ALUMINIUM FOILS, PLATES AND SHEETS

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Aluminium is the world’s most abundant metal and is the third most common element, comprising 8% of the earth’s crust. The versatility of aluminium makes it the most widely used metal after steel. Although aluminium compounds have been used for thousands of years, aluminium metal was first produced around 170 years ago. In the 100 years since the first industrial quantities of aluminium were produced, worldwide demand for aluminium has grown to around 29 million tons per year. About 22 million tons is new aluminium and 7 million tons is recycled aluminium scrap. The use of recycled aluminium is economically and environmentally compelling. It takes 14,000 kWh to produce 1 tonne of new aluminium. Conversely it takes only 5% of this to remelt and recycle one tonne of aluminium. There is no difference in quality between virgin and recycled aluminium alloys. Pure aluminium is soft, ductile, and corrosion resistant and has a high electrical conductivity. It is widely used for foil and conductor cables, but alloying with other elements is necessary to provide the higher strengths needed for other applications. Aluminium is one of the lightest engineering metals, having strength to weight ratio superior to steel. By utilising various combinations of its advantageous properties such as strength, lightness, corrosion resistance, recyclability and formability, aluminium is being employed in an ever-increasing number of applications. This array of products ranges from structural materials through to thin packaging foils.

PROPERTIES

The major advantages of using aluminium are tied directly to its’ remarkable properties. Some of these properties are outlined in the following sections.

(1) STRENGTH TO WEIGHT RATIO

Aluminium has a density around one third that of steel and is used advantageously in applications where high strength and low weight are required. This includes vehicles where low mass results in greater load capacity and reduced fuel consumption.

(2) CORROSION RESISTANCE

When the surface of aluminium metal is exposed to air, a protective oxide coating forms almost instantaneously. This oxide layer is corrosion resistant and can be further enhanced with surface treatments such as anodising.

(3) ELECTRICAL AND THERMAL CONDUCTIVITY

Aluminium is an excellent conductor of both heat and electricity. The great advantage of aluminium is that by weight, the conductivity of aluminium is around twice that of copper. This means that aluminium is now the most commonly used material in large power transmission lines. The best alternatives to copper are aluminium alloys in the 1000 or 6000 series. These can be used for all electrical conduction applications including domestic wiring. Weight considerations mean that a large proportion of overhead, high voltage power lines now use aluminium rather than copper. They do however, have a low strength and need to be reinforced with a galvanised or aluminium coated high tensile steel wire in each strand.

(4) LIGHT AND HEAT REFLECTIVITY

Aluminium is a good reflector of both visible light and heat making it an ideal material for light fittings, thermal rescue blankets and architectural insulation.

(5) TOXICITY

Aluminium is not only non-toxic but also does not release any odours or taint products with which it is in contact. This makes aluminium suitable for use in packaging for sensitive products such as food or pharmaceuticals where aluminium foil is used

(6) RECYCLING

The recyclability of aluminium is unparalleled. When recycled there is no degradation in properties when recycled aluminium is compared to virgin aluminium. Furthermore, recycling of aluminium only requires around 5 percent of the input energy required to produce virgin aluminium metal.

The combination of two remarkable properties of aluminium makes the need to recycle the metal obvious. These first of these factors is that there is no difference between virgin and recycled aluminium. The second factor is that recycled aluminium only uses 5% of the energy required to produce virgin material. Currently around 60% of aluminium metal is recycled at the end of its lifecycle but this percentage can still be vastly improved.

Aluminium is a chemical element in the boron group with symbol Al and atomic number 13. It is a silvery white, soft, ductile metal. Aluminium is the third most abundant element and the most abundant metal in the Earth’s crust. It makes up about 8% by weight of the Earth’s solid surface.

