1.

Billets to be used for pressing are placed on a billet loader which is moved to the billet conveyor into the billet heater or furnace (this has 3 chambers of heaters, max is 450 degrees) as soon as it attains its require temperature, the billet is clamped at the required length so as to be cut and conveyed to the pressing machine/ extrusion plant. 2. The extrusion machine is operated at a high temperature to enable pressing of the heated billet through the die. (Temperature of the die, billet and container must be complementary). 3. As it presses the mould/ molten billet through the die, the profiles formed are called press finish. The die opening could be 2 cavity or 3-cavity depending on the profile being extruded. 4. A try square is used to check the flatness/smoothness of the press finish as it comes out through the die. 5. The press finish is conveyed to the stretcher table for a. Cooling (using the exhaust fan above and the fans below. b. Stretching (using the stretcher machine at both ends. (The press finish is elastic at this point). NB: Press finishes on the stretcher table are called economy. After the billet is pressed through the die, the bottom part of the billet contains impurities and is cut off as scrap called the butt end or the bottom end. The butt end is weighed to measure the percentage of scrap to the useful press finish 6. The stretched and cooled press finish is sent to the cutting machine for the press finish to be cut into defined lengths and arranged in batches. 7. The batched lengths of press finish are sent to the ageing furnace for heating. The aim of ageing is for the press finish to regain all its lost strengths as a result of its subjection to very high temperature. The ageing process seizes its elastic properties and regains its hardness. 8. After the ageing process for 6-8hrs, the quality control officer checks for hardness with the use of the hardness tester. This is to ascertain the hardness from 10min-15max. 9. Treatment with Alukleen (8min) and Alucoat (chromate) (5min) and rinsing water (2min). Then dried in the drying tank using hot air. 10.Loading on the rack hanger to prepare for spraying. Spraying guns 8 (four Left and right). (Powder coating). QC will check for proper powder coating coverage before sent to the oven. 11.Then moved to the oven. The profile should be monitored to prevent over baking.

12.The QC checks for the micron of the powder (thickness). 50min-100max

Billet Heating/Cutting machine Temperature Pressure Length of billet Flow rate/Speed Time spent under heat Chemistry Explanation Mechanical and Electrical Explanation

Billet Extrusion Temperature Pressure Length of billet Time spent under heat Flow rate/Speed/Extrusion Speed Chemistry Explanation Mechanical and Electrical Explanation

FLOW CHART

Billet formation

Re-melting

Billet Heater Ballen (Recycling of scrap (butt end)

Billet Cutter

Billet extrusion/Press

Butt end removed

Press finish cooling

Stretching of Ageingfinish press of Press finish (ageing Powder on the furnace) of Treatment of Cutting Coating boot rail) finish Press finish Press (spraying gun