This success story is about the innovative solution that changed radically the production lines of the aluminium extrusion group ALUMIL, through tangible results.

The main challenge was initially the identification of scrap production as early as possible during the extrusion process, by detecting defects on the profile surface and alert the press operators in real time..

With more than 30 years of experience and 2.200 employees, ALUMIL group is one of the most advanced companies in the design and production of architectural aluminium systems worldwide. The group accommodates state-of-the-art production lines in 12 factories across Europe.

The problem that we were challenged to solve was the high scrap percentage in both primary (extrusion) and secondary production (powder coating, anodizing, and packing).

There is no doubt that high scrap percentages accumulate undesired costs in every aluminium industry while affecting the production capacity as well as the reputation of the company.

In order to downsize high scrap rates, we installed on Alumil premises our system CYRUS, as part of the overall EXTRUSION 4.0 solution.

CYRUS is an innovative machine vision solution that uses Artificial Intelligence to identity defects and recurring defect patterns in real-time. Moreover, the system triggers smart alerts to the press operators on a 24/7/365 basis.

CYRUS identifies the following defects during the extrusion process: blisters, dents, scratches, pickups and rough surface. Defect detection takes place in real-time (less than 50msec) and with high accuracy.

The system records the defect localization map and saves the history record per meter and per runout, for all extrusions, to a common data repository. Big data analytics allow for business intelligence reporting related to the surface inspection while enabling yield optimization.

Watch the video and learn more.

The equipment installed in ALUMIL’s shop floor consists of: