About factory
Omid alborz company after many years activity in production and commercial in many kinds of steel sections field, with study and feasibility of community need to aluminium foil and plates at 2020 decided to setting up Omid alborz aluminium complex in a land of 25000 m² and covered space of 14000 m² and at the moment it is known as one of the biggest producers of aluminium foil and plate in Iran.
Production units
Omid alborz aluminium complex contains of 3 main production units and 2 subsidiary units.
First production unit
Cold rolling unit and anil, produce kinds of aluminium foil from 6 to 300 µ thickness
All machinery and equipment of this part installed at 2022 and setting up and now in being exploited and presents many kinds of aluminium foils from 6 to 300 µ thickness with high quality production and offers to exports markets and domestic customers.
Second production unit
Cold rolling unit and anil of simple plate and ribbed from 0.3 to 7 µ thickness
Machinery and equipment of this production unit is installing it turns aluminium casting coil to high quality.
Cold rolling and it anticipated that from begging of 2024 is ready to exploit.
Third production unit
Continuous casting and alloying unit, aluminium coil production from 6 to 10 µ thickness
This unit has 5 full lines of continuous casting of aluminium coil with melting and holding furnaces specific to each line which turns aluminium ingot to aluminium alloying coil and non-alloying coil and it is anticipated to end of 2024 is ready to exploit.
First sub. Unit
Machinery and turning unit
This unit supports and guarantee the quality and polished Ness of the rollers of production parts and has entire effects at final products’ quality.
Second sub. Unit
Ingot recycling and production unit
In different levels production parts of foil, cold rolling plate and this material casting coil we are always faced with aluminium waste which is completely recyclable and can return to production process again.
In recycling unit this material again melts in ground furnaces and with casting method turn to aluminium ingot at 10-pound molds.
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Omid alborz aluminium complex
Products
Some of the brief specifications of the products offered by this production unit are:
- Aluminium foil for wrapping butter with a thickness of 6.5 and 7 microns and alloy 8011 and 1235-HO
- Aluminium foil for Tetrapak and Aseptic with a thickness of 6 and 7 microns and alloy 8011 and 1235 – HO
- Aluminium foil for cigarette packaging with a thickness of 6.5 microns and alloy 8011 and 1235 – HO
- Aluminium foil for coating isogamic insulation with thickness of 12 and 14 microns and alloy 8011 and 1235 – HO
- Aluminium foil for packaging lids of mineral water industries with a thickness of 12 and 14 microns and alloy 8011 and 1235 – HO
- Aluminium foil for packaging lids of mineral water industries with a thickness of 12 and 14 microns and alloy 8011 and 1235 – HO
- Aluminium foil for wrapping dairy products with a thickness of 14 microns and alloy 8011 and 1235 – HO
- Aluminium foil for use in pharmaceutical packaging (blister) with a thickness of 15 to 30 microns and alloys 8006, 8011 and 8079 – H18
- Aluminium foil for food packaging with thicknesses of 20, 30, 32, 35 and 40 microns. Alloy 8011 – HO
- Aluminium foil for the production of disposable containers with thicknesses of 40 to 70 microns and alloys 3003, 8006 and 8011 – H22, H24
- Aluminium foil for use in ventilation and cooling industries with thicknesses of 90 to 300 microns. Alloy 8011 – HO
Product features
Considering that the production of this factory relies on customer orders, it is necessary to know the following parameters.
Hardness (temper), alloy, application, thickness, width, weight of each roll, inner diameter, type of packaging, appearance
🔵 Heat Treatment, Tempering, Annealing
Product temper is actually the type of heat treatment of the product, which indicates its hardness or elasticity, which includes soft tempers and hard tempers. By performing this operation on a product that has been rolled and reached the desired thickness, the mechanical properties of the alloy, such as hardness and formability, brittleness and elasticity are changed.
