Extrusion Equipment

Sergio Vazquez del Mercado, Ricardo Ivan Ocaranza Trujillo, Christopher Rivera Cisneros, Interlub Group, Mexico 

Automated dosing systems are redefining lubrication in aluminum extrusion by delivering precise, repeatable application across critical components such as saws, dummy blocks, shears, molds, and billets. This presentation explores the impact of programmable dosing technology on process consistency, waste reduction, and equipment longevity. With cycle accuracy of ±0.1 ml and speeds up to 25 cycles per second, these systems ensure uniform lubrication even under demanding conditions. Their integration flexibility—via standard connectors and multiple operation modes—makes them suitable for diverse industrial setups. Attendees will gain insights into how automation supports safer, more efficient, and sustainable extrusion operations through improved control and reduced lubricant consumption. 

Pawel Kazanowski, Dubai Extrusions Investments, LLC, United Arab Emirates 

The quenching of light profiles after hot extrusion yields common conditions, such as profile distortion, sneaking, and various stains. In most cases, the stains are not visible on the surface right after quenching and coiling. The stains develop over time, leading to abnormal scrap in the consecutive manufacturing steps, including brazing. The experimental study results reveal a connection between specific quench box characteristics and the formation of black stains. The type of quench box nozzles, the efficiency of the quench box water cooling system, and the volume of water flow during the steady state of the quenching process are among the key variables that impact the staining of the light profile surface. If followed, the recommendations included in this report should lead to the almost complete elimination of the surface stains originating from the light profile quench after extrusion. 

Raffaele D’Andrea, Emmebi Srl, Italy; and Brad Stevens, Alspex Extrusions, Australia 

This paper presents an innovative skid-based logistic system designed for efficient handling and transportation of aluminum profiles. The system operates along a circular path, enabling automated stacking of profiles into skids for streamlined delivery to customers. Skids offer modular functionality: they can be piled vertically to create temporary storage solutions, optimizing space utilization in production and distribution environments. Additionally, the design incorporates removable side tubes, which can be detached once the skid is empty, significantly reducing shipping volume and associated costs. This approach enhances flexibility, minimizes material handling time, and supports sustainable logistics by improving transport efficiency. The proposed system demonstrates how automation and modularity can transform traditional profile distribution into a more adaptive and resource-conscious process. 

Omid Madani, Williamson Corporation, USA 

Accurate temperature control of billets is critical for optimizing extrusion process parameters, ensuring quality, and improving energy efficiency. However, most infrared pyrometers have shown unreliable measurements due to significant variations in emissivity caused by Oxide Vitrification, and thin film interference from the oxide layer. This issue is especially exacerbated when Billet temperatures exceed 500°C, which has been the trend for the industry for advanced applications like automotive and aerospace. These variations can lead to temperature errors exceeding 20°C –30°C, impacting extrusion performance. This paper presents how Williamson Multi-Spectral Infrared pyrometer (MWx) adapts to the emissivity variations of the high temperature Billets and produces repeatable accurate measurements regardless of surface conditions. The Key approach includes the dynamic algorithms resulting from solving simultaneous equations that adjust emissivity in real-time, without requiring prior knowledge of surface conditions. Experimental results demonstrate improved measurement accuracy to within ±5°C, even under varying surface states. 

Eva Kesisoglou and Dimitris Katsikas, D-Cube Immersive Solutions, Greece 

Surface defects remain a costly challenge in aluminum extrusion, with traditional inspection methods unable to capture all non-conformities before they propagate downstream. D-Cube, in partnership with Williamson, presents CYRUS, an AI-powered surface inspection system that transforms defect management from simple detection into actionable decision-making. Deployed across multiple production lines at industry leaders including EMAX, Estral, APT, ETEM Gestamp, ALUMIL, and Hydro, CYRUS delivers 100% defect detection through modular 360-degree inspection configurations with sub-50ms response times. This presentation demonstrates how CYRUS enables multi-level scrap reduction: real-time press optimization through immediate alerts, production-wide efficiency gains via advanced analytics, downstream scrap prevention using defect mapping, and claim management through comprehensive production history. Case studies reveal measurable Return on Investment (ROI) through reduced manual interventions, optimized process parameters, and eliminated downstream propagation. CYRUS represents the evolution from reactive quality control to proactive production intelligence in aluminum extrusion. 
 

