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SUPPLYING MARKET LEADERS ALL OVER THE WORLD

ALEMO has Developed & Manufactured more than 90 extrusion lines and other conversion machines for Polyethylene, Polypropylene and Polystyrene foam production. In the past 15 years we supplied foam extrusion lines and other foam machinery to market leaders in almost every part of the World – Europe, North & Latin America, Australia, India, Russia, Japan and Central Asia.

DEDICATION TO EXCELLENCE

ALEMO has an in-house research and development team. Besides that, we cooperate with external partners and institutions as well. We are all constantly looking for technical solutions to make better machinery. The goal is to increase productivity. We also seek to achieve a higher and more constant quality of the product itself. Plus, we are focused on reducing scrap, make the equipment more customer-friendly and reduce energy consumption.

The choice of installing first-class components and using the best quality materials is our philosophy. This approach allows us to reach a long lifespan of equipment, reliability and higher performances. One of the pillars of our approach and business philosophy is the strong aftersales support with technology upgrades. What’s more, we offer on-line remote service support. Along with a process know-how to reach excellent product quality results. All in the shortest time possible after machinery start-up.

REDUCING ENERGY AND RAW MATERIAL CONSUMPTION BY HIGHER PRODUCTIVITY

EPE foam production has still many possibilities to be improved, in terms of lower density, better cell size, strength, performance, but also in terms of productivity. Extrusion of good quality thin PE foam on 1500mm (60”) or 1800mm (72”) roll width requires one level of technology, but extrusion of foam sheet on 3000mm (120”) width at 0.5mm / 1mm (0.02 / 0.04 inch) thickness keeping less than 5% deviation in thickness and density requires a completely other level of technology. The productivity can be more than doubled thanks to a better die, expanding mandrel and winding technology. Indeed, such technology is today already proven and available at ALEMO Foam machinery producer.

This is a comparison of raw material and energy consumption between an Top performing extrusion line producing foam at 1500mm (60”) width and between a New ALEMO technology line able to produce EPE thin foam sheet on 3000mm (120”) width (2x 60”). The subject of this comparison is the quantity of raw material and energy consumption to produce one unit of product.

Please refer to the below charts where the red column data were collected as an estimation and the green column data measured directly and taken from production reports.

Raw material consumption

*Main source of raw material reduction which is not even included in the graph, is in scrap required for die changes starts / stops. With 95’’- 120’’ width regulated by expandable mandrel all the widths required by the market can be produced without any line starts / stops and die change but just with SLITTING CHANGE.

The raw material consumption for producing one (1) ft2 of PE sheet foam of 1/32’’ thickness on the “New ALEMO line” is 25% lower compared to “Top performing lines” around the world. The raw material consumption for producing one (1) ft2 of PE sheet foam of 3/32’’ thickness on the “New ALEMO line” is 22% lower compared to “Top performing lines” around the world.

Actual productivity

The actual productivity in terms of ft2/h (PE sheet foam, 1/32’’ thickness) of the “New ALEMO line” is 127% higher compared to “Top performing lines” around the world. The actual productivity in terms of ft2/h (PE sheet foam, 3/32’’ thickness) of the “New ALEMO line” is 117% higher compared to “Top performing lines” around the world.

Actual energy consumption

The energy consumption in (kWh) for producing one (1) lb of PE sheet foam of 1/32’’ thickness on the “New ALEMO line” is 180% lower compared to “Top performing lines” around the world. The energy consumption in (kWh) for producing one (1) lb of PE sheet foam of 3/32’’ thickness on the “New ALEMO line” is 180% lower compared to “Top performing lines” around the world.

Actual energy consumption

The energy consumption in (kWh) for producing one (1) ft2 of PE sheet foam of 1/32’’ thickness on the “New ALEMO line” is 273 % lower compared to “Top performing lines” around the world. The energy consumption in (kWh) for producing one (1) ft2 of PE sheet foam of 3/32’’ thickness on the “New ALEMO line” is 250 % lower compared to “Top performing lines” around the world.

From above mentioned charts we may understand more clearly about the volume of raw material, huge costs savings and lower carbon footprint thanks to technology improvement.