipment. The feedback received from Aluminum Insights team was very positive and the equipment was successfully accepted and cleared for shipment. The entire Presezzi team Is looking forward to the installation and commissioning phase: the latest technology supplied to Aluminum Insights will be installed and commissioned during first quarter 2022.
The perfect combination of the mechanical equipment powered by Presezzi Extrusion electrical and automation systems guarantee remarkable efficiency in terms of hourly production costs (OpEx); thus providing Aluminum Insights with the shortest ROI and high market competitiveness, in full respect of the environment.
This 26-MN front loading extrusion press, will process each-inch billets of length between 600 and 1800 millimeters, 100% manufactured in Italy and is equipped with the latest technological packages developed by PRESEZZI GROUP, including the patented PE.E.S.S. environmental friendly energy-saving system. A sustainable technological package, that will permit a reduction in installed power and energy consumption: indeed our unique system is capable to stop the unnecessary pumps during the extrusion phase, therefore reducing the energy consumption and notably enhances the performance in terms Dead Cycle Time reduction and consequently productivity increase. The press will be equipped with fully electric billet loader and high speed die change station. PE.E.S.S. also is equipped with a VFD (Variable Frequency Drive) that minimizes energy consumption; the plant power factor is dictated and optimized by extrusion conditions since not all pumps are required to function at maximum delivery rates. The HMI solution with dedicated control pulpit is designed for an extraordinary experience of the machine control, for integrated diagnostics and energy management, meeting industry 4.0 machinery feedback, including maintenance and remote service support.
In addition to the extrusion press Presezzi Extrusion will also supply complete log oven area and complete handling system, including single-puller frontal type and fly saw, cooling table, stretcher, final cut to end saw, stacker and basket handling conveyors. Going into detail, the extremely flexible Presezzi Extrusion line will be designed with the following key design figures:
And in this connection, we would like once again to thank partner Aluminum Insights - who are in fact real front-runners - for the constant stimulus, ideas and co-operation they offer in a spirit of win-win partnership, always striving to be a step ahead.
The brilliance of the results we obtain is a mirror of the passion of the people who work on our projects, their perseverance, their resilience: a unique and distinctive wealth of knowledge. We remain beside our partners, step by step, day by day, with our focus, our passion, our experience and our services. We defined our strategy based on a clear vision of the challenges awaiting us currently and in the future. Being in a global market requires us to be focused on innovation and strong integration and cooperation with suppliers and customers. We are proud of our technological achievements in support of the progress of the Aluminum and NF-Metal industries through the experienced companies that make up the Presezzi Extrusion Team. This has been possible thanks to our innovative spirit, investments in R&D, and the partnership established with our Customers.
The pride we feel in these achievements will drive us onward to meet all the challenges of the future.