Revolutionizing Aluminum Recycling: OMAR & ITR Partner with ALUMIL to Drive Sustainability in the Foundry Industry

Intro

In a significant advancement for the international foundry industry, OMAR Air Filtration Systems and its specialised division, ITR Recycling Technologies, have forged a strategic partnership with ALUMIL Group, a leading European manufacturer of architectural aluminum systems. This collaboration aims to enhance aluminum recycling processes, improve environmental sustainability, and optimise production efficiency within ALUMIL’s operations.

ALUMIL Group: A Pillar in Architectural Aluminum Systems

With over three decades of experience, ALUMIL Group has established itself as a prominent figure in the design and production of architectural aluminum systems. The company operates 12 state-of-the-art manufacturing facilities across Europe, employs a workforce of 2,200 professionals, and maintains a robust presence in more than 60 countries through 32 branches. Boasting a production capacity exceeding 100,000 tons annually, ALUMIL is renowned for its advanced production lines and stringent quality control measures that ensure excellence throughout the manufacturing process.

Central to ALUMIL’s operational philosophy is a commitment to sustainability. The company acknowledges that economic growth must harmonise with environmental stewardship, implementing measures such as regular environmental inspections, comprehensive training programs for personnel, and strategies aimed at minimising energy consumption, CO₂ emissions, and waste generation. This holistic approach underscores ALUMIL’s dedication to reducing the exploitation of primary resources and promoting a circular economy.

OMAR’s Expertise in Emission Control

OMAR Air Filtration Systems has been a trusted partner of ALUMIL, providing cutting-edge solutions for the extraction and filtration of fumes and pollutants generated during aluminum melting processes. In a recent project, OMAR designed and installed a sophisticated fume extraction and filtration system at one of ALUMIL’s facilities. This system is engineered to effectively capture and neutralise acid pollutants emitted during the recycling of aluminum materials.

The filtration system employs specialised filter media within a PJ dynamic configuration, equipped with an automatic cleaning mechanism to maintain optimal performance. To address safety concerns, the system includes a pre-abatement feature for the removal of incandescent particles and incorporates ATEX-certified components suitable for operations in potentially explosive atmospheres. Operating continuously at a flow rate of 100,000 cubic meters per hour and handling dust-laden air at temperatures of 160°C, the system exemplifies OMAR’s commitment to efficiency and safety in industrial air filtration.

ITR Recycling Technologies: Revolutionising Aluminum Scrap Processing

Building upon the successful implementation of the fume extraction system, ALUMIL engaged ITR Recycling Technologies, OMAR’s division specialising in recycling solutions, to develop a comprehensive plant for processing aluminum scraps and profiles. This initiative aligns with ALUMIL’s strategic objective to enhance production flexibility and capitalise on the expanding aluminum products market.

The cornerstone of this recycling plant is the TSS 180 double-shaft shredder, a robust machine designed for the precise volumetric reduction and rough processing of aluminum scraps. With an impressive throughput capacity of 8 tons per hour, the TSS 180 prepares materials for subsequent refinement and separation stages. Its sturdy construction, utilising high-quality steels, and a versatile array of blade configurations make it adept at handling diverse shredding applications. The shredder’s low-speed, high-torque operation, powered by hydraulic motors, ensures efficient processing while minimising energy consumption. Maintenance is streamlined through a design that allows quick access for component replacement, reducing operational downtime and associated costs.

To further enhance processing capabilities, the plant incorporates a mobile HMM 100 hammer mill, a compact grinding and selection unit mounted on a movable platform. This mobility enables ALUMIL to reposition the equipment as needed, adapting to spatial constraints and evolving production requirements. The hammer mill is equipped with an integrated material separation and extraction system, facilitating the efficient segregation of aluminum from inert substances.

Post-grinding, the material is directed to an SCP eddy current separator, which employs electromagnetic fields to distinguish non-ferrous metals from non-metallic materials. This step ensures the purity of the aluminum output, which is critical for maintaining high-quality standards in recycled products. Subsequently, the separated material undergoes screening to isolate fractions smaller than 30 mm. Both fine and coarse fractions are subjected to advanced X-ray treatment systems designed to detect and remove contaminants such as screws, bolts, and other impurities, thereby producing clean, ready-to-use aluminum material.

To maintain air quality and ensure a safe working environment, the facility is equipped with a dedicated dust extraction and filtration system. This system plays a vital role in preserving the integrity of the recycled aluminum and safeguarding the health of personnel by capturing airborne particulates generated during processing.

Operational Excellence and Future Outlook

The integrated recycling system has garnered commendation from ALUMIL for its exceptional efficiency, versatility, and user-friendly maintenance. The plant’s operations are centrally managed through an intuitive touch-panel interface, allowing operators to monitor processes and adjust parameters in real-time. This control system, custom-developed by ITR’s software engineering team, supports the storage of multiple operational programs tailored to different material types, facilitating seamless transitions between processing tasks. Moreover, the system is designed for compatibility with Industry 4.0 smart factory frameworks, enabling remote monitoring and integration with broader enterprise resource planning systems.

This collaboration between ALUMIL, OMAR, and ITR Recycling Technologies exemplifies a synergistic approach to advancing sustainability and operational efficiency in the aluminum industry. By leveraging cutting-edge technology and engineering expertise, the partnership not only enhances ALUMIL’s production capabilities but also reinforces its commitment to environmental responsibility.

As the exclusive representatives of ITR and OMAR in Australia and New Zealand, Hard Recycle is poised to bring these innovative solutions to the Australasian market, offering industries access to state-of-the-art aluminum recycling and air filtration technologies that align with global best practices.

Through this strategic alliance, the companies are setting a benchmark for excellence in aluminum recycling, contributing to a more sustainable and efficient future for the international foundry sector.