• The Process and Plant status is presented to the operator with a set of screen pages in which all the objects are represented with icons and animations. This allows the immediate identification of any process/equipment that is not in the proper operating condition.
• A continuous check of the process and the equipment status of the area is performed. As soon as a relevant problem is detected, an “alarm” is immediately issued to the operator on the bottom line of the operator panel monitor.
• The non-volatile database of the Process Control System is designed with particular care to data consistency and integrity.
• A standard open-type relational database is used to allow the customer developing new applications that access this database, using the standard access method ANSI-SQL. The relevant information concerning each extrusion cycles are stored in this Data Base.
• The extrusion Reports are generated and can be displayed and printed on operator’s request. Report per shift, day, week are available and printed upon operator request or automatically at the end of the operating cycle.
• The Ethernet network of the Tecalex aluminium extrusion plant is completely independent from the customers’ network in order to avoid possible conflicts and allows communicating the customer equipment with our Technical Service through the main control board.
• On the HMI Human Machine Interface can be obtained the following information that to help the operator and maintenance team:

• Robust structure made of welded steel profiles driven by a chain for the transport of the logs.
• Hydraulic system with cylinders and flow compensation to assure a precise loading of the logs and avoids shocks.
• The precise movements are done at very low noise level and the log is placed exactly on the furnace axis.
• Soft guidance on the logs pushing rollers.
• The feeder is driven from a gear drive, placed near to the furnace entrance, equipped with a position feedback to control the input length of the log.
• Quick replacement of alloys because of the 0º slope.

• This brushing unit it is composed by a planetary disc that turns on two big bearing balls. This disc is moved by a motor gear of alternative three-phase with trapezoidal belts transmission.
• On this disc, and placed at 120º on to each other, there are 3 brushes with steel barbs that its diametrical position can be adjusted independently with a thread mechanism. Once the brushers are placed correctly to the required diameter it can be block at this position. Also, each one of these mechanism has a spring that compensate for the effect of the centrifugal force.
• Additionally, each brusher has an anti-turn system that guarantied the optimum contact between the steel barb and the aluminium bar.
• The protection of the machine is made by four pieces screwed between them to make an easy maintenance of the machine.
• The main body of the machine has two lateral windows for connection of an aspiration tube that goes to a machine of aspiration and filtering the dust.
• The dust-exhaust filter system is explosion-proof type.
• The cartridges are self-cleaning by means of automatic washing in counter-current with compressed air.
• The dusts accumulated in the cartridges are discharged by means of a hopper in a proper seal-tight container.

• Structure coated inside with a refractory ceramic material and ceramic fibre panels, it has been specially designed to maintain the temperature and insulate the inside of the furnace from the outside.
• The aluminium log enters the furnace at ambient temperature and leaves it at a temperature of approximately 500ºC. Progressively higher temperatures within the furnace are obtained by the independent control of each of the burner areas.
• Between combustion chamber and pre-heating chamber a bridge of refractory steel with an insulating panel prevents heat dissipation.
• Situated in each of the different areas of the furnace, the thermocouples monitor the temperature of the log and record it by direct contact and are situated laterally to allow an easy access for maintenance.
• The hot exhaust gases system benefits from a heat resistant turbine that sucks the gases form the burner areas and through a distribution system the gases are blasted onto the surface of the incoming billets at high speed. This increases the heat transfer coefficient and creates an important temperature increase.
• The log is guided through the furnace by stainless steel rollers platforms.
• To have an easy and fast maintenance, the top of the furnace can be removed easily with a crane because of its special light weight design.

• Optimised soft movements during clamping to avoid any damage on the billet surface.
• Special design and strict tolerances of the clamping system that allows having a very clean cut with minimum deformation on the billet end diameter and a flat vertical surface at both ends that avoids any air entrapment when the billet is precompressed.
• High quality guiding and hydraulic cylinders system that provide a precise shearing operation.
• Billet rest optimisation program that allows working with two piece billets as if it was a continuous log feeding and minimizing the scrap to zero.

• The translation movement is done with electrically operated gear drive and toothed thermoplastic polyurethane belt with integrated steel cords.
• High positioning precision controlled by encoder.
• Inverter controlled linear speed.
• Fast and precise movements minimizing the dead cycle time and giving a high precision positioning of the billet on the extrusion axis as required for the newest front loading modern presses.
• The billet is transported on two movable arms, hydraulically operated.
• The movements of the telescopic rollers shelve are done with hydraulic cylinders and allow working with two pieces billets.
• Encoder controlled opening, adjusting it to the actual billet length (container opening depending on the actual billet length).
• Low maintenance requirements.
• Robust structure made of welded steel anchored to the floor of the workshop to avoid vibrations on the system.
• High quality guiding processing a precise and quick feeding operation.

