Industry Overview
Aluminium extrusion is a metal forming process in which a billet is forced through a die opening to produce a section with a smaller cross-sectional area. The process may be carried out by direct or indirect compression and can be performed under hot, warm, or cold conditions depending on the alloy and required properties. Extrusion offers the ability to produce a wide variety of profiles with close tolerances, enhanced grain structure and strength properties, and little material waste.
Extrusion performance depends on factors including the shape and size of the section, alloy, extrusion ratio, tongue ratio, tolerance, surface finish, extrusion speed, billet temperature, pressure, and scrap ratio. Proper control of billet temperature and extrusion speed is essential for achieving acceptable surface quality and dimensional accuracy. Aluminium extrusion also involves billet preparation, extrusion, quenching, stretching, cutting, artificial aging, inspection, and testing. The report further covers aluminium ingot manufacturing, raw-material preparation, melting, alloying, degassing, casting, quality control, plant and machinery, market aspects, plant layout, and suppliers.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (15000 sq.mt.) | Rs. 11.07 Cr |
| Plant & Machinery | Rs. 8.95 Cr |
| Working Capital for 2 Months | Rs. 14.97 Cr |
| Total Capital Investment | Rs. 35.62 Cr |
| Rate of Return | 47% |
| Break Even Point | 43% |
Content Index
- INTRODUCTION
- FACTORS AFFECTING EXTRUSION
- ADVANTAGES OF THE EXTRUSION PROCESS
- TYPES OF EXTRUDED PROFILES
- CLASSIFICATION OF ALUMINIUM EXTRUSION
- (A) DIRECT (FORWARD) EXTRUSION
- (B) INDIRECT (BACKWARD) EXTRUSION
- (C) HOT EXTRUSION
- (D) COLD EXTRUSION AND WARM EXTRUSION
- PROPERTIES
- PROPERTIES OF ALUMINIUM
- WEIGHT
- STRENGTH
- LINEAR EXPANSION
- MACHINING
- FORMABILITY
- CONDUCTIVITY
- JOINING
- REFLECTIVITY
- SCREENING EMC
- CORROSION RESISTANCE
- NON-MAGNETIC MATERIAL
- ZERO TOXICITY
- USES AND APPLICATION
- USES
- APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS
- DESCRIPTION OF PROCESS
- MANUFACTURING PROCESS OF ALUMINIUM INGOT
- (1) SCRAP PRETREATMENT
- METHODS OF PRETREATMENT
- (A) COMMINUTION
- (B) CLEANING
- METHODS OF CLEANING
- (I) MECHANICAL CLEANING
- (II) PYROMETALLURGICAL CLEANING
- (III) HYDROMETALLURGICAL CLEANING
- (C) SORTING
- METHODS OF SORTING
- (I) MAGNETIC SEPARATION
- (II) AIR SEPARATOR
- (III) EDDY CURRENT
- (IV) DENSE MEDIA SEPARATOR
- (V) HAND SORTING
- (VI) HOT CRUSH
- (VII) INNOVATIVE SORTING SOLUTIONS
- (D) DECOATING
- (2) CHARGING AND FLUXING
- CLASSIFICATION OF FLUXES FOR MELTING ALUMINUM
- (A) COVER FLUXES
- (B) DROSSING FLUXES
- (C) CLEANING FLUXES
- (D) WALL CLEANING FLUXES
- (E) DEGASSING FLUXES
- (F) GRAIN REFINERS
- (G) SILICON MODIFIERS
- (H) DEMAGGING FLUXES
- (3) MELTING PROCESS
- TEMPERATURE CONTROL
- SKIMMING
- ALLOYING
- (4) DEGASSING (MELT TREATMENT)
- (5) INGOT CASTING
- (6) QUALITY CONTROL
- (5) EMISSIONS AND CONTROLS
- (A) SCRAP PRETREATMENT EMISSIONS
- (B) SMELTING/REFINING EMISSIONS
- (6) SHIPMENT
- EXTRUSION PROCESS
- (1) BILLET PREHEATING
- TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE LUMINUM ALLOYS
- TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS
- (2) EXTRUSION
- (3) QUENCHING
- (4) STRETCHING
- (5) CUTOFF
- (6) ARTIFICIAL AGING
- TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS
- (7) INSPECTION AND TESTING
- EXTRUSION MATERIALS INSPECTION
- ALUMINUM ALLOY CHECK
- EXTRUSION DYE CHECK
- ADDITIVES CHECK
- EXTRUSION VISUAL INSPECTION
- VISUAL DEFECTS CHECK
- COLOR AND GLOSSINESS CHECK
- DIMENSIONAL INSPECTION
- COATING AND FINISHING CHECK
- WEIGHT AND DENSITY CHECK
- EXTRUSION PERFORMANCE INSPECTION
- TENSILE TEST
- WELDABILITY CHECK
- WORKABILITY CHECK
- CORROSION RESISTANCE
- FLAMMABILITY TESTING
- HARDNESS TEST
- WEATHERING RESISTANCE TESTING
- ABRASION RESISTANCE
- CHEMICAL RESISTANCE
- PLANT AND MACHINERY
- EXTRUSION PRESS
- DESCRIPTION OF EXTRUSION PRESS
- PROCESS FLOW CHART
- (A) FOR INGOT
- (B) FOR EXTRUSION
- MARKET OVERVIEW OF ALUMINIUM EXTRUSION
- ALUMINIUM EXTRUSIONS - THE PROS AND CONS
- INDIAN ALUMINIUM EXTRUSION INDUSTRY
- THE PLAYERS
- THE FUTURE
- SPREADING AWARENESS
- TOP TEN ALUMINIUM EXTRUSION COMPANIES IN INDIA
- JINDAL ALUMINIUM
- MAAN ALUMINIUM
- HINDALCO
- THE SUPERFINE GROUP
- GLOBAL ALUMINIUM
- ALOM GROUP
- CENTURY EXTRUSIONS
- GALCO
- SALCO
- EAGLE EXTRUSION PRIVATE LIMITED
- GLOBAL MARKET POSITION OF ALUMINIUM EXTRUSION