Philipp Hettich and Norbert Meinikmann, Laubinger + Rickmann GmbH & Co. KG, Germany; and Martin Hartlieb, Viami International Inc., Canada 

Maximizing properties and productivity while achieving required tolerances of extruded structural profiles is often very challenging. The integration of dimensional measuring of profiles in-line can significantly reduce scrap rate and help optimize process parameters for maximum productivity. Latest developments in measuring technologies (with new support and transfer systems) allow in-line measurement of 100% of the profiles in any given cycle time with multiple line lasers – permitting contactless measurement of all sides and entire cross sections for inner and outer dimensional accuracy. OK-parts directly continue in the process, while nOK-parts are transferred into a straightening system (that can be retrofitted later). The same measuring system afterwards measures straightened profiles before introducing them back into the line – handing over coordinates for machining to achieve a true best fit. This new modular and scalable concept with easy access allows maximum flexibility for many profiles and coordinate systems with reduced initial investment. 

Chris Ebnet, Alexandria Industries; and Cristiano Baiano, Cometal North America, USA 

In the mid-1990s, Alexandria Industries switched from pre-cut billets to on-demand cutting with bandsaw. Lack of predictable blade life and overall blade replacement costs mounted over the years as well as a need to maintain an operator at the saw due to a high-mix low volume situation that required frequent billet length and alloy changes. In 2020, an automated log handling system was installed to service both 7” press lines in Alexandria, making it possible to eliminate the full-time operator and uncertainty of blade life. Manual, semi-automatic and fully automatic solutions were provided by three reputable extrusion equipment suppliers, each focusing on one of these particular solutions and Cometal’s semi-automatic solution fits Alexandria Industries’ needs very well. Cometal’s solution provided the ability to run for 2-4 hours with no interference and being able to cut very short drops at a reasonable price point within a limited amount of space. 

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman 

This paper presents a practical case study on restoring a 30-year-old, poorly performing die oven into an energy-efficient and reliable unit. The restoration work began with addressing the heating system, where obsolete heating elements and long-term bypassing had reduced oven efficiency to below 50%. New-technology heating elements were selected, and a redesigned internal casing was fabricated to accommodate the required number of elements within the existing space. Following successful commissioning of the new heating system, a complete oven revamp was undertaken. The oven was shut down, fully dismantled, and inspected, revealing severe distortion of the internal chamber and poor blower conditions. All internal components were re-fabricated using SS310 sheets, with proper insulation and thermal expansion allowances incorporated. A new pneumatic system was also developed in-house. Post-installation results confirmed stable operation, improved efficiency, and reliable performance of the restored die oven. 
 

Jan Guenter, Extrutec GmbH, Germany 

In response to the changing market situation due to energy shortages in Europe and the desire to substitute fossil energy sources, extrutec has developed a high-speed convection furnace equipped with electric resistance heating elements. The concept of operating the heater exclusively with electricity opens up the possibility of complete avoidance of   CO2 emissions, provided the oven is operated with “green” electricity. Since the high-speed convection furnace can achieve efficiencies of 87% but cannot produce sufficient taper, it is necessary to integrate an induction module. The induction furnace can be combined either as a 'stand-alone' version or in extrutec's patented 'inline' version. The EHKO furnace with the combination of electrical resistance with induction heating pairs maximum energy efficiency with state-of-the-art taper heating. As a result, it makes it possible to take the step towards CO2-free production of extrusions. 

Michael Werner, Extrutec NA, USA 

In recent years, induction technology has seen huge improvements in terms of energy efficiency. Innovations such as the direct inverter, friction-free billet handling and Power Focus technology have made the systems more robust and much more energy efficient. However, one of the biggest steps is yet to come. Integrating an energy-saving unit (ESU) decreases energy consumption by 15% compared to a process without an ESU. Combining all these technologies results in an overall energy efficiency of up to 79%. With advantages such as high energy-density during the heating process, continuous temperature measurement and components which do not contain critical minerals, modern induction heaters provide solutions to future challenges. 

Jan Guenter, Extrutec GmbH, Germany 

Modern profile quench systems increasingly require intelligent, software-integrated solutions to ensure reproducible material properties and minimal profile distortion. This presentation introduces an advanced cooling system featuring automated preset and simulation capabilities. The system automatically recognizes the profile geometry, aligns nozzle angles accordingly, while dynamically adjusting nozzle pressure based on distance to the profile and the required cooling effect. A simulation module performs plausibility checks to validate input targets, such as strength and ductility, and identifies conflicting or physically infeasible conditions. Based on alloy composition and targeted mechanical properties, the system calculates the cooling rate and determines the cooling strategy. The resulting process is designed to be only as fast as necessary and as slow as possible, ensuring gentle treatment of the material, resulting in reduced internal stresses, and therefore minimized distortion. This approach enables optimal process control, resulting in improved product quality, and increased robustness in industrial profile quenching applications. 