Temper products are determined according to their application. For example, the foils used to wrap chocolate have a soft temper. Soft tempered aluminium foils are used for food packaging and have the ability to print and make polymer, polyester and paper laminates. In contrast to hard tampers, it is used for packaging such as blisters or tablets, and the contents should be easily removed from the container with low pressure, and the rest of the structure should remain intact.
When naming aluminium alloys, letters are seen that represent the type of thermal or mechanical treatment performed on the alloy. Some of these symbols are:
- F: That is, no additional process has been done to harden and improve the strength properties of the alloy
- O: Annealing or softening by controlled heating and cooling
- H: Strain hardening or rolling hardened by cold rolling method
- T: The product has been subjected to heat treatment, aging, and sometimes cold rolling
In this company, all types of heat treatment necessary to achieve the desired properties of the products can be performed according to the customer’s needs and product standards.
🔵 Thickness
Another important feature of the products is their thickness. Usually, thin aluminium sheets with a thickness of less than 300 microns are called foils, and higher thicknesses are called aluminium sheets or aluminium coils.
This factory has the ability to produce all kinds of aluminium foil from 5.5 to 300 microns and all kinds of plain and ribbed cold rolled sheets from 0.3 to 6 mm thick and casting coils from 4 to 10 mm.
🔵 Appearance characteristics
Considering that the product produced by this factory is used as a raw material for the production of other products by other manufacturers, therefore, for any type of application, the produced aluminium foil must have other characteristics in addition to the alloy specifications, dimensions and hardness. Below we mention some of these features.
🔷 Pinhole or hole
According to international standards and according to the intended use of the foil, in any thickness, the number of very small holes that can be seen with the unaided and armed eye should not exceed a certain number. This case is very important in the packaging foils of food, pharmaceutical, cosmetic and health products and sachets, and it plays a key role in the duration of the expiration date and the speed of spoilage of those products.
🔷 The amount of oil remaining from rolling
In cases where foil is used to produce disposable containers or printed foils for food and medicine packaging, the foil should not smell of oil, and the amount of rolling oil remaining on their surface is very important and should be close to zero. so that it can be printed and does not change the taste and spoil the product inside the package. Iranian National Standard No. 3010 deals with the amount of oil allowed.
🔷 The effect of oil and water stains
There should be no traces of oil, water and other pollutants in food, pharmaceutical and printing foils.
🔷 Oxidation
Aluminium foil, especially in some alloys, if it is exposed to moisture and heat higher than usual, it oxidizes quickly and loses its mechanical and chemical properties, and if the amount of oxidation is high It should be melted again and the alloying and rolling operations should be repeated. In order to prevent the oxidation of the foil, you should first avoid exposing it to moisture and direct sunlight and other sources of heat. After making sure that there is no moisture, heat, dust particles and other contamination, open the wrapper so that air can circulate on the product. Also, foil should not be kept in the warehouse for a very long time, especially in low thicknesses, and this time has a direct relationship with the humidity and heat conditions of the warehouse environment.
🔷 Product integrity
In some applications, it is very important that the entire product produced along the length of the roll is integrated and there are no welds or multiple pieces.
🔷 Uniformity
From the beginning to the end of the roll, it should be uniform in terms of thickness, width, alloy, hardness, and appearance quality, without any tolerance outside the standard, and both the bottom and the surface should be free of tears, cracks, chips, and wrinkles.
🔷 Smooth and uniform edges
The edges of the foil are one of the most sensitive parts of it, and during packaging, the edges should not be under pressure and become dented, deformed or torn. Also, it should not have pleated foil edges and should be completely smooth and sharp.
🔷 Finishing of foil surfaces
Aluminium foil for food and drug packaging industries, cigarette and butter foils and some foils for sachets, bottle caps, etc., according to the customer’s needs and intended use, in the form of two-sided shiny, one shiny side and One side is matte.
🔷 Adhesion of foil layers in rolls
The foil layers in the produced rolls should not be sticky in any way and the foil layers in the roll should be separated easily.
🔷 Mechanical properties
According to the type of