By Rose Eaton, Associate Publisher.
Architectural & Metal Systems (AMS) based in Little Island, Cork, Ireland, is the country’s sole producer of aluminum façade systems and bespoke extrusions for a variety of end users (Figure 1). Ireland is AMS’s biggest market, however, the company and their customers collectively ship fully finished aluminum extrusion profiles and ready-made façade systems all over the world. The company installed a new extrusion press earlier this year and is currently in the process of installing a new horizontal powder coating line to expand their finishing capabilities.
Company Background
Founded by Chris Martin, Dave Rawlings, and Pat O’Hara (Figure 2), AMS is a testament to resilience and innovation. With their collective experience in the aluminum industry during the 1980s, the three founders identified a gap in the market for stocking and selling aluminum in southern Ireland. After a decade working in the non-ferrous industry for another company, they decided to venture out on their own.
When it was launched in January 1990, AMS operated from a 6,000 sq ft warehouse. The company began by selling unplasticized polyvinyl chloride (UPVC) window systems imported from Germany and aluminum extrusions primarily sourced from the UK. The initial five years were fraught with challenges. The global impact of the Gulf War in August 1990, coupled with debts and the closure of their financing house, made profitability a struggle. However, the founders remained steadfast in their commitment to the business.
A significant transition occurred in 2001, when AMS moved to Little Island, Cork, and evolved from a company that sold aluminum to a manufacturer of aluminum itself. They purchased an expansive 86,000 sq ft facility, formerly a Sea Ray boat factory, and grew their team to 22 employees. Despite the uncertainty following the September 11th attacks in the U.S. later that year, AMS continued to forge ahead.
In 2002, the company installed its first horizontal paint line, marking the first time they had control over one of their own processes. This milestone was a turning point for AMS, and they’ve continued on a forward trajectory. Since 2019, the company has spent over €42 million ($45.4 million) to upgrade its facilities. This includes the purchase of two buildings on adjoining lots, which house AMS’s dispatch warehouse and sheet metal fabrication. Additionally, two purpose-built buildings house a new extrusion press line from GIA Clecim and a new anodizing line from Surface Aluminium Technologies (SAT).
From a Rugby Squad to the AMS Team
Pat O’Hara, managing director of AMS, is a retired Irish rugby union wing-forward. He won 15 rugby caps between 1988 and 1994 and was in the 1991 Irish World Cup squad. He also had the honor of winning the Irish rugby writers’ Player of the Year Award and won the Texaco Rugby Sportsperson of the year award for the 1989/90 season.
Being part of a champion team must have instilled a collaborative mindset in O’Hara, as today he runs the business with the same spirit of teamwork. Light Metal Age (LMA) had the privilege of a tour of the AMS facility led by O’Hara. As he swiftly walked the grounds, despite two knee replacements, he checked in with many of the employees, greeting them by name and asking questions about the current projects they were working on.
O’Hara takes a hands-on approach to his business and never stops moving. He is proud of what he helped to build, explaining, “We acquired the property in 2001 when it was just 86,000 sq ft across three buildings. Today, we’ve expanded to almost 400,000 sq ft.”
When the site was a former Sea Ray boats facility, O’Hara struggled to get in the door as salesman of non-ferrous metals. He never would have imagined then that he would eventually be in control of the whole place.
“We run our company almost like a family business, and although we have a large workforce, which now stands at 315, they all understand how we operate and have bought into this method of operation,” said O’Hara. The method he’s referring to is best described by their company motto, “Service Means Sales.” AMS does everything in its power to make sure that they are in control of all of the processes.
“We have spent years ticking off one process at a time. We now have the capacity to do everything in house under one roof from the very start of the process to the end without having to depend on anybody other than our billet, powder, and chemical suppliers,” O’Hara said. “Our customers know we can deliver and that is why they deal with us. We do not use an ERP system to tell us when the customer will get their orders. We depend on our own strengths to manage the screamers [sections that are urgently required], and if a customer is stuck they get sorted in hours or a few days rather than weeks.”
Inventive Products
AMS holds many patents, mainly on its thermal break systems for windows and doors. “The rest of Europe uses polyamide to separate the inside of the window from the outside. We have used polyurethane for years,” said O’Hara. “In the old days it was pour and cut like they use in North America. In fact, we still buy some products from AZON, who are market leaders in the U.S. Over the years, we developed products like our Thermstrip, which stretched the thermal break out to 38 mm (1.5 inches). Now we use foam in our top systems and that gets the effective thermal break out to about 60 mm or almost 2.5 inches.”
The company’s thermal break systems use a proprietary method to inject foam into extruded parts for improved thermal performance. One of the main uses of these thermal break systems is in doors and windows for hot and cold air separation. Lately, AMS has been producing 100 doors per week for American clients. A polycarbonate machine allows them to glaze doors in-house and the doors are fully assembled on-site prior to shipment.
