Matalco Inc. utilizes the most modern and efficient equipment available in the world to produce the highest-quality products with the most environmentally-informed manufacturing process available anywhere. We have incorporated the latest advances in remelting, grain refinement, degassing, filtering, casting, tooling, handling, homogenization, cutting and packaging into our production units.
Only clean metal is charged into our melting furnaces. If required, the scrap is delacquered prior to remelting to greatly reduce melt loss and possible inclusions. High-capacity chip processing systems allow for an effective handling and melting process with high recoveries. 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.
Matalco’s plants operate using a straight-line metal flow process, receiving scrap at one end and shipping out high quality billet at the other (see Figure 1). The scrap is received, segregated, and stored indoors. Depending on the alloy being produced, a combination of primary aluminum ingots, toll, post-consumer and in-house generated scrap and saw chips is charged into the melting furnaces to be melted; alloying ingredients/hardeners may be added if required. Once the required chemistry target is achieved, any dross is removed and the molten metal is transferred from the melting furnace into a tilt design holding/casting furnace. There the molten aluminum bath is stabilized and held until it is ready to be cast. At that point, the liquid metal is released into a trough where it is grain refined, degassed and filtered prior to being cast. Matalco utilizes Wagstaff AirSlip™ casting tooling to produce high-quality billet in any one of eight different billet diameters from 6 inches (152 mms) to a maximum of 13 inches (330 mms). The finished cast logs are placed on a feed conveyor system or charge cars which transports the logs automatically into a continuous-homogenizing furnace or batch furnaces, depending on the casthouse. Once cooled, the log integrity is tested using automatic ultrasonic testing equipment. The logs are then cut into either cut-to-length billets or logs with a maximum length of 288 inches (7,315 mms), marked, packaged and labeled. 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.