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Matalco is a primary-quality aluminum manufacturer of billets and logs for the aluminum extrusion manufacturing industry, utilizing world-class remelt technology. The company produces aluminum billets and logs in the 6000 alloy range in lengths up to 288 inches, with diameter sizes of 6, 7, 8, 9, 10, 12 and 13 inches, and 14 inches in the near future.
Matalco is dedicated to providing its customers with superior product quality and unmatched service in the industry. Customer orders can be readily met on demand as a result of its continuous supply of cleaned and sorted aluminum scrap from Triple M Metal Inc. Tolling is provided, including pickup.
From the onset, MATALCO chose the most modern and efficient equipment available in the world to effectively and efficiently produce the highest-quality product with the most environmentally-informed manufacturing process available anywhere. We have incorporated the latest advances in remelting, degassing, filtering, casting, tooling and continuous homogenizing. By delacquering the scrap metal prior to remelting, we greatly reduce melt loss and possible inclusions. Only clean metal is charged into our furnaces. Energy recovery systems are employed by reheating combustion air to lower costs and reduce emissions. Matalco welcomes toll converting from extruders without remelt capacity of their own, and also sells additional quantities of billets to meet their total needs.
The material flow is a straight-line through the plant (see Figure 1).
All scrap is received at one end, segregated in bins, and kept indoors. The scrap is then delacquered and charged into two melting furnaces. Once the chemistry is adjusted, the molten metal is transferred into a holding furnace. It is stabilized, and when the casting unit is ready, the metal flows through a degassing unit and a filter into Wagstaff tooling to produce any one of seven different billet diameters from 6 inches to a maximum of 13 inches. All furnaces are of the tilt design. The finished cast logs are placed on a feed conveyor which transports the logs automatically into a continuous-homogenizing furnace. Upon exiting the cooling area, log integrity is tested by way of automatic ultrasonic testing equipment. The logs are cut and packaged into either cut-to-length billets or logs with a maximum length of 288 inches. Finally, the product is loaded onto trailers for shipping to customers. From the casting pit to finished product, the process is fully automated, only handled when ready to load onto trailers.
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