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman 

Hydraulic hot log shears are critical equipment in aluminum extrusion plants, where valve wear and internal leakage can disturb cylinder positioning, leading to equipment damage, product loss, and unplanned downtime. Aging systems face additional challenges due to obsolete components and lack of OEM support. At Napco, a hot log shear hydraulic system operating for over 25 years suffered from reliability issues, with all major valves discontinued. Full system replacement options were evaluated but rejected due to high cost and long shutdown requirements. Instead, a localized upgrade approach was adopted in collaboration with a Rexroth dealer. The hydraulic circuit was redesigned using current-generation valves while retaining the original operating logic. A new powerpack was fabricated in-house and installed during a planned weekend shutdown. The upgraded system was commissioned successfully with minimal production impact, improving reliability, reducing maintenance risk, and extending equipment service life. 
 
 

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman 

At Napco, the log furnace has been in operation for over 20 years. While the original refractory block cover functioned adequately, it presented several challenges: long cooldown times (~5 hours) before maintenance, slow startup from ambient temperature, heavy parts increasing handling costs, and frequent cracks causing hot flame leakage that damaged insulation and nearby components. To address these issues, the furnace cover was redesigned as a single-piece assembly using ceramic blankets and ceramic boards, with expansion joints and repositioned gas piping to avoid hot zones. The modified cover was installed during a two-day planned shutdown without issues. This upgrade significantly simplified maintenance, reduced downtime, improved operational safety, and increased inspection frequency. The modification enhanced furnace stability and availability, demonstrating a cost-effective, practical approach to modernizing legacy aluminum extrusion furnace technology. Then after a few small parts were also developed in-house like taper zone cover, burner bricks and moveable vice, etc. 
 
 

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman 

Puller holding fingers and jaws in aluminum extrusion presses are commonly operated through hydraulic or pneumatic systems. At Napco, the puller system was driven by a pneumatic monoblock vane compressor mounted on a trolley without an air receiver tank. Due to unavailability of a receiver tank, the system operated continuously regardless of load, resulting in excessive wear, frequent failures, and annual compressor replacement. To address these issues, a standard heavy-duty compressor with an air receiver tank was selected. The trolley was structurally modified to accommodate the revised system while maintaining allowable load limits. The pneumatic circuit was upgraded to eliminate leakages and incorporate new-generation valves. The original motor was retained as an emergency spare. The modified system was commissioned successfully and demonstrated improved reliability, reduced maintenance, and lower operating cost. This upgrade enabled import substitution and eliminated dependency on a single proprietary compressor supplier. 
 

Mike Wahl, SMS group GmbH, USA 

Modern extrusion plants require continuous performance, predictable reliability, and long‑term equipment support. Digital service solutions provide a connected framework that monitors process, condition, and energy parameters in real time, converting machine data into actionable insights. This enables predictive maintenance strategies that reduce unplanned downtime, extend component lifetime, and stabilize production quality over the years. Through a lifecycle partnership approach, supporting extrusion lines from commissioning to long‑term operational success is vital. Data‑driven diagnostics guide maintenance planning, spare‑parts strategies, and investment decisions, ensuring consistent performance even as equipment ages. The same digital backbone also facilitates upgrade and revamping paths, allowing plants to integrate new technologies—such as the electric shear retrofit—to enhance safety, efficiency, and sustainability without replacing the entire press. By combining digital intelligence, remote support, and structured local lifecycle services, extrusion plants maintain reliable, efficient, and future‑ready operations throughout their full operating life. 

Matt Morell, Pennex Aluminum, USA 

Effective billet heating is foundational to extrusion quality, process stability, equipment longevity, and overall plant productivity. Yet, many extrusion operations lack a standardized, quantitative method for evaluating the true performance of their billet heating systems—particularly as induction units introduce thermal inconsistency, energy inefficiency, and higher scrap rates. This paper presents the development, deployment, and analysis methodology of a Survey Billet, a purpose-engineered billet instrumented to measure temperature uniformity, heat-up rate, and thermal consistency throughout the billet heating process. Designed as a diagnostic tool, the Survey Billet enables extrusion plants to conduct comprehensive audits of billet furnaces, induction heaters, billet-handling & auxiliary equipment, and even operator-dependent practices that affect thermal variability. 

