OPNENING UP A GREAT FUTURE FOR ALUMINIUM/ALMINE Co.,LTD.
アルミの未来を、ひらく 株式会社アルミネ ホームへ戻る
ALMINE's technology is the crystallization of the sweat shed at the production site. Keeping in close proximity to the production line one can form more than mere theories. Practical ideas forged here, on the production floor, raise production efficiency even higher. Watching closely as the products are being made, one can envision even better production techniques. This is how our method for producing aluminium bars with the world's largest diameter was created. ALMINE's technology is the best in the world because it is truly a union of skill and craftsmanship, born out of the efforts of the front-line production workers.

Factory Production capacity Product size  
Osaka(factory)
(wires)
2,000t/month Diameter 25φ ~0.1φ Coil weight:
300 kg/coil max
MAX Single weight of wire carrier:500kg
Misumi(factory)
(wires・bars)
4,000t/month Diameter 35φ ~0.1φ Coil weight:
2,000 kg/coil max
MAX bar Length:4,000㎜
Kawakami
(factory)
(sheets・coils)
3,000t/month Sheet thickness 4.0~0.1㎜
width max1,040㎜
Coil weight:
5,000 kg/coil max
MAX sheet Length:4,000㎜

ALMINE・VIETNAM
(Vietnam)
(wires・bars)

4,000t/month

Diameter 35φ ~0.1φ

Coil weight:
2,000 kg/coil max
MAX bar Length:4,000㎜

Osaka-Plant  Misumi Plant
Large single-head drawing wire machine 6 Aluminium melting furnace 2
Large drawing wire machine 3 Aluminium holding furnace 2
Medium-size drawing wire machine 1 Aluminium refining furnace 2
Wire peeling machine 2 Nline molten gas filter 1
Swift drawing wire machine 2 Aluminium bar/wire continuous casting and rolling mill 1
Line up coiler 6 Aluminium bar continuous traveling cutte 1
Quenching furnace 1 Large wire machine

5

Annealing furnace 2 Medium-size drawing wire machine 3
Drying furnace 1 Horizontal drawing wire machine 3
Degreasing system 3 continuous bar drawing machine 8
Fully automatic packing machine 2 Annealing furnace 3
Packing machine 2 Quenching/annealing furnace 2
Overhead crane 10 Eddy current flaw detector 10
    Overhead crane 14
Screw compressors, lathes, boring machines, etc Lathes, milling machines, radial boring machines, screw compressors, etc.
   
Kawakami Plant  

Aluminium melting furnace

1    
Aluminium meintenance
furnace

Aluminium sheet continuous casting line

2


2

   
6 Hi cold rolling mill 1    
Tension leveler 1    
Die-set shear line 1    
Slitter line 2    
Edge line 2    
Washing line 1    
Annealing furnace 3    
Grinding machine for mill rolls 1    
Overhead crane 12    
X-ray thickness meters,      

screw compressors, truck scale (50 t), scrap disposal system, etc.

     

ALMINE・VIETNAM CO.,LTD.

Melting furnace

2
Wire continuous casting and rolling mill

1

Drawing wire machine 7
Continuous bar drawing machine 7

Quenching furnace

Refining furnace

Annealing furnace

Drying furnace

 

1

1

1

2

 

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WIRE

Aluminum wire production process

Wire materials are produced mainly at the Misumi Plant.
The production lines there can be roughly divided into two processes, wire rod and drawing wire.
The main facilities include melting furnaces, continuous casting and rolling mill, continuous winding machines, drawing wire, winding machines, cutters, heat treatment furnaces, and inspection and research equipment.

In the wire rod process, there are two melting furnaces:

① from which molten metal is constantly supplied.
They are tilting air furnaces, therefore only the required amount of molten metal is supplied via automatic tilt control.
The molten aluminium from the melting furnace is treated in the holding furnace, then sent to ALMINE's cutting-edge continuous casting and rolling mill ②.
The ingots produced by the continuous casting machine ③ are continuously checked by X-ray for internal defects and flaws.
The results of the inspection are kept as data to be verified every time a coil is wound.
Next, they go to the roller ⑤to be hot-rolled to a diameter of 9.5-50 mm.
The eddy-current flaw detector ⑥ installed at the outlet of the roller automatically checks for surface defects.
A red, yellow, or green lamp blinks depending on the level of matter or defects detected; if the red lamp is lit, the product is returned to the melting stage to begin the process all over again.
The 9.5-mm-diameter wire rod coming off the continuous casting and rolling mill at the high speed of 800 meters per minute is taken up on a 2-ton coil by the winding machine ⑦.
Two winding machines are in operation, and when one reaches 2 tons, the process is automatically switched over to the other winding machine in 0.5 seconds.
Wire rod then undergoes a heat treatment which best suits the material or type.
After a strict quality inspection, it is moved to the next stage, which is either shipment or the drawing wire process.



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SHEET

Aluminium sheet production process

All sheet products are fabricated at the Kawakami Plant. The main facilities there include a melting furnace, continuous casting machine, 6 Hi cold rolling mill, washing device, tension leveler, cutters/slitters, die-set shear, and heat-treatment furnaces.
ALMINE also produces the hot coil we use for making aluminium sheets. The molten aluminium from the melting furnace ① automatically flows to the continuous casting machine ② and the hot coil is slowly taken up. While the hot coil is being taken up, test pieces are sampled and arranged in chronological order to undergo a series of tests. The hot coil thus produced is fed to the 6 Hi cold rolling mill ③, where it is rolled to a thickness of 0.1-4 mm. Our technical staff made significant improvements on the 6 Hi cold rolling mill to achieve high-speed, high-productivity operations. As a part of our thorough quality assurance system, the AFC* and AGC** systems help to maintain the high quality of our products.
Completely flat rollers are needed to produce perfectly flat sheets, there fore the 6 HI cold rolling mill rolls are ground and polished with newest technology grinding machine for mill rolls ④. The equipment is entirely surrounded by a 5-meter-deep groove to shut out vibration, as extremely high precision measured in microns is required.
The rolled sheets are washed with organic solvents to remove dirt and aluminium powder deposited during rolling. They are then sent to the tension leveler, where the degree of the sheet flatness is even further improved. After that, the sheet, which has been rolled to the specified thickness, is cut to the required length by the die-set shear (traveling cutting machine) if it is for sheet products (meter size). If the sheet is intended for bar products, it is cut to the required width with the slitter (width cutting machine) ⑥ and taken up in bar form. Depending on the material and product type, heat treatment is applied during the production process by injecting DX gas for anoxic treatment. Following a strict quality inspection, the products are shipped.

AFC (automatic flatness control) system: An automatic control system for maintaining a stable profile and flatness.
**AGC (automatic gauge control) system: An automatic control system for maintaining sheet thickness measured in microns to achieve the set sheet thickness.



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BAR

Aluminum bar production process

This plant has a line that can continuously produce aluminium bars up until 35 mm in diameter.
This innovative production line is the realization of ALMINE's many years of experience and impressive production record concerning continuous cast rolling techniques.
It represents the aluminium materials production process elevated to the height of perfection.
As aluminium continues to replace other metals, the possibilities for new technologies are limitless.




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