AES helped Arconic streamline aluminum extrusion scrap handling with a semi-automated scrap management system designed to reduce manual cutting and bundling, minimize production interruptions, and support future expansion.
Overview
Arconic Corporation operates a high-volume aluminum extrusion facility in Cranberry Township, Pennsylvania. The plant runs on a continuous production schedule and generates significant volumes of aluminum scrap throughout its operation.
Before the AES system was installed, employees had to manually remove long aluminum extrusions, cut and bundle scrap for shipping, and clear storage racks when they reached capacity. This process pulled production staff away from their primary work and created bottlenecks that could interrupt production.
What problem did AES solve?
Arconic needed a better way to process high volumes of aluminum extrusion scrap without relying on manual cutting, bundling, and frequent operator intervention.
AES designed a customized semi-automated scrap management system that allowed long aluminum extrusions to be processed through a high-powered shredder, conveyed through the system, and discharged into self-dumping hoppers for easier handling.
Scope of Work
- System Design & Equipment Selection
- Semi-Automated Scrap Management System
- 150HP Dual-Shaft Shredder
- Semi-Automatic Rack Tipper
- Chain Feed Slat Table
- Feed Conveyor
- Discharge Conveyor
- Self-Dumping Hopper Discharge
- Turnkey Installation
- System Commissioning & Training
The Challenge
Arconic’s aluminum extrusion facility generated a continuous flow of scrap material, with production reaching approximately 1,500 pounds of aluminum scrap per hour. Without an automated scrap handling system, employees had to manually manage long aluminum extrusions and prepare them for shipping.
Scrap was stored on racks until personnel could process it. When racks reached capacity, production had to stop until the material was cleared, creating delays and pulling workers away from production tasks.
The main challenges we had to address:
- Aluminum scrap volumes were too high for the existing manual process.
- Employees had to cut and bundle extrusions into 8-foot sections for shipping.
- Long aluminum extrusions up to 26 feet had to be manually removed and handled.
- Scrap storage racks created bottlenecks when they reached capacity.
- Production staff were being diverted from their primary responsibilities.
- The system needed to support future upgrades, including a baler and robotic rack unloading.
AES needed to provide a scrap management system that reduced manual handling, improved material flow, minimized downtime, and supported Arconic’s long-term production goals.
The AES Solution
AES partnered with Arconic to design a customized scrap management system for the facility’s high-volume aluminum extrusion production needs. After reviewing multiple configurations, AES recommended a semi-automated shredding system designed for continuous, high-capacity scrap processing.
The system included a 150HP dual-shaft shredder, semi-automatic rack tipper, chain feed slat table, and 48-inch-wide feed and discharge conveyors. AES also provided turnkey installation, commissioning, and on-site training to help Arconic’s team operate the system with confidence.
AES System Components
The aluminum scrap management system included:
- 150HP dual-shaft shredder
- Semi-automatic rack tipper
- Chain feed slat table
- 48-inch-wide feed conveyor
- 48-inch-wide discharge conveyor
- One-cubic-yard self-dumping hoppers
- System layout for future baler integration
- Future robotic rack unloading capacity
- Turnkey installation
- Custom integrated aluminum scrap processing layout
The completed system gave Arconic a more efficient way to process high volumes of aluminum extrusion scrap while reducing the need for manual cutting and bundling.
By combining shredding, rack tipping, material handling conveyors, installation, commissioning, and training, AES helped Arconic streamline scrap flow and support a more productive manufacturing environment.
The Results
With the new aluminum scrap management system in place, Arconic gained a more efficient way to process extrusion scrap while reducing manual cutting, bundling, and production interruptions.
Scrap aluminum extrusions are now processed through the shredding system and discharged into one-cubic-yard self-dumping hoppers, with each hopper filling in approximately 13 minutes at an average weight of 1,001 pounds.
Download the Full Case Study
Download the complete Arconic case study to see how AES designed and installed a semi-automated aluminum scrap management system with shredding, rack tipping, conveyors, hopper discharge, installation, commissioning, and training.
An Aluminum Scrap Management System Built for High-Volume Production
This project shows how a properly engineered scrap management system can improve more than scrap removal. For Arconic, AES helped reduce manual handling, minimize production bottlenecks, improve workflow, and prepare the facility for future expansion.
For aluminum extrusion plants, metal converting operations, manufacturers, and recycling-focused production facilities, AES designs custom systems around scrap volume, material size, production flow, available space, safety needs, and long-term operating goals.
Frequently Asked Questions
An aluminum scrap management system helps collect, process, convey, and prepare aluminum scrap generated during manufacturing or extrusion operations.
Arconic’s facility generated approximately 1,500 pounds of aluminum scrap per hour, and employees were manually handling, cutting, and bundling long aluminum extrusions for shipping.
The system included a 150HP dual-shaft shredder, semi-automatic rack tipper, chain feed slat table, 48-inch-wide feed and discharge conveyors, and self-dumping hoppers.
Instead of manually cutting and bundling long extrusions, scrap is processed through the shredding system and discharged into one-cubic-yard self-dumping hoppers.
Yes. AES designs and installs custom scrap handling, shredding, conveying, and material processing systems for aluminum extrusion plants, metal converting operations, and other high-volume manufacturing facilities.
