Tag: Alit Technologies

At the heart of the dynamic Portuguese company Extrusal S.A., a big change is revolutionising the extrusion die cleaning process. Through the introduction of Claris 9346MB, an innovative product, Extrusal has achieved relevant results that are changing the landscape of the dies cleaning plant managing. Let’s find out how this winning partnership has not only optimised Extrusal’s operational efficiency but also contributed to a more sustainable management of the environment.

Before we dive into the wonderful technicalities of Claris and its effects, it is only right to introduce you to Extrusal, who it is and what it does!

EXTRUSAL S.A. is a Portuguese company operating in the metallurgical sector, specializing in the extrusion of aluminium components and profiles for the construction industry (window and door systems, shading and cladding solutions, railings, and facade systems), general industry (transportation, engineering, energy, among others), and the automotive industry. Founded in March 1972, Extrusal has consistently remained at the forefront of technology, with a primary focus on the quality of its products and services to ensure maximum satisfaction for both direct and indirect clients.

Extrusal S.A. headquarters in Aveiro, Portugal.

Currently, the industry represents approximately 74% of the company’s turnover (26% automotive industry and 43% general industry), with direct exports accounting for 37%. Architectural sector exports primarily target PALOP countries, while the Industry sector exports to Europe.

Extrusal’s production process consists of:

• Engineering and Development Department: Equipped with the latest CAD/CAM systems, it plays a crucial role in internal R&D. Collaborating with the Product Marketing Department and the Prototyping Center, this department develops technical solutions for the Construction sector;
• Die Factory: Extrusal has an autonomous die factory that produces the majority of the dies used in the extrusion process. It is equipped with milling machines, machining centers, non-conventional lathes, turning CNC machines and EDM. The increasing complexity of products makes die manufacturing an increasingly important step in Extrusal’s production process;
• Extrusion: Extrusal currently operates two extrusion lines (17MN and 20MN) with an annual extrusion capacity of approximately 13,000 tons (depending on productivity and profile type). The company has a dedicated Extrusion support laboratory for R&D of extrusion profiles and their control, conducting tests such as tensile tests, Brinell hardness, Webster hardness measurement, and roughness tests;
• Machining: The machining section is equipped with saws, presses, milling machines, balancers, bending machines, and various dedicated equipment. Extrusal’s machining process complies with the NP EN ISO 9001 standard;
• Thermal Cutting: Extrusal was the first company in Portugal to produce thermal cutting systems for architecture, with a dedicated production line;
• Surface Treatments (powder coating, anodizing, and wood effect decoration): Extrusal has three sections dedicated to each type of in-house surface treatment. For anodizing, an electrolytic process, Extrusal has held Qualanod certification (no. 1405) since 1983. Powder coating, a Thermosetting coating process, has also been certified by Qualicoat since 1995. An internal laboratory ensures the quality control of processes and products.

Extrusal was the first Portuguese company, and one of the few in Europe, to obtain certification for the global quality management system – NP EN ISO 9002 – in the areas of die manufacturing, extrusion, anodizing, and .Thermosetting powder coating. Additionally, in 1997, Extrusal was the first Portuguese company, and one of the few in Europe, to obtain certification for the global quality management system – NP EN ISO 9002 – in the areas of die manufacturing, extrusion, anodizing, and powder coating.

A pioneer in environmental defense and preservation, Extrusal built a wastewater treatment plant in 1982. Environmental awareness has driven the acquisition of new equipment and technologies, leading to the implementation of an Environmental Management System and obtaining ISO 14001 environmental certification in 2002. Process optimization and a focus on reuse/recycling have been fundamental at Extrusal. The company has embraced an ecological organizational culture with all stakeholders, promoting sustainable practices throughout the organization.

In the architectural sector, the focus is on developing solutions using recyclable or recycled materials, energy-efficient, and durable. Extrusal’s portfolio includes hinged and sliding systems, cladding systems, shading solutions, facade systems, balustrading solution, shutters, and aluminium systems for indoor use. Window and door solutions undergo tests for thermal, acoustic, and AEV (air permeability, water tightness, and wind resistance) performance. Extrusal is one of the pioneering companies in adopting the Class+ labeling system promoted by ADENE.

