SINCE 1952
ALWAYS IN THE FOREFRONT IN
EXTRUSION SYSTEM
Aluminium Middle East 2013
Innovation Podium
HIGH RELIABILITY AND EFFICIENCY ALUMINIUM
EXTRUSION PLANTS
Author : Giulia Bertoli – Sales Manager
OMAV S.p.A.
Italy
OMAV - 2013
•Facility
•Employees
•Turnover 2011
•Products
20.000 sqm
180 people
45 mln euro
press feeding line
handling systems
aging oven
die cleaning equipments
aluminium foudries
heat treatment furnaces
OMAV - 2013
THE GROUP
QUALITY ASSURANCE
PRE-ASSEMBLY AS A QUALITY TEST
THE ELECTRICAL & SOFTWARE
DEPARTMENT
This section of our company is dedicated to planning and designing the
electrical project, prepare and complete all the wiring on board of the
machines.
We make safety and reliability our prime objectives and use the latest
technology to ensure that our machines meet all electrical safety standards
and customer’s requirements.
HIGH AVAILABILITY AND HIGH EFFICIENCY
EXTRUSION LINE
OMAV has focused on the standardization of middle size
extrusion lines for logs of diameters 7” (177,8 mm) – 8” (203,4
mm) – 9” (228,6 mm) in order to be more competitive and to be
able to reach a 99% AVAILABILITY for the press feeding line and
99% for the handling system line.
EAP - EQUIPMENT AVAILABILIY PERCENTAGE
(Available time – Downtime time)
Available time
x 100%
7” EXTRUSION LINE – STD CONCEPT
PROFILE STACKER
AGING OVEN
COLD SAW
LOG FURNACE LOG STORAGE TABLE
HOT LOG SHEAR
STRETCHER TAILSTOCK
STRETCHER HEADSTOCK
HAND OFF PULLER
WITH SAW ON BOARD
AIR COOLING SYSTEM
LOG PUSHER
7” EXTRUSION PLANT – STD CONCEPT
SECTION OF THE PLANT
7” EXTRUSION LINE – MAIN DATA
MAIN TECHNICAL FEATURES
PRODUCTIVITY OF THE LINE
1.000 kg/h
LOG DIAMETER
7”
LOG FURNACE PRODUCTION
2.450 kg/h – 36 b/h
LOG FURNACE LENGTH
12,3 m
HOT LOG SHEAR
80 Ton
MAX PROFILE WEIGHT
8 kg/m
PROFILE DIMENSION
height = 150 mm; width = 350 mm
QUENCH UNIT
6 m with air cooling
6 m water spray cooling - 120m3/h
water consumption
LATERAL DOUBLE PULLER WITH SAW ON
BOARD
20 kg - 100 kg pulling force
STRETCHER FINGERS TYPE
50 Mton
FINAL CUT SAW
7.500 mm
LOG FURNACE
LOG FURNACE PRODUCTIVITY
 2450 kg/h 35 b/h
 ENERGY CONSUMPTION from 180 kcal/kg to 220 kcal/kg ± 10% for 2450 kg/h at 400°C
LOG FURNACE
REDUCTION OF HEAT DISPERSION
• New concept of door for the log entry and exit
• Thermocouple gate
LOG FURNACE
BETTER MAINTENANCE
• Movable external protection
• Thermocouple on the top of the furnace
• Increasing of rollers mean-life of 30% thanks to better alloy and new design.
LOG FURNACE
HIGH INSULATION
• First layer faced to the burners made in
refractory concrete
• Second layer made with insulating material
in ceramic fiber
BIGGER HEAT EXCHANGER to reach 300° C air
temperature.
CONTINUOUS REGULATION of the COMBUSTION
RATIO in function of the temperature of the
combustion air.
HOT LOG SHEAR
MAIN FEATURES
Horizontal shearing.
Movable knives to facilitate the
introduction of the log into the shear body
reducing the log deformation (8%) and to
avoid blisters on the profiles.
Optimization of the cycle through a
software that allows to use the pre-cut
billets without changing the tools.
Reduction of the shearing time thanks
to the system of auto -measurement of
the log. Shearing cycle of 40 sec.
Special cycle for hard alloy and pre cut
billets.
HOT LOG SAW
MAIN FEATURES
OMAV has engineered and built hot log
saws up to 14”.
In case of hard alloys the cutting
temperature is more than 500°C.
A double blade system in case of logs
with diameter more than 335 mm to
reduce the chips.
Controlled lubrication system with
nebulized spray directly on the blade
teeth.
Control of the cutting speed.
No need of cooling the blade.
Aspiration system to suck the smokes
due to blade lubrication.
