From source to dispatch, the operative word is premium

The lifecycle of our extruded products begins at the raw material stage, where we use only high quality aluminium billets from Vedanta to ensure reliability.

The aluminium ingots are then melted and cast into billets of the required size. The billets are then heated to the optimum temperature and fed into any one of our three presses according to the client’s requirements.

The extruded aluminium is then cooled according to specification and it is to be noted that KMC enforces strict quality regulations at each step of the production process.

KMC houses an advanced tool shop that is capable of producing and designing very intricate die setups. The tool shop has continually proved its capability to handle even the most complicated dies.

Process flow of Aluminium Extrusion

Furnace

Furnace is where aluminum ingots or aluminum materials are melted down and moulded into finished or semi-finished products by molten casting as shown in the image.

Billet cutting

A billet is a section of metal used for rolling into bars, rods and sections. It can be produced with ingots or directly by continuous casting. Billets are used as raw materials or extrusion processing operations.

Continuous Billet Heating

Metal billets are heated prior to forming operations (extrusion, for example). Heating the metal softens it and makes it malleable. If the metal is heated too much, then excess time and energy is used and damage can occur as extra heat is generated during the deformation process. If the billet is not heated enough, then the cool billet will be too hard to form or it may not achieve the desired hardness properties upon cooling. If the billet is too hard, it may not flow to the required shape and it may cause excessive die wear.

Die Heating Oven

Properly used, the die oven should heat the tooling to the desired temperature without regard to where each tool is placed in the oven. The tool’s time in the heater should be carefully managed: if not heated long enough the die may break; if heated too long the hardness will be lost (also resulting in breakage), and oxidation or pitting of the surfaces may occur.

Extrusion Press

Direct extrusion is the most common extrusion process. It works by placing the billet in a heavy-walled container. The billet is pushed through the die by a ram or screw. There is a reusable dummy block between the ram and the billet to separate them. Due to this, the greatest force required is at the beginning of process and slowly decreases as the billet is used up. At the end of the billet, the force greatly increases because the billet is thin and the material must flow radially to exit the die. The end of the billet (called the butt end) is not used for this reason.

Transfer Table Conveyor

A conveyor system is a common piece of mechanical handling equipment that moves materials. Conveyors are able to safely transport materials from one level to another, which when done by human labor would would reduce accuracy of the dimensions of the product.

Stretching & Straightening

For the straightening of solid bars, square and rectangular tubes as well as hollow profiles, our profile straightening machines are designed especially for your application to reach an optimum straightening quality. The number of straightening rolls, as well as the number of straightening planes are adapted to the profiles to be processed. For square and rectangular tubes, straightening machines with adjustable straightening rolls’ pitches are used.

Cutting

This process facilitates easy operation, reliable performance and convenient maintenance through an advanced technique. The profile cutting size adopts the digital display technique to ensure high efficiency and accuracy. The imported carbide saw blade gives accurate processing and high efficiency. Subsequently, two cutting heads can work together to avoid deviations in cuts and increase accuracy.

A high efficiency cutting machine is used for aluminium window and door profiles, industrial aluminium profiles and curtain wall aluminium profiles, aluminium ladder profiles, etc.

Ageing

The aluminium profile should perform ageing treatment after extrusion. The purpose is to improve the intensity of the aluminium alloy shape and benefit to operation, storage and transportation for the after extrusion procedures, and also for normal usage of the clients. Technical Process:190 ℃ ~ 195 ℃ for keep warm about 3.5 hours, and then adopt the forced-air-cooling process.

Packing

We package our aluminium extrusion profiles with the same care and attention as we devote to producing your extruded aluminium profiles, to ensure that they arrive in perfect condition. Smart packaging also takes your logistical and production processes into account so that you can set to work using your aluminium extrusion profiles with the minimum of effort. We offer packaging options for visible and non-visible surfaces.

Dispatch

Dispatch notes are important to buyers because they allow him to track an order. They are equally important to the seller. Often, if a buyer is not satisfied with their purchase upon its delivery, he must attach part of the dispatch note, or include the invoice number found in the dispatch note.