TECHNOLOGY

About production

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.

Production capacity

Wire rod・Wire・Bar
 

Misumi Plant

In Misumi plant, with the unique continuous casting rolling method, we can produce aluminium alloy wires and bars until 35Φ.

Production capacity
4,000t/month
Product size
Diameter 0.1Φ~35Φ

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

Access here

In Misumi plant, with the unique continuous casting rolling method, we can produce aluminium alloy wires and bars until 35Φ.

Production facility

Item

quantity

Aluminium melting furnace
2
Aluminium holding furnace
2
Aluminum refining furnace
2
Nline molten gas filter
1
Aluminium bar/wire continuous casting and roling mill
1
Aluminium bar continuous traveling cutte
1
Large continuous drawing wire machine
5
Midium-size wet continuous drawing wire machine
3
Vertical wire drawing machine
1
Horizontal dry continuous drawing wire machine
3
Continuous bar drawing machine
8
Annealing furnace
3
Quenching/annealing furnace
2
Eddy current flaw detector
10
Overhead crane
14

Lathes, milling machines, radial boring machines, screw compressors, etc.

Wire
 

Osaka Plant

In Osaka plant, we produce drawing wire until 0.1Φ from origina lmaterials produced in Misumi Plant. Osaka Plant is also a relay physical distribution spot.

Production capacity
2,000t/month
Product size
Diameter 0.1Φ~25Φ

Coil weight : 300 kg/coil max /
MAX single weight of wire carrier : 500 kg

Access here

In Osaka plant, we produce drawing wire until 0.1Φ from origina lmaterials produced in Misumi Plant. Osaka Plant is also a relay physical distribution spot.

Production facility

Item

quantity

Large single-head drawing wire machine
3
Medium single-head drawing wire machine
1
Small single-head drawing wire machine
1
Large drawing wire machine
5
Small drawing wire machine
1
Wire peeling machine
2
Line up coiler
6
Quenching/annealing furnace
1
Annealing/refining furnace
2
Refining furnace
1
Degreasing system
3
Fully automatic packing machine, Packing machine
4
Overhead crane
10

Screw compressors, lathes, boring machines, etc.

Sheet・Coil
 

Kawakami Plant

In Kawakami P lant, With u nique c ontinuous casting rolling method, we can produce all aluminium sheets and coils with max width until 1040mm.

Production capacity
3,000t/month
Product size
Sheet thickness 0.1~4.0㎜
width max1,040㎜

MAX Sheet Length:4,000mm /
Coil weight:5,000 kg/coil max

Access here

In Kawakami P lant, With unique continuous casting rolling method, we can produce all aluminium sheets and coils with max width until 1040mm.

Production facility

Item

quantity

Aluminium melting furnace
1
Aluminum maintenance furnace
2
Aluminium sheet continuous casting line
2
6 Hi cold rolling mill
1
Tension leveler
1
Die-set shear line
1
Slitter line
2
Edge processing 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 (50t), scrap disposal system, etc

Wire rod・Wire・Bar
 

Production capacity
4,000t/month
Product size
Diameter 0.1Φ~35Φ

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

Access here

Production facility

Item

quantity

Melting furnace
2
Aluminium bar/wire continuous casting and roling mill
1
Large drawing wire machine
5
Medium drawing wire machine
2
Line up coiler
2
Continuous bar drawing machine
6
Quenching/annealing furnace
1
Annealing furnace
2
Refining furnace
2
Eddy current flaw detector
9
Overhead crane
14

Lathes, milling machines, radial boring machines, screw compressors, etc.

ISO 9010(2015)
Certification

ISO 14001(2015)
Certification

Manufacturing technology

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

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.
The ingots produced by the continuous casting machine 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 to be hot-rolled to a diameter of 9.5-35 mm.
The eddy-current flaw detector 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 1,000 meters per minute is taken up on a 2-ton coil by the winding machine.
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.

Production process 
[Misumi Plant、Osaka Plant、ALMINE VIETNAM]

Wire rod process

Ingot

 

Melting

Melting furnace

Continuous casting and rolling mill

Chemical analysis of components

Casting

Continuous casting
machine

X-ray flaw detector

Rolling

Continuous rolling
machine

Eddy-current flaw detector

Winding

Continuous winding
machine

 

Wire rod

 

To shipment or drawing wire stage

Drawing rod process

Wire rod

 

Drawing

Continuous drawing wire machine

 

Winding
coiling

Winding machine,
coiling machine

 

Measurements, tests

Weight measurement
Dimensions measurement
Tensile test
Conductivity test
Hardaness test
Compression test
Metallurgical inspection

 

  1. Wire rod

  2. Coil style

  3. Carrier style

  4. Bobbin style

BAR

Aluminum bar production process

We have production line capable of continuously manufacturing all kinds of aluminium alloy bars up to 35mm in diameter.
This is culmination of experiences and achievements of the continuous casting and rolling method that Almine have piled up until now.
This line further develops the aluminium wire manufacturing process.
We expanded the possibilities for new technologies by facilitating the replacement from other metals to aluminium.
By Combined process for all alloys from aluminium coils, we are producing high quality and no defect coils up to 35mm in diameter with state-of-the-art technology.

Production process 
[Misumi Plant、ALMINE VIETNAM]

Wire rod process

Ingot

 

Melting

Melting furnace

Continuous casting and rolling mill

Chemical analysis of components

Casting

Continuous casting
machine

X-ray flaw detector

Rolling

Continuous rolling
machine

Eddy-current flaw detector

Winding

Continuous winding
machine

 

Wire rod

 

To shipment or drawing wire stage

Drawing rod process

Wire rod

 

Drawing

Continuous drawing
wire machine

 

Winding
coiling

Winding machine,
coiling machine

 

Combined

Combined machine

Eddy-current flaw detector
Ultrasonic wave flaw detector

Measurements, tests

Weight measurement
Dimensions measurement
Tensile test
Conductivity test
Hardaness test
Compression test
Metallurgical inspection

 

  1. Bars

  2. Bars

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 automatically flows to the continuous casting machine 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 , 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. 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) 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.

Production process 
[Kawakami Plant]

Casting process

Ingot

 

Melting

Melting furnace

Chemical analysis of components

Casting

Continuous casting
machine

 

Hot coil

 

Rolling process

Rolling

6 Hi cold rolling mill

X-ray thickness meters
AFC(automatic flatness control)system
AGC(automatic gauge control)system

Washing

Washing equipment

 

Purifying process

Purifying process

Cutting

Tension Leveler

 

Slitter

 

Die set shear

 

Heat treatment

Heat treatment furnace

 

Measurements, tests

Weight measurement
Dimensions measurement
Tensile test
Conductivity test
Hardaness test
Compression test
Metallurgical inspection

 

  1. Coil products

  2. Sheet producys