HongJie Mai, Save Intelligent Equipment Co., Ltd., China 

To meet the rigorous demands of rail transit, 3C products, and new energy vehicles, aluminum extrusion quench systems must ensure three critical outcomes: dimensional accuracy, enhanced mechanical properties, and superior appearance quality. Advanced solutions achieve this through sufficient cooling speeds matched to alloy sensitivity, alongside adjustable cooling intensity for varying cross-sections to minimize deformation. By maintaining uniform cooling rates and radial strength adjustment based on section structure, these systems guarantee consistent performance, reduced bending, and optimal structural integrity. 

James Johnson, Bonnell Aluminum, USA 

The paper is a lesson learned by our plant. Maintenance managers have a commitment to safety and improving equipment availability in their organization. This example will share knowledge on how to avoid safety events, insurance claims, and costly downtime around the press log shear and log oven. After a fire that reached the roof and did significant damage, a proactive approach was taken to reduce or eliminate the chances of this event happening again. The hydraulic units use HD-32 hydraulic oil, which is highly flammable and substituted with a flame-retardant oil called Quintolubric 46-888. We reached out to oil suppliers to see if there were any compatibility concerns from changing the oil. For aluminum extrusion companies, this is a gamechanger, and can result in improved safety, service factor, and insurance claims. 

Pau Vial Serrat, Kautec Solutions R+D Department, Spain 

Quench sensitivity is a key characteristic of hard alloys that plays a critical role in achieving the final mechanical properties of extruded Aluminum profiles. To address this sensitivity and prevent profile deformation caused by uncontrolled quenching, intensive quenching tables implementing the variable geometry nozzle configuration have been developed. This approach enables adjustment of the nozzle incidence angle and precise control of the delivered flow rate. However, for a given profile geometry, identifying an optimal configuration that prevents profile deformation is challenging. To help press operators in finding the best cooling plan, we present GOTA, a web application that allows users to upload the profile geometry and analyze spraying coverage and cooling behavior across the profile cross-section. Moreover, the platform includes a tool to automatically determine the optimal cooling plan and enables direct transfer of the cooling parameters to the quenching system. Implementation results obtained on an extrusion line are presented. 

Pau Vial Serrat, Kautec Solutions R+D Department; Andreu Corominas, Beta Robots, Spain 

One effective approach to increase productivity and throughput in aluminum extrusion plants is to improve the flexibility of the transport system for profile baskets between production cells. The introduction of a fleet of Autonomous Mobile Robots enables the interconnection of extrusion lines, painting cells, anodizing cells, and warehouses with a fully automated logistic system that enhances operational safety, ensures full material traceability, and improves plant accessibility by eliminating fixed conveyors which complicate maintenance operations. The robots rely on a LIDAR-based safety and localization system and navigate through the facility using a predefined virtual road map that connects all plant cells. A fleet management software platform is also deployed to coordinate operations among all robots and other plant devices, and to provide real-time visualization. Moreover, digital twins of several extrusion plants have been developed implementing the robotic logistic system to analyze the plant productivity and evaluate the logistic system capacity. 

Pau Vial Serrat, Kautec Solutions R+D Department, Spain 

Accurate billet heating prior to Aluminum extrusion is crucial to approach isothermal extrusion conditions to ensure the final mechanical properties of extruded aluminum profiles made from hard alloys. Traditionally, precise billet heating has been achieved using induction heaters based on electric coils. However, induction heaters require frequent maintenance on the copper windings and demand a very high installed electric power supply due to their low energy efficiency. To improve efficiency while maintaining heating capacity, we present the permanent magnets heater. This machine replaces coils with permanent magnets that rotate around the billet, inducing the required heating. Based on this principle, efficiencies higher than 80% can be archieved with heating rates up to 1.9ºC/s, while also enabling billet tapering. Moreover, the furnace consists of a single rotor, that prevents the formation of cold sections along the billet and significantly simplifies machine maintenance. Results obtained on an industrial extrusion line are provided. 

