Ongoing collaboration results in successful, on-time start-up of S5 mill

Continued cooperation between ARC and HULAMIN

We are thrilled to have moved into our new office in Wimborne, Dorset.

In September 2023, HULAMIN awarded the contract for the widening of their S5 aluminium cold rolling mill to A Richards Consulting Ltd (ARC). This followed one of several engineering studies carried out by ARC and resulted in the S5 widening project being awarded against a tight deadline to complete Phase 1 by December 2023 ready for board approval. This was immediately followed by Phase 2 which will see the widening project designed, manufactured and implemented by the second quarter of 2025. Project key features: Increase maximum strip width capability of the mill to 1875 mm Higher material temperature capability from faster, back-to-back rolling Improved strip quality including: New flatness sensor incorporating load cells New strip scanner heads New spray system New enhanced ARC strip dryness system An upgraded optical centre guide system A new, ARC designed compact 3-roll entry bridle with colouring roll A new oil-air lubrication system for the mill Upgraded spool handling to cater for dual spool lengths Wider Strip Processing Increasing the maximum strip width will open new markets to HULAMIN and allow the S5 mill to focus on processing wider, 14-out high quality can stock material. In addition, this will enable better distribution of product across all areas of the plant thereby increasing the overall plant utilisation. The main component of this upgrade being a new entry bridle with colouring roll designed and supplied by ARC, which not only allows the wider material to be processed but also includes features to ensure accurate roll positioning, stable tension control and ease of maintenance. Also included are new, longer work rolls and back up rolls with new bearing arrangements and the associated chock modifications to accommodate the increased width and higher operating temperatures. The ARC design caters for increased strip temperatures and speeds but also meets the challenges of accommodating the new surface inspection cameras, strip scanners, strip dryness equipment and flatness measurement system in an already congested area of the mill. Mill Upgrades Upgrading a rolling mill is often necessary when introducing a new product and provides an alternative to investing in completely new equipment. Upgrading is also a cost effective solution to updating old or obsolete technology and can also minimize the loss of production associated with replacing equipment with new. However, this is a very specific area of expertise and one which requires the highest level of know-how. Such is the case with the HULAMIN upgrade, where ARC has designed the new and upgraded equipment and planned the implementation to minimize the loss of production and disruption to the plant. The ARC team has many years of experience in modernisations and upgrades of rolling mills and processing equipment for the steel, aluminium and other non-ferrous industries. Working closely with HULAMIN over the past year or so, ARC has been able to provide insight into the process aspects of this upgrade and the analysis and evaluation of different solutions. ARC also provided CAPEX estimates for the design, supply and implementation and now the full design, supply and supervision of installation & commissioning of the new upgraded S5 cold mill. Aluminium Supplier to Africa and the World HULAMIN is not only the largest aluminium rolling operation in Sub-Saharan Africa, but is one of the largest exporters, which represents more than 60% of sales. Aluminium semi-fabrication in the form of plate, sheet & foil is supplied to customers across South Africa, Africa and the world focusing on specific product and end-use markets such as automotive, packaging, transportation, building and electrical applications. www.hulamin.com A Richards Consulting Ltd (ARC) is a specialist consulting and engineering group with it’s registered office in London. ARC operates from Dorset with a highly experienced team of experts dedicated to the rolling mill industry. This experience is based on many years gained working with companies such as Davy McKee, VAI, SMS Parkegate, FATA Hunter, HATCH etc. Specialising in upgrades and modernisations, the ARC team understands the critical and complex nature of this business and is ideally placed for providing an efficient, flexible and proactive service to support clients. ARC services range from feasibility studies, due diligence and asset integrity reports, through to full engineering design, project management and supply services.

A Richards Consulting Ltd is proud to be supporting Bridgnorth Aluminium with design and detail engineering for technology upgrades. Having manufactured aluminium strip since 1933, Bridgnorth Aluminium Ltd has firmly established itself as a trusted supplier of rolled aluminium products with knowledge and experience spanning many decades, evident in the work they do today. A Richards Consulting Ltd (ARC) includes a team of engineers with many years' experience in the aluminium and steel industries, providing engineering services, general technical consulting, due diligence services, asset integrity reports, process optimisation, capacity plaing and general business advice, particularly in the metals, industrial and manufacturing sectors.