• Tecalex quenching table is able to work with two fluids in order to cool the profiles properly: Air cooling and water cooling.
• Air Cooling is used with profiles with relatively thin wall thickness or in profiles sections where mass is not uniformly distributed and differential shrinking effects due to high cooling speed are expected. The air is distributed all over the table’s surface with a distributor channel and exit nozzles.
• Water Cooling is used with profiles with large wall thickness and in profiles where not differential shrinking is expected. The water nozzles are distributed all over the table’s surface to guarantee homogeneous quenching operation. Sprayed water, which has not evaporated on the profile is collected with the tray and can be used again with a re-circulation system.
• Regulation of the height of the tray is adjusted by hydraulic cylinder near to the press mouth.
• The top cover lifting system allows to the operator has easy access to all parts of the tray and press mouth.

• Rectangular nozzles give the air stream the optimal shape to cool profiles uniformly.
• Centrifugal fans are easily controlled by means of frequency inverters adapting the air speed to the requirements of each profile.
• Wind boxes can be placed beneath the profile (inside the lead-out table) or above the profile at a height over the puller.

• Equipped with high temperature resistant Kevlar rollers.
• Automatic tilting rollers system allows any misalignment between the profile and the extrusion axis during the interchange of profiles with the double puller flying cut system.

• There are three types of puller systems, the single puller, the double puller flying cut and the twin bypassing pullers with independent saw.
• The double puller flying saw is able to cut profiles with no need to stop the extrusion process.
• The flying saw system cuts exactly on the weld mark so scrap share is minimized.
• The puller movement transmission is driven by a toothed belt and gear motor.
• Clamps movements in both pullers are powered by hydraulic cylinders with hydraulic units on board.
• Forward movement of the disk saw by means of a screw jack system.
• The disk saw is powered by a double speed electric motor.

• Robust support structure made of welded steel profiles, with modular conception, easily adaptable to the specified length and prepared for and easy commissioning and maintenance.
• Run out conveyor with textile rollers made out of high resistant temperature, with up/down movement to produce a smooth horizontal transfer to the extracting arm.
• Profile handling based on arms, with an aluminum structure with textile belts resistant to the temperature on each area, securing a smooth passage avoiding profile damages and keeping the appropriate distances to guaranty the final cooling before the stretcher.
• Automatic sliding arms for the transfer of the profile to the stretcher, allowing the stretcher head to move automatically as well to the desired stretching position.
• Saw conveyor with textile rollers, with up/down movement, to allow an smooth transfer of the profiles from the batching arms, placed after the stretcher section.

• Stretching is produced between two heads, one fixed and one mobile that automatically adapts to the length of the profiles to be stretched.
• The design of the clamps and bottom plate is made with a special geometry avoiding the profile slipping out of the head during traction.
• Smooth transfer of the profiles to each head by means of devoted lifting arms.
• Possibility to work in different ways from two operators, one in each head, to one operator in the fixed head with cameras placed in the mobile and finally in automatic mode, with no operators.
• Infrared communications between both heads for control signals.
• High quality image. Signal transmission between heads by means of industrial web-cam of high performance qualities. Colour monitor of 12” (PC Panel).
• Distance between heads controlled by laser system.

• High quality of guidings and geardrives, giving a precise positioning movement and saw cut.
• The clamping system allows holding the profile with a force controlled by the operator.
• The saw carriage andvances by means an inverter in a close loop control system.
• The saw blade is rotating all the time.
• A powerfull vacuum unit works all the time removing the chips generated during the cutting process.

• High speed heated air is passed from a combustion chamber, through the length of the oven and recirculate through an upper channel.
• These ovens are of optimum efficiency and make use of high quality isolation materials therefore being of very low energy consumption.
• Metal structure lined with insulating panels and a very low thermal inertia.
• Galvanized inner parts in order improve resistance and durability.
• Skip transfer through the oven means of motorized rollers.
• Swivel or guillotine door options available.
• Fully automated operation and cycle control.

• Compact design and high efficiency.
• Electrically heated and are electronically controlled/monitored.
• Pneumatically operated oven lids.
• Stainless steel inner heating chamber with the outer structure made of steel plate fixed on a laminated structure.
• Ceramic fibre and mineral wool offers good thermal isolation in a reduced volume.
• Outside surface no higher than 40ºC above room temperature.

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