- INCREASING ADOPTION OF PRE-ENGINEERED BUILDINGS
- PLANT LAYOUT
- CUSTOMER LIST OF ALUMINIUM EXTRUSION
- SUPPLIERS OF ALUMINIUM EXTRUSION SECTIONS
- SUPPLIERS OF ALUMINIUM PROFILE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ALUMINIUM SCRAP
- SUPPLIERS OF SILICON POWDER
- SUPPLIERS OF IRON POWDER
- SUPPLIERS OF COPPER POWDER
- SUPPLIERS OF MAGNESIUM POWDER
- SUPPLIERS OF NICKEL POWDER
- SUPPLIERS OF ZINC POWDER
- SUPPLIERS OF LEAD POWDER
- SUPPLIERS OF TIN POWDER
- SUPPLIERS OF PACKING MATERIAL
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF DEGREASING CHEMICAL
- SUPPLIERS OF OIL AND GREASE
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CRUCIBLE FURNACE
- SUPPLIERS OF INGOT CASTING MACHINE
- SUPPLIERS OF SILICON CARBIDE CRUCIBLE
- SUPPLIERS OF SHEREDDER
- SUPPLIERS OF DE-COATER
- SUPPLIERS OF MAGENETIC SEPARATOR
- SUPPLIERS OF CASTING LADDLE
- SUPPLIERS OF SPECROMETER
- SUPPLIERS OF POROSITY TESTING MACHINE
- SUPPLIERS OF ALUMINIUM EXTRUSION PLANT
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Aluminium extrusion is a metal forming process in which a billet is forced through a die opening to create a section of a required cross-sectional shape. The process applies compressive forces to the billet and can be performed using direct or indirect extrusion methods. Depending on the alloy and production requirements, extrusion may be carried out under hot, cold, or warm conditions. The process is widely suited to producing profiles with consistent cross-sections and can provide close tolerances, useful mechanical properties, and efficient material utilization.
Aluminium extrusion performance is affected by the profile shape and size, alloy, extrusion ratio, tongue ratio, tolerance, surface finish, extrusion speed, billet temperature, extrusion pressure, and scrap ratio. These factors are interrelated and influence the ease of extrusion, dimensional accuracy, surface quality, production rate, and press requirements. Billet temperature and extrusion speed require particular attention because excessive values can adversely affect metal flow, dimensional tolerances, and thin edges or sharp corners.
The extrusion ratio is the area of the billet divided by the area of the extruded shape. It indicates the degree of mechanical working applied during extrusion and provides an important indication of extrusion difficulty. A lower ratio means that some portions of the material may receive relatively little mechanical work, while a higher ratio requires greater pressure to force the metal through the smaller die opening. The suitable ratio also depends on the alloy and the actual geometry of the extrusion.
Aluminium extrusion can produce a wide variety of shapes and can provide enhanced grain structure and strength properties under suitable cold and warm extrusion conditions. The process can achieve fairly close tolerances, particularly in cold extrusion, and generally produces little or no wasted material. Extrusion is therefore suitable for manufacturing long sections with uniform cross-sections. The report also identifies the ability to produce complex shapes, subject to the limitations imposed by alloy, geometry, extrusion ratio, tolerances, finish, and other process factors.
The main extrusion stages described in the report include billet preheating, extrusion, quenching, stretching, cutoff, artificial aging, and inspection and testing. The broader aluminium manufacturing process may also include scrap pretreatment, charging and fluxing, melting, alloying, degassing, ingot casting, quality control, emissions control, and shipment. Inspection can cover alloy composition, visual condition, dimensions, coating and finishing, weight and density, tensile strength, hardness, corrosion resistance, weathering, abrasion, chemical resistance, and other performance characteristics.
An aluminium extrusion plant may require equipment for scrap preparation, melting and casting, extrusion, material handling, testing, utilities, and environmental control. The report specifically covers an extrusion press and its description, as well as equipment such as crucible furnaces, ingot casting machines, silicon carbide crucibles, shredders, de-coaters, magnetic separators, casting ladles, spectrometers, porosity testing machines, extrusion plants, DG sets, EOT cranes, transformers, electrical panels, cooling towers, air compressors, weighing machines, and material-handling equipment.
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