Extrusal offers a wide range of solutions for the Industry sector, leveraging aluminium’s characteristics such as lightness, conductivity, durability, malleability, recyclability, and non-toxicity across various industries (from food to aerospace). For the automotive sector, Extrusal develops structural and decorative components with high-quality finishing. The company also contributes to the solar industry through its “Pro-Solar” solutions, designing and developing innovative aluminium structures for mounting solar panels or collectors.

Last but not least, alongside offering pre-conceived profiles, Extrusal provides clients with the opportunity to present their own projects.

Now that we have laid the groundwork for the case history of Extrusal S.A., it is time to dive into the practical part that will capture the attention of the industry’s technicians. We will explore how the use of the Claris 9346MB in the mould cleaning department has brought observable benefits and revolutionised the way Extrusal approaches this crucial operational aspect.

Dimensional Quality control of dies by Extrusal S.A.

The die cleaning tank used in Extrusal has a nominal volume of 1000 litre. Before the introduction of CLARIS in this plant the customer was using the dye cleaning solution, consisting in sodium hydroxide 30% w/w, for 24hours. As described by our colleague Pedro Oliveira “After this time has elapsed the alkaline solution was regularly dismissed because it was exhaust, no longer useful for cleaning of new extrusion dies. Practically there was a consumption of about 1000 litre of NaOH 30% every 24h work, and during this time the average amount of cleaned materials was about 6 baskets of extrusion dies”. Pedro continues by telling us that “After a visit to the die cleaning plant, and after collection of the preliminary technical date, it was organized a first test with Claris 9346MB. It was prepared the 1000 litre of NaOH 30% as usual, and it was added 25 g/l of CLARIS 9346MB, namely 25 Kg. Then the operators started the cleaning of extrusion dies as usual. After  24 hours, the operators realized that the bath was still effective, i.e still able to clean the extrusion dies, so a new cleaning cycle was started without changing the alkaline solution and without adding again CLARIS 9346MB. The cleaning of materials in this second cycle of 24h was perfectly efficient and after a total of 48 hours of use, the die cleaning bath was disposed of”. Pedro tells us that “with great customer satisfaction, the lifetime of the alkaline solution was doubled, without compromising its efficiency and productivity in any way“. The thermographic profiles collected against time are shown in Fig 1.

Pedro explains to us that “The blue colour profile refers to the test conducted WITHOUT Claris 9346MB, while the orange colour profile refers to the test conducted WITH 25g/l of Claris 9346MB dissolved in the alkaline cleaning solution. It can be observed that in the presence of CLARIS 9346MB, after about 24 hours, it was possible to insert a new load of baskets into the die cleaning tank, the temperature of the bath rose (also thanks to the exothermic reaction of aluminium dissolution) up to around 90°C, and then gradually dropped to at approximately 80°C over the next 24 hours. The thermographic profile was similar to that of the solution (blue line) without CLARIS, but the lifetime of the alkaline solution was double: An addition of 25 Kg of CLARIS 9346MB permit to the cleaning solution to treat double quantity of parts: truly fantastic!”

Fig 1: Thermographic profile of the alkaline cleaning solution without (blue) and with CLARIS 9346MB

We asked Pedro to explain  us why the presence of Claris prolongs so much the lifetime of the extrusion die cleaning bath. And he replied that ” Cleaning an extrusion die means first removing the solidified aluminium that remains in the holes of the die. If Claris 9346MB is present in the alkaline solution, the dissolution process of the solid aluminium is modified, and thanks to Claris 9346MB it becomes in practice possible to mechanically extract the aluminium block from the matrix without dissolving too much of it in the liquid solution. In this way the process bath is not enriched too much with aluminium, and therefore remains much more active. To the point that, in the presence of a correct dosage of Claris 9346MB, the quantity of treatable dies can be doubled”.

An example of aluminium residues that can be extracted from extrusion dies without dissolving  too much aluminium in the alkaline solution is visible in Fig. 2.

Fig 2: residual aluminium blocks extracted from extrusion dies using 25g/l of CLARIS 9346MB in the alkaline solution.

Pedro confirms that “The use of Claris 9346MB at Extrusal S.A. it is now a consolidated practice, and the customer declares himself fully satisfied with the benefits deriving from its introduction in the dies cleaning process. The consumption of alkaline solution has been significantly reduced and with it the disposal of used alkaline solutions. From the environmental point of view, much more aluminium can be recycled and thanks to the controlled reaction, less gas is expelled into the atmosphere. This die cleaning process reduces smells in the working area, ensuring better working conditions to the operators”.

