Hydro Extrusion North America placed an order for a complete 8 inch, 25 MN extrusion line from SMS group and OMAV, a specialist in the field of aluminum extrusion systems. Engineered to Hydro’s high operational standards, the new line features an innovative HybrEx® press and a patented electric scrap shear will be installed at the company’s facility in Gainesville, Georgia. The line is designed to significantly enhance production efficiency, operational safety, and sustainability in the production of extruded profiles.
“At Hydro, we are committed to modernizing our operations with equipment that improves our safety, efficiency, and capacity,” said Ralph Westphal, vice president and general manager of Hydro Extrusion North America’s South and East regions. “This investment in Gainesville represents a significant step in our modernization strategy and we are excited to implement these cutting-edge technologies.”
Hydro’s Gainesville plant in Georgia has 350 employees and provides extrusion, fabrication, and finishing services to the building and construction industry and other key markets in North America. The new HybrEx extrusion press line will be used to replace an existing line at the facility.
A key feature of the HybrEx press is that it provides a significant reduction in hydraulic system oil usage, because traditional oil tanks and high-temperature cylinders around the hot billet container are no longer required. The press achieves a reduction in oil volume by combining the use of hydraulics to generate the press force and the electrification of the travel paths, which ensure safe operation and consistent performance without any temperature-related fluctuations. This intelligent combination of hydraulic and oil quantity reductions means more than 30% less energy is consumed compared to conventional extrusion presses, as well as shorter dead cycle times.
The HybrEx line also includes a high-efficiency gas furnace and the SMS-patented electrical scrap shear, which delivers high precision and reliability in cutting processes, both crucial for efficient production. The fully electrical shear eliminates the need for hydraulic systems, creating an oil-free hot zone, which enhances operational safety and reduces environmental impact. This system incorporates a self-adjusting, moving scrap shear, which automatically adapts to the height of the material, ensuring optimal, clean cuts. Furthermore, the electric shear technology addresses the wear challenges commonly associated with conventional systems, enhancing longevity and performance.
A special focus of the close collaboration between Hydro and SMS involved the safety of the new extrusion line, with the aim of protecting and securing both personnel and machinery. This emphasis on safety reflects Hydro’s commitment to creating a safe working environment and minimizing the risk of accidents.
“This project underscores our longstanding partnership with Hydro,” said Massimo Marinelli, CEO of OMAV, “By combining SMS group’s technological leadership with OMAV’s automation expertise, we have delivered a future-proof solution that meets Hydro’s high standards in efficiency, safety, and sustainability.”