Pau Vial Serrat, Kautec Solutions R+D Department, Spain 

Automation plays a key role in increasing security and reliability, as well as improving the long-term productivity of Aluminum extrusion lines. Consequently, advanced automation of handling equipment is essential to ensure maximum extrusion press productivity. This paper reviews recent advances in this field. First, fully electric pullers are presented as an alternative to conventional hydraulic systems, improving accuracy and overall performance. The use of servomotors enables precise tracking of all kinematic links within the machine, allowing advanced motion control strategies that reduce dead time and ensure smoother movements. Secondly, magnetic gripping systems for handling the spacers used by profile stackers enhance stacking reliability by preventing spacers from falling during operation, a common case of unplanned downtime in traditional solutions. Moreover, the electromagnets use enables adjustment of the gripping force according to process requirements. Finally, rotatory stretchers are presented to align twisted profiles caused by thermal stresses generated in massive profiles. 

Carsten Dede, SMS group, USA 

As technology evolves, so does the availability of furnaces and equipment that incorporate cutting-edge heating systems. New systems include high efficiency gas fired log furnaces, hybrid gas/electric systems, full electric convection systems, magnetic zero emission ovens, induction, and finally auxiliary efficiency boosting systems such as TERS. Naturally the options available can be confusing or intimidating. Extruders rightfully ask, “what’s right for me, what makes my plant future proof?” This paper seeks to give extruders wanting to upgrade from older gas-fired ovens a decision guide on what technology is best for them. Based on real world examples technologies are compared in terms of throughput, investment cost, and operating efficiency. Rather than a simple sales pitch the paper goes through applied project elements such as replacement strategies, process analysis, personnel involvement and optimization for peak performance. Specific energy efficiency calculations are shown and analyzed for lowest pre-heating cost and process precision. 

Bjorn Biehler, Alexander Daniker and Julia Wachter, ASCONA GmbH, Germany; and Brad Allen, iNOEX LLC, USA 

The increasing demand for large aluminum extrusion profiles has driven expanded press capacities and more complex geometries. As profile dimensions exceed the limits of traditional shop floor metrology tools, calipers and mechanical gages become insufficient for quick, reliable verification at the press. Samples are often transferred to quality labs for measurement, delaying feedback and limiting real-time process control. To address this challenge, ASCONA developed the promex MAX 800/1100. Engineered for profiles up to 1100mm x 800mm, this system is essential for the high-precision requirements of the automotive and railway industries. Uniquely developed hardware eliminates the requirement for precise sample squareness of cut, reducing preparation time and operator variability. With an optimized, high-speed cycle time, the system enables rapid dimensional verification directly at the press. This supports the strict quality standards required for complex applications while ensuring tighter process control and measurable scrap reduction in large-profile operations. 

Bjorn Biehler, Alexander Daniker and Julia Wachter, ASCONA GmbH, Germany; and Brad Allen, iNOEX LLC, USA 

In the fast-paced aluminum extrusion industry, measuring a new profile quickly and accurately is key to staying productive. To perform a measurement, the ASCONA promex system uses a "Reference File" — a digital blueprint that defines exactly which dimensions and tolerances to check. While creating these files in the Reference Editor is already a straightforward process, ASCONA is now making it even faster. ASCONA introduces AIRE (Artificial Intelligence Reference Editor), a transformative development within the promex CONTROL software. Instead of an engineer manually defining each measurement, AIRE can now "read" a dimensioned drawing and create the Reference File automatically. It identifies key features and applies standard industry tolerances in seconds. This update significantly reduces setup time and eliminates the risk of manual entry errors. The user still maintains full control to adjust measurements, but the software does the heavy lifting, keeping the press running and the shop floor efficient. 

Steve DeMar, HBT Americas, LLC, USA 

In January 2026 the modernized hydraulic system was commissioned for a unique World War II era extrusion press, at Hydro’s facility in Cressona, PA. This project will be examined as follows:  a functional description of the press, what makes it an extrusion press like no other, and the products that keep it in high demand, featuring a press cycle animation; original water hydraulic systems, including cartridge valve blocks, and equipment condition; engineering solutions to special challenges, such as achieving piercer pressure control during speed control of the main ram, for consistent product wall thickness; new hydraulic system scope of supply, including engineering process, manifolds, installation, commissioning, and overall timeframe; project summary, including before and after cycle time comparisons, featuring a time-lapse video of the project from start to finish. In conclusion, the net improvements and challenges to the press operation since resuming operation, will be summarized. 