CONCLUSION:

Claris 9346MB is an innovative additive for aluminum extrusion die cleaning, offering enhanced efficiency, cost savings, and extended bath life. It significantly improves the cleaning process, ensuring better performance and sustainability. Want to learn more? Visit our product page and contact us through our form. Follow ALIT Technologies on LinkedIn to stay updated with the latest advancements. Our commercial and technical staff are ready to assist you with any inquiries!

More and more coaters are choosing to paint strip the hooks and frames employed in their coating operations to avoid using them as disposable items. The standard method requires stopping production so they can be removed, replaced with new ones, and paint stripped separately. Aware of the importance of working with a continuous flow, however, ALIT Technologies has designed a plant that fulfills this task without interrupting the manufacturing cycle. FASTRIP ISP was conceived precisely to tackle the challenge of integrating the hook and frame paint stripping phase into coating lines.

    1. Hanging frames used for industrial coating operations

As mentioned, many companies today need to remove the paint residues deposited on their coating tools, including hanging hooks, load bars and frames, through a paint stripping operation aimed at re-using them.

But why do hooks and frames need to be cleaned?

Especially when it comes to electrostatic coating, the excellent electrical conductivity of the parts is of the essence. However, this can be significantly undermined by any impurities and paint layers deposited on the hooks and frames and acting as electrical insulators. Decreased conductivity also increases overspray, thus likely affecting the coating results. Therefore, paint stripping hooks and frames allows companies to re-use these accessories countless times without incurring the cost of buying new ones while ensuring flawless finishes.

FASTRIP ISP is ALIT Technologies’ solution for perfect in-line paint stripping of hooks and frames

Recognizing the importance of this process, ALIT Technologies accepted the challenge of developing an efficient solution for paint stripping hooks and frames. With this goal in mind, it designed and built FASTRIP ISP. Thanks to its modular design, this in-line chemical paint stripping system for hooks and frames can be easily integrated into existing production lines, ensuring the continuity of the coating cycle.

2. An example of a customized FASTRIP ISP machine for in-line paint stripping of hooks with a connected filter press

How is FASTRIP ISP made, and how does it work?

The FASTRIP ISP paint stripping system consists of two main units: the paint stripping tank and the FASTRIP FP series filtration system.

The tank is made of AISI 304 steel and contains an adjustable volume of paint stripper, which is simultaneously heated and subjected to ultrasonic waves. The combined effect of the chemical attack by the paint stripper, high temperature, and ultrasound allows removing a paint layer in as little as 3 minutes. While remaining hooked onto the overhead conveyor, the items to be paint-stripped are partially submerged into the stripping tank as they pass through. The tank’s linear length is proportional to the coating line’s speed, usually within a range of 4-8 meters. The paint stripping product is heated by electric heating plates attached externally to the tank, guaranteeing high standards of safety and ease of maintenance at the same time. The ultrasonic batteries are also externally flanged, easy to access, and highly robust. The tank is insulated to minimize heat loss and its shape optimizes sludge filtration.

The FASTRIP FP series filtration system is connected to the paint stripping tank and allows consistent removal of the coating sludge that accumulates in the bath. Sludge is continuously removed from the tank’s bottom and filtered with a filter press. The clean paint stripper can then be automatically recirculated to the paint stripping tank. The configuration options of the filter press, liquid tanks and piping are extremely varied and can be customized according to customer needs.

Adding a water rinse module to remove any paint stripping oil residues and an infrared lamp system for drying is also possible.

What are the advantages of this plant?

The benefits of using FASTRIP ISP for paint stripping hooks and frames are numerous:

• the system enables to perform paint stripping operations without removing the hooks from the chain;
• the process is easier to manage, as there is no need for downtime to clean the tank;
• the labor involved in managing the hooks (i.e. cyclically removing the dirty ones and positioning the clean ones) is significantly reduced;
• hooks and frames are always clean;
• thanks to its modular design, the system can reach any length, as well as a hook and frame immersion depth of up to 30 cm.
• FASTRIP ISP can be used for paint stripping any metal because it is not aggressive to surfaces, even with light alloys. Hooks and frames will always be as good as new!