COOLING SYSTEMS - GENERAL
OMAV engineers and builds different cooling systems according to the
customers’ requirements. OMAV offers different solutions for these types of
cooling systems:
• Intensive air cooling
• Water spray and water wave
• Water wave, water spray and air in the same quench
AIR COOLING FOR LIGHT PROFILES
AIR COOLING
The cooling occurs from the top through air channel with suitable slot
nozzles near the profiles and from the bottom with air channel.
The hood is fed by a fan dedicated controlled by frequency converter and
butterfly valve.
COOLING SYSTEMS
This configuration gives the maximum flexibility on the cooling regulation of
the tunnel, allowing to adjust any deformations of the profiles due to the
asymmetric shape.
All the valves, ON/OFF and the proportional ones, are controlled by the PLC, it
is possible to choose a cooling configuration, according to the profile shape, to
put in the PLC memory and to recall the wanted configuration in case of using
the same die.
DOUBLE PULLER
OMAV has engineered and built pullers
up to 4000 kg (8800 lbs) pulling force.
In 2002 OMAV introduced a
revolutionary puller system with a rack
and pinion drive system.
•The drive motor is installed directly on board on the
puller carriage.
• The movement occurs thorough a rack and pinion
system (helical-toothed).
• Power supply by contact rails or power track
DOUBLE PULLER
Key Advantages
• Smooth and precise movement of the puller carriage with no surface
damage to the profiles (vibrations, die marks).
• Significantly lower power requirement for the drive motor due to
elimination of power transmission elements (chains, cables)
DOUBLE PULLER INSTALLED POWER
TRADITIONAL
PULLER WITH
TRANSMISSION BY
CHAIN
OMAV’s PULLER WITH
TRANSMISSION BY
RACK-PINION AND
MOTOR ON BOARD
200 kg
200 kg
Max Extrusion speed
80 m/min
80 m/min
Max Return speed
200 m/min
200 m/min
27 KW
11 KW
MAIN DATA OMAV
PULLER
Pulling force
INSTALLED POWER
STRETCHER
• The movement is provided by powered wheels.
• Jaw with fingers for a better gripping of the profile and equipped with a
common hole to lock together all fingers in case of solid bar.
• Stretching drive through hydraulic cylinder.
• Positioning of the tailstock by an absolute encoder or laser photocell.
• The positioning of the tailstock is locked by a proper anchoring pin.
• The scraps are 500 mm long each part (headstock and tailstock) but it can
change according to different types of profiles.
COLD SAW
QUALITY
•Cutting surfaces completely smooth
•High cutting precision
•Optimization of the cycle with a scrap
handling
RELIABILITY
•Hard sharps according to the type of
alloy
•Increase of number of cuts per blade
•Reduction of the noise during the cutting
phase thanks to silencer blade
EFFICIENCY
•High performance system for chips
evacuation, that are sucked from three
points, upper lower and lateral position.
•95 % chips aspiration
•Cutting cycle of 30 sec
OMAV SAW GAUGE TABLE - LATERAL
Lateral moveable gauge travels on
lateral guides.
Movement through AC motor and
frequency converter
acting through a pinion gear and rack
mounted on the frame.
Locking brake actuated by air-oil
pressure booster, clamps the gauge
stop firmly in position.
OMAV AUTOMATIC PROFILE STACKER
TYPE: Overhead stacker with 3-axis, with brushless motors and semiautomatic feeding system of spacers.
SPACER DISTRIBUTOR: This is a semi-automatic station for spacer feeding. The
spacers must be placed manually by the operator inside of a collection box under
which are installed the pickup devices. Automatically then the spacers are picked up
and sent to feeding position under the stacker.
MAIN FEATURES
•HIGH STACKING PRECISION
•HIGH QUALITY PRODUCT KEPT THROUGH
ALL THE CYCLE
•HIGH CYCLE TIME –
 30 sec without spacers
 35 sec with spacers distribution
system
•HIGH AVAILABILITY
OMAV’s CHALLENGE FOR THE FUTURE
OMAV is always focusing on the satisfaction of his customers and wants to be
even more close to them.
For this reason we believe that is strategic to have a well organized after sales
office. We have a unit in OMAV with dedicated people who follow up the
customers from the starting project up to the after sales. Then we have
established two other units:
• OMAV FOSHAN for our Chinese customers
• OMAV NORTH AMERICA for the American market, with dedicated people on
the service and after sales.
We believe that the results that we have already reached will be a beginning
for even better long-term results with the main objectives to satisfy our
customers.
THANK YOU FOR YOUR ATTENTION
We are available for any questions
or any additional information