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Description

INTRODUCTION
PROPERTIES
(1) STRENGTH TO WEIGHT RATIO
(2) CORROSION RESISTANCE
(3) ELECTRICAL AND THERMAL CONDUCTIVITY
(4) LIGHT AND HEAT REFLECTIVITY
(5) TOXICITY
(6) RECYCLING
PHYSICAL PROPERTIES OF ALUMINIUM
OTHER INFORMATION ABOUT ALUMINIUM
USES OF ALUMINIUM
(1) ALUMINIUM PLATE:
(2) ALUMINIUM SHEET:
SPECIFICATIONS
USES
ALUMINUM SHEET ADVANTAGES
CONTINUOUSLY RECYCLABLE SHEET METAL
HIGH-PERFORMANCE ARMOR
ALUMINUM SHEET GAUGE
THE COLDER THE TEMPERATURE, THE STRONGER THE ALUMINUM
ALUMINUM SHEET APPLICATIONS
PACKAGING INDUSTRY
HOME APPLIANCES
BUILDING & CONSTRUCTION INDUSTRY
(3) ALUMINIUM FOIL:
SPECIFICATIONS
USES AND APPLICATION
(A) FOR PLATE
(B) FOR SHEET
(C) FOR FOIL
USES
USE OF ALUMINIUM IN FOOD & BEVERAGE SECTOR
1. FOIL ROLLS OF DIFFERENT THICKNESS & WIDTH
SPECIFICATIONS
USES
USE OF AN ALUMINIUM FOIL IN MAKING OF FOOD CONTAINERS
1. FOIL ROLLS – PRINTED FOR BLISTER PRODUCTS
SPECIFICATIONS
USES
USE OF PRINTED FOIL ROLLS FOR PACKEGING & IN PHARMACEUTICALINDUSTRY
2. FOIL ROLLS – PLAIN FOR PHARMACEUTICAL INDUSTRY
SPECIFICATIONS
USES
USES OF PLAIN ALUMINIUM FOIL
B.I.S. SPECIFICATION
PROCESS FLOW DIAGRAM
(A) FOR INGOT
(B) FOR PLATE
(C) FOR SHEET
(D) FOR FOIL
FOR LAMINATION AND COATING
MANUFACTURING PROCESS
(A) MANUFACTURING PROCESS OF ALUMINIUM INGOT
(1) SCRAP PRETREATMENT –
(A) MECHANICAL CLEANING –
(B) PYROMETALLURGICAL CLEANING –
(C) HYDROMETALLURGICAL CLEANING –
MELTING
MOC-SKELNER FURNACE
TEMPERATURE CONTROL
DEGASSING
POURING
CLEANING
(3) EMISSIONS AND CONTROLS
(A) SCRAP PRETREATMENT EMISSIONS –
(B) SMELTING/REFINING EMISSIONS –
SHIPMENT PROCESS FOR INGOT:
(A) MANUFACTURING PROCESS OF ALUMINIUM PLATE
(C) MANUFACTURING PROCESS OF ALUMINIUM SHEET
DISCRIPTION
ROLLING PROCESS
(D) MANUFACTURING PROCESS OF FOIL
WORKING PROCESS FOR LAMINATION AND COATING
1. CHART
DESCRIPTION
MEANING OF ROLLING:
HOT ROLLING
COLD ROLLING MILLS
FOIL MILLS
DEFECTS IN ROLLED PRODUCTS:
(I) EDGE CRACKING:
(II) FOLDS:
(III) ALLIGATORING:
(IV) SCALE FORMATION:
ROLING MILL AND EQUIPMENTS
KEY EQUIPMENTS
KEY EQUIPMENTS IN SHEET DIVISION
1. 4-HI REVERSING ROLLING MILL
SPECIFICATIONS
2. SLITTER MACHINE
SPECIFICATIONS
3. CUT TO LENGTH MACHINE
SPECIFIVATIONS
4. ANNEALING FURNACE (ELECTRICIALLY HEATED)
SPECIFICATIONS
KEY EQUIPMENTS IN FOIL DIVISION
1. ROLLING MILL
SPECIFICATIONS
KEY EQUIPMENTS IN CONVERSION DIVISION
1. HEAT & PRESS LAMINATOR MACHINE
SPECIFICATIONS
2. COATING MACHINE
SPECIFICATIONS
DISCRIPTION
ROLLING PROCESS
WORKING PROCESS IN FOIL DIVISION
1. CHART
DISCRIPTION
WORKING PROCESS IN CONVERSION DIVISION
2. CHART
DESCRIPTION
EQUIPMENTS
KEY EQUIPMENTS IN SHEET DIVISION
1. 4-HI REVERSING ROLLING MILL
SPECIFICATIONS
2. SLITTER MACHINE
SPECIFICATIONS
3. CUT TO LENGTH MACHINE
SPECIFIVATIONS
4. ANNEALING FURNACE (ELECTRICIALLY HEATED)
SPECIFICATIONS
KEY EQUIPMENTS IN FOIL DIVISION
1. ROLLING MILL
SPECIFICATIONS
KEY EQUIPMENTS IN CONVERSION DIVISION
1. HEAT & PRESS LAMINATOR MACHINE
SPECIFICATIONS
2. COATING MACHINE
SPECIFICATIONS
MARKET OVERVIEW
SWOT ANALYSIS OF THE INDIAN ALUMINUM INDUSTRY
1. STRENGHTS:
2. WEAKNESS:
3. OPPORTUNITY:
4. THREATS:
MARKET GROWTH
GLOBAL MARKET
PLANT LAYOUT
SUPPLIERS OF ALUMINIUM PLATE AND SHEET
SUPPLIERS OF ALUMINIUM FOIL FOR FOOD AND PHAMEUTICAL INDUSTRY
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM SCRAP
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ALUMINIUM ROLLING MILL
EUROPEIAN SUPPLIERS OF ALUMINIUM FOIL MILL
INDIAN SUPPLIERS FOR ALUMINIUM FOIL MILL
EUROPEIAN SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF ANNEALING FURNACES
EUROPEAN SUPPLIERS OF AUTOMATIC FLATNESS CONTROL,
AUTOMATIC GAUGE CONTROL AND SEPARATOR
SUPPLIERS OF FOIL PRINTING MACHINE, LAMINATING MACHINE
AND EMBOSSING MACHINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF MILLING MACHINE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF BOARING MACHINE
SUPPLIERS OF POWER HACKSAW
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
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 – 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)

Additional information

Plant Capacity

200 MT/Day
Land & Building

(20,000 sq.mt.)
Plant & Machinery

US$ 17461428
Rate of Return

44%
Break Even Point

43%

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