James Dyla, AMCOL Corporation, USA 

Automatic extrusion tool lubrication systems have gained widespread use worldwide. These systems have evolved to improve performance, reliability, repeatability, and safety with seamless integration on advanced press designs. Systems are installed as Original Equipment by the press and handling manufacturers or retrofitted to older equipment. The ability for an extruder to monitor and document causes and timelines for press downtime has dramatically such that it is now possible to provide cost benefit analysis to justify committing time and effort to ensure proper automatic lubrication. Underuse results in premature tool wear. Overuse results in machine component wear and malfunctions. It is now relatively easy to analyze data specific to various upgrades and the impact on overall productivity and output capability. This presentation will explore these operator and maintenance driven developments and the real impacts on press uptime, tool wear, product quality, machine downtime, chemical consumption, and the related. 
 

Ronald Manganello, Carlesa NDE Services, USA 

Some cracks in press components are difficult to detect and measure. The following will explain an example of one of these conditions. Some press components are fabricated with steel plate structure welded to a forged steel main hydraulic cylinder, rear platen, weld, and main cylinder.  The diagram shows one of these difficult-to-detect cracks. Diagram shows tie rod, rear platen, main cylinder pressure wall, weld, operating force, crack.  Because of the orientation of the cracks, they give little magnetic flux leakage necessary for indication with the Magnetic Particle method. These cracks develop oblique to an ultrasonic examination beam yielding little to no detectable reflection. This paper will describe the Magnetic Particle and Ultrasonic Nondestructive Examination methods and show the necessary techniques to detect and measure these cracks. 
 

Mike Horan and Alireza Alizadeh, Danieli Breda, Italy 

The quench system is equipped with an innovative apparatus (patent pending) called the Profile ThermoLog (PTL). This moving unit, installed inside the quench box, measures real time temperature variations using onboard contact thermocouples and records the profile’s actual cooling curve. Before the first extrusion starts, the quench simulation software generates the optimal (target) cooling curve based on process and profile parameters, and the automation system sets the quench parameters accordingly. As extrusion begins, the PTL records the actual cooling curve. If the deviation of the actual cooling curve from the target curve exceeds the allowed tolerance, the system automatically adjusts the quench parameters to correct it. Temperature measurements by the PTL are repeated; the actual cooling curve falls within the defined tolerance. 

Michael Kramer, Bosch Rexroth Corporation, USA 

In many cases, high construction costs and/or lengthy production outages make modernizing an existing extrusion press a better choice than purchasing a new press. However, the true outcome of such a large project may carry some uncertainty which makes decision making difficult. Fortunately, modern technology can be harnessed to predict the outcome of a complete press upgrade. Using existing tools, a digital twin of the system can be created and evaluated prior to making the final decision. The press circuit and control are modeled using software and the functions simulated. This produces an accurate representation of press performance, productivity and energy use which can be used to determine the project’s outcome. In addition, the benefits of applying competing drive and control systems and new technologies can be demonstrated, which helps quantify their value and assists in determining the best application of capital to the extrusion process. 

Marcello Rossi and Giovanni Cheldi, HEATAL SRL, Italy 

The conventional die cleaning process consumes chemicals such as sodium hydroxide, energy and time. The innovative system described in this paper has been developed to ensure faster aluminum removal (up to five times faster than a conventional system). The automatic dynamic reaction control optimizes and reduces chemical consumption by a minimum of 50%. The new design enables the extraction of hydrogen produced by the reaction with sufficient purity for combustion in specialized hybrid burners. The absence of a suction system, energy recovery and the combustion of hydrogen guarantee significant savings in chemicals, electricity and natural gas consumption. The reduced chemical consumption decreases the transport and handling of corrosive solutions, which is a significant advantage in terms of both: safety and cost. The process details, including efficiency evaluation, safety aspects and carbon footprint reduction are described in this paper.  
 

Richard Manganello, Carlesa NDE Services, USA 

This paper examines the varying risks of failure associated with the design and material composition of aluminum extrusion press components. It explores how to effectively apply NDE methods to mitigate risks to safety and production continuity. As extrusion facilities often operate a mix of modern and legacy equipment, NDE practices must be adjusted based on the specific design, material, and operational history of each press. The recommended scope of examination should vary based on known failure points, which are influenced by factors such as operating tonnage, press alignment, and maintenance practices. By considering these design and material factors when developing nondestructive examination procedures, the risk of unplanned component failure can be significantly reduced.