The ideal chemicals for FASTRIP ISP

One of the goals of ALIT Technologies is to offer complete systems that provide all-round solutions. The market demanded a plant capable of paint stripping the hooks and frames used in coating processes – and the ALIT team met this need by designing and launching FASTRIP ISP. Of course, this type of plant also requires the use of chemical agents, so ALIT Technologies also developed a wide range of paint stripping products that guarantee optimal results when combined with the FASTRIP ISP system. These include as follows:

• 14XX Series METALSTRIP

These paint strippers are used to fill the tank during the plant’s start-up. Usually, their use is limited to this phase.

• 16XX Series METALSTRIP AKTIVATOR

They are used routinely to feed the paint stripping tank during regular operation. They should be added periodically to maintain optimal bath chemical parameters. The operator determines the quantities to be added through a simple chemical analysis of the bath.

• COVER LAYER Series METALSTRIP

This non-toxic liquid forms a floating layer of about 4 cm above the paint stripper in the tank. It helps reduce heat loss and odor emissions and preserve the paint stripper from contact with air.

• METALSTRIP 1465

This new product has improved fluidity and sludge settling capacity characteristics. One of its main features is its full compatibility with ALIT Technologies’ other paint stripper series, meaning that it can be added directly into the FASTRIP ISP tank, gradually replacing the product used previously without the need to refill the tank completely.

All these products are part of ALIT’s METALSTRIP product range, and in addition to providing excellent performance, they meet strict environmental sustainability requirements.

A case study testifying to the effectiveness of FASTRIP ISP

Background

A major company in Northern Italy producing and marketing wire mesh, fences and gates asked us to supply two complete FASTRIP ISP plants for paint stripping its hooks and frames. The paints to be removed were polyester coatings and the size of the hooks ranged from 70 cm in height to 50 cm in width.

The issue

The company had two already existing coating lines: due to space constraints and the chain’s layout, we had to design two custom plants with elevated paint stripping tanks.

Our solution

ALIT’s Engineering division conducted a detailed geometric survey of the space available and the overhead conveyor in the area of interest. It then presented the customer with a design that was gradually refined until approval. The paint stripping and filtration areas were designed to fit into the existing spaces without interfering with the adjacent coating and robotic unloading areas.

With regard to automation, it was agreed that the plant would comply with INDUSTRY 4.0 standards. The main switchboard was equipped with advanced technologies to exchange process data with the customer’s management software and allow for remote service and monitoring. The wiring and insulation materials on board the machine were selected based on ALIT’s experience in the paint stripping industry, balancing the required chemical and thermal resistance characteristics.

The company protagonist of this case study has undoubtedly obtained many benefits from its new FASTRIP ISP. In addition to radically decreased costs, opting for this plant from ALIT Technologies has enabled it to lower its environmental impact, reduce its long-term costs and increase its turnover by eliminating the need to stop the coating line.

Would you also like to implement such an innovative system for your business?

Get in touch with the ALIT team: together, we will identify the most suitable solution for your production needs!

In an increasingly dynamic industrial world, it is essential for a company to innovate but also to renew itself to offer increasingly comprehensive services to the market. Strong on this approach, ALIT Technologies decided to expand its reach by creating MAS-KING, a new brand specialising in industrial masking based on innovation, progress and responsiveness to the demands of an increasingly demanding market.

The San Bonifacio (VR) based-company is pleased to announce the transition from dealers to owners of a new line of business operating in the field of masking for coating and other surface treatments. MAS-KING, the brand chosen for this new business, presents a range of products of the highest quality, designed with precision and made with advanced materials. The brand aims to set a new standard in industrial masking and represents the commitment signed ALIT Technologies to excellence in the protection of artifacts during all stages of surface treatment.

The new brand has a strongly international vision made possible by the ALIT Technologies’ global network of agents. To Italian customers, MAS-KING offers an innovative service based on speed of delivery, supplier-customer trust, problem-solving ability as well as on good price-quality ratio: a dedicated van, loaded with solutions for protecting parts during coating, will be available to customers directly at the workplace, thus guaranteeing immediate and customised supply.

Progress and innovation are two goals to be pursued at both strategic and operational levels for any solid and dynamic company. ALIT Technologies, excited about this new adventure into the world of surface treatments, invites all its customers to learn more about the features of the new MAS-KING masking products by contacting the customer service.

Join us to write the beginning of a new chapter in the history of masking.