Additionally, AMS supplies the Data Center industry. Each data center uses a lot of aluminum, not just inside on the containment, but in hot and cold aisle separation, louvres for ventilation (that could cover thousands of square meters outside of the data center), air handling units, and shading for cooling. Since AMS is a full-service supplier, they not only make all the parts, but also comprehensively package their products, including all necessary components for easy installation at the data centers.
“There is a lot of expertise in this industry in Ireland and our customers have been involved in projects all over the world,” said O’Hara. “They rely on a quick turnaround of product from the time of ordering, as these projects tend to go quickly once they start and any delays could lead to them losing orders or not being considered for future work. Having all our processes under one roof enables us to react quickly and support their requirements.”
LMA noticed a few other interesting projects of note during its tour of the facility, including profiles to be used as components for voting booth structures (Figure 3) in the upcoming American elections, as well as large aluminum extrusion profiles for an American company that makes stadium signage. “We’re pushing the limits of what our hydraulic extrusion press can do,” O’Hara proudly admitted.
Extrusion Operation
AMS sources aluminum billet (Figure 4) from several companies including primary aluminum from Emirates Global Aluminium (EGA), low carbon prime billets (produced using hydroelectricity) from Alcoa Inc. and Rio Tinto Group, and low carbon post-consumer billets sourced from Hydro’s facility in Deeside, North Wales. O’Hara noted that the current market trend increasingly favors environmentally sustainable options. Consequently, the provision of Environmental Product Declarations (EPDs) and Life Cycle Assessments (LCAs) for products has become a standard requirement for AMS. Although this trend has not yet fully permeated the North American market to the extent observed in Europe, it is anticipated to escalate rapidly once initiated.
The company operates three extrusion lines—all manufactured by GIA Clecim in Spain. The first is a 7-inch, 1,800 tonne press installed in 2010; the second an 8-inch, 2,400 tonne press commissioned in 2019; and the most recent addition (that began running in May 2024) is a 7-inch, 2,200 tonne press (Figure 5), along with space for a potential fourth press. The older presses run 24 hours a day, while the newest 7-inch press operates 12 hours a day, five days a week. The extrusion production capacity is capable of exceeding 300 tons per week through the state-of-the-art presses.
Control over their extrusion process enables the company to cater to non-standard lengths, an approach that minimizes waste and optimizes efficiency. After extrusion, the aluminum profiles undergo aging and strengthening via heat treatment. The final profile is either ready for delivery to the customer or can seamlessly progress through any of the AMS finishing processes, including powder coating, anodizing, a Decoral sublimation line dedicated to wood finishes, thermal break, or sheet metal fabrication.
Finishing Capabilities
AMS’s manufacturing capabilities are further enhanced by three powder coating lines and an anodizing line. The company has five HURCO CNC machines (and have just ordered one more). They also perform welding and some sheet metal work.
“Aluminum is so versatile you can do almost anything with it,” said O’Hara. “We supply extrusions for windows, doors, façades, ladders, signage, cladding, lighting, heatsinks, and renewable energy mountings—the list is endless. We don’t just want to sell mill finish. We want to coat or process the extrusions in some way to add value not just to our sales, but also to our customers.”
Powder Coating
AMS installed a horizontal paint line in 2002. A second line was originally installed in 2005, but was eventually decommissioned. The company then installed a vertical powder coating line by SAT in 2008. Although the vertical paint line was designed and installed more than 15 years ago, it was supplied with some innovative concepts that are still applicable today.
The vertical line features a pre-treatment tunnel in PVC/PP with cascades, drying and curing ovens combined in a single structure with a common wall in the center, and a coating booth with three self-cleaning walls and parallel guns to paint profiles that hang from rotating hooks. It was specially manufactured by SAT to fit the layout needs of AMS and to rationalize the flow of the material to seamlessly integrate with the facility’s production cycle from extrusion to finished product. The high-volume vertical line coats around 4,000 profiles in a 15 hour shift, but has the nominal capacity to process 5,000 profiles in 8 hours.
Now, AMS is preparing to install a new (second) horizontal powder coating line designed and procured by Richard Blevins, Aluminum Coating Services Ltd., which will oversee the installation.
Manufactured by Paint Finishing Systems, based in Wigan, in northwest England, the new horizontal powder coating line will sit beside the existing horizontal line. The goal is for both lines to run side by side when the capacity is required. The new line will have deeper tanks, providing AMS with 25% more capacity.
The oven has the latest hybrid curing and heat exchange technology leading to lower carbon emissions, and a heavy-duty conveyor, resulting in greater load density.
The Wagner SuperCenter EVO color-changing center provides industry leading powder application and dust free operation, as well as a full fire detection system.
“We are now producing a lot of brackets, fittings, and components that need powder coating, so the decision to install a second line was not only an insurance policy for the future, but also gives us greater capacity. The old line runs 24 hours a day 6 days a week, so if something were to go wrong with this, we would be in big trouble,” said O’Hara. “We also wanted to upgrade our pretreatment and effluent treatment for this area, so the decision was made to make the investment in a brand-new line with bang-up-to-date technology.”
