Our Firm

It was established June 18th, 1980, for the purpose of Producing and selling aluminum slugs, discs, plates and strips.

Alucenca uses in it´s process, primary aluminum ingots, produced in Venezuela by the world known aluminum industries “CVG Alcasa” and “CVG Venalum”

 
 
Our Mission

To satisfy the demands of our clients and to continue being the best suppliers of aluminum slugs in the world, allowing profits that permit us to grow in capacity, technology and service to the client.
 
 
 
        Our Principal Values
  • Clients, our main reason for existing.
  • Workers, main booster of our organization.
  • Products, motive of pride and compromise.
 
Production Process - Illustration
 
 

Production Process

Smelting

This stage starts by loading furnaces Nº 1 y Nº 2 with 30MT each of raw aluminum (alloy AA1070, purity 99,7%), which is supplied by world known aluminum producers. Once production cycle is established following charges will be based on percentages of 60% in-plant scrap and 40% ingots (raw aluminum). Once furnaces are loaded temperature is brought up in order to melt the metal; The melt is subject to treatment using salts from which the chlorine has bee removed, in order to produce a melt that is as low as possible in hydrogen and oxides. Stirring, dead-melting and slag removal is done afterwards. In the meanwhile furnace exits and channels are prepared to receive the melt when it is ready for casting. By hydraulically tilting means the furnaces are emptied in a uniformly controlled manner. To ensure a consistent metal quality with low oxide levels, the molten aluminum is degassed, refined and filtered before it enters the casting wheel. All atmospheric emissions from the furnaces are within the environmental regulations due to the fact that we use 99.7% pure aluminum.

Continuous casting and hot-cold rolling

The melt is poured into the strip casting wheel, which rotates at a speed of 6 meters/min. A strip of 220 mm wide by 20 mm thick is formed between the grooved periphery of the strip casting wheel and the endless steel belt. The strip casting wheel is water cooled. The cast strip leaves the unit at a temperature of about 350 ºC in a horizontal direction without any transverse deviation. It is immediately hot rolled down by 50% by means of the Hot Roll Mill and then it is coiled in 900 kgs coils. Each coil is properly identified with heat number, weight, thickness and then is moved to a natural cooling area. Casting time using furnace Nº 1 and Nº 2 is 9 hours. Both furnaces produce 60 MT/day, which turns out to be 66 coils per day (59400 Kg), which will be used in next stage.

Cold Lamination

Following, coil’s thickness is reduced accordingly to customers specifications by means of cold rolling. This stage is very important because it is precise to keep a close control on specifications in order to fill international standards norms, which aloud a maximum tolerance 0,02 mm.

Stamping

This stage counts with four stamping presses, each one has a decoiler where a coil is mounted. Strip is fed into the press, and at the center of it is located the die. This die has a series of punches that has the size of the diameter of the slug. The strip is lubricated while it is being punched. Cut slugs fall on a conveyor belt which takes them into a holding hopper and then into rectangular baskets. Punched strips (scrap) are then cut in pieces which are then compacted before sent back to the furnace. In this process we get about 50% of slugs for each Ton of punched strip. This of course might change according to the slug size. Our four presses cut about 18MT per day in two shifts which represents 1000 MT/month (based on 25 days).

Thermal Treatment

This stage counts with two annealing furnaces, electrically controlled. The aim of annealing is to produce a material with minimum strength, maximum ductility and soft temper. In order to obtain this, baskets with slugs are placed inside an annealing furnace and temperature is rise to 520 ºC for four hours, temperature and time necessary to occur annealing. With this we obtain a Brinell hardness of 17 a 19 HB. Total time of loading furnace, pre-heating, annealing and unloading is of eight hours, permitting two cycles per furnace per day obtaining 1000 tons of annealed slugs per month

Surface Finish

The surface of the slugs is treated in order to obtain a rough texture. This is done by placing the slugs inside of mechanically operated gyratory drums. Slugs hit each other hence roughening the surface. Final customer needs this roughness in order to apply a lubricant necessary for cold extrusion. If slug has an inner hole, surface finish is done by a shot-blasting machine that uses aluminum pellets. The surface finish stage last between 12 and 15 minutes depending on slug size. This stage also makes sure no scrap is attached to the border of the slug. Once surface treatment stage is completed, slugs are transported by a conveyor belt to a hopper which will feed the next stage.

Selection and Packing

In this last stage slugs exit the hopper by means of a conveyor into 5 automatic packing lines. Slugs keep going on the conveyor until they fall inside a carton box which is filled until it reaches 25 Kg. Each box is properly weighted and identified. Once boxes are marked with customers information, they are placed on 1.00mts x 1.20mts wooden pallets, containing 40 boxes of 25 kgs each. Each pallet weights 1.000 kg which is protected with plastic wrap ideal for export purposes. Daily capacity of this stage is 40MT per day which enable us handle 1000 MT per month.