Scrap Management System

Arconic Corporation, a prominent manufacturer in the aluminum converting industry, operates a high-volume aluminum extrusion facility in Cranberry Township, Pennsylvania. The plant’s continuous production schedule generates significant volumes of scrap material. 

The Challenges

Operating continuously, Arconic’s facility produces approximately 1,500 pounds of aluminum scrap per hour. Without an automated scrap handling system, employees had to manually remove aluminum extrusions up to 26 feet in length, a process that presented numerous challenges for both the facility and its workers.

High Scrap Volume

The constant flow of aluminum scrap demanded frequent attention from production personnel to cut and bundle extrusions into 8-foot sections for shipping.

Resource Diversion

Production staff were frequently pulled from their primary tasks to manage scrap, impacting productivity and straining resources.

Production Bottlenecks

Scrap was stored on racks until personnel could process it. When these racks reached capacity, production halted until the racks could be emptied, disrupting operational flow.

Sustainability and Efficiency Needs

Arconic aimed to minimize manual intervention, reduce downtime, and improve their recycling process.

To overcome these obstacles, Arconic needed a solution that would streamline the scrap handling processes and support production goals.

AES Solutions

Advanced Equipment Sales (AES) partnered with Arconic to design a customized scrap management system tailored to the facility’s high-volume aluminum extrusion production needs. After evaluating multiple configurations, AES recommended a semi-automated shredding system. The design also accounted for future upgrades, including the addition of a baler and an automated robotic arm for rack unloading.

Results

The AES shredding system has significantly improved Arconic’s operations by enhancing efficiency and minimizing downtime. Scrap aluminum extrusions are now processed through the shredding system and discharged into one-cubic-yard selfdumping hoppers, eliminating the need for manual cutting and bundling. Each hopper fills in approximately 13 minutes, with an average weight of 1,001 pounds per hopper.

With AES’s solution, Arconic’s team can focus on production, achieving a smoother and more efficient workflow through streamlined scrap management. The system not only aligns with Arconic’s commitment to operational efficiency but also accommodates future expansion, ensuring the facility is well-prepared to scale as production demands grow.