Gerhardi Alutechnik in Lüdenscheid is implementing a new kind of cooling concept for the extrusion of aluminium profiles. The aim of the pilot project is to raise energy and material efficiency during the production of aluminium profiles. The innovative project is receiving support from the Federal Environment Ministry (BMU) in the form of roughly 120,000 euros from the Environmental Innovation Programme.
In the production process for aluminium profiles made of high-strength alloys, in order to achieve the ideal material structure the extruded profile must be abruptly cooled with water downstream from the press. Currently the cooling process takes place in a seven-metre long cooling tunnel with fixed water jets. Because the jets are arranged in fixed positions, the water jets don’t reach “small” profile cross sections, or only partially. This factor has a negative effect on product quality and productivity. Moreover, a lot of water and electricity is wasted.
Gerhardi Alutechnik has now invested in a new profile cooling system with thirteen pivoting and radial adjustable jet lines, in order to be able to adapt the cooling system to the specific profiles. This way the distance between the individual jets and the profile can be optimally adjusted to efficiently utilize only the amount of water actually required and the pump power necessary. With the cooling chamber now positioned closer to the machine, the cuttings are also shorter.
Compared to a classic extrusion process with a water cooling system, at a throughput quantity of 2500t/annually roughly 78,000 kilograms of aluminium and 112,500 cubic metres of water can be saved. Moreover roughly 52,500 Kilowatt hours of electricity can be saved. This saves 29,700 kilograms in CO2 emissions annually.