The new pretreatment system has covers for all the heated tanks, and the dry off oven is also a sealed unit. The old line will be decommissioned, and the new pretreatment system will feed both horizontal paint lines. “The old dry off oven as well as the main stoving oven and jig burning oven leaked heat. We expect that there will be a considerable saving of energy on these items alone over time,” said O’Hara.
Anodizing Capabilities
In 2021, AMS introduced a state-of-the-art anodizing line (Figure 6) from SAT. This new anodizing line is designed to meet the highest standards of productivity and environmental friendliness. It is equipped with advanced features, including caustic etch to ensure a smooth and clean surface for anodizing, three anodizing tanks each with a capacity of 15,000 A, and a single electro-color tank with an 8,000 A capacity for adding color to the anodized products.
Additionally, hot sealing tanks are used to seal the anodized layer, enhancing durability. The line also includes all necessary auxiliaries, such as boilers, chillers, and water or steam distribution systems, ensuring smooth and efficient operation. Each tank is delivered with its own set of auxiliaries, making the process seamless.
An air collection system is in place for some tanks, with air being sucked in by encapsulated cranes and forwarded to a scrubber. This ensures environmentally friendly operation, reducing emissions and maintaining a clean working environment.
The entire process is controlled from a dedicated room, where a single operator monitors process parameters and ensures production follows the set recipes and plans. This is achieved through the human machine interface (HMI) of the anodizing line, allowing for precise control and adjustments. “We check the coating thickness after it comes out of the anodizing tank,” said O’Hara. “For internal use, we aim for 10 microns, while architectural applications require 20 to 25 microns.” Elaborating on the process timing, he said, “Each micron takes two minutes in the anodizing tank and seal. So, a 25-micron coating requires 50 minutes in the tank.”
The anodizing line boasts an impressive productivity rate of approximately 6-8 tonnes per shift (8 hours), making it a highly efficient system. “We have five sealing positions and three impact tanks. It’s beneficial to mix high and low micron processes and colors to optimize production,” said O’Hara, detailing the anodizing process. “We start with a dipping tank, followed by a rinse, then the anodizing tank that gives the desired finish.”
The SAT anodizing line features an I-shape layout, which is ideal for space saving in a building with limited width. Three automatic cranes manage the bars, including the return of empty bars from unloading to loading areas. Lifting devices make the loading and unloading of profiles ergonomic and efficient. Bars can be stored near the loading points and made available to operators without the need for cranes, thanks to special devices.
Sustainability
AMS has demonstrated a strong commitment to sustainability, as evidenced by its attainment of ISO14001, ISO50001, and LEED certification. The company has integrated approximately 40% recycled aluminum into its product mix, underscoring its dedication to environmental responsibility and resource efficiency.
Recent infrastructural enhancements, such as the construction of new walkways and cycle paths for employees, reflect AMS’s efforts to promote eco-friendly commuting options and improve the overall work environment. These initiatives not only contribute to the well-being of employees, but also align with broader sustainability goals.
During LMA’s tour of AMS’s facilities, the integration of the company’s anodized aluminum extrusion profiles into the building’s exterior (Figure 7) was highlighted. This seamless incorporation showcases the versatility and aesthetic appeal of AMS’s products, while also demonstrating the company’s commitment to sustainable design practices. O’Hara gave an example of the durability of anodized aluminum products. When they were remodeling their current office space, they needed to remove windows from a 40-year-old building. The bronze anodizing had retained its color and maintained a thickness of 25 microns on both sides, illustrating the long-term resilience of anodized aluminum, particularly in harsh environments like the Cork saltwater estuary, where AMS is situated.
The company’s commitment to renewable energy is evident in its extensive solar panel installation. The company has installed 2,500 solar panels on its roof, generating 1 MW of power. On sunny days, the solar panels generate 658 kW, with only 982 kW being drawn from the grid, accounting for over one-third of the company’s total energy consumption.
This solar installation has enabled AMS to produce approximately 15% of its electricity requirements per year, significantly reducing its reliance on grid electricity. Further, the company has plans to increase this capacity to 4 MW over time.
In addition to its renewable energy initiatives, AMS has implemented extensive water harvesting systems. Since Ireland is no stranger to rainfall, it is easy for the extruder to harvest rainwater from its roofs. The storage capacity for the water is 170,000 liters (or 45,000 gallons). This has been very helpful to AMS as they use a lot of water between the powder coating and anodizing lines. O’Hara noted that they have plans to keep this spent water in a loop rather than discharge it, as this will help reduce water usage even more.
“I’ve been with the company for 28 years now,” O’Hara said. “I was one of the original 22 employees who moved to this site in 1996. It’s been a great journey. The management has invested heavily in the facilities, which keeps things interesting. There’s always something new happening. We’ve come a long way since those early days.”
Editor’s Note: This article first appeared in the October 2024 issue of Light Metal Age. To receive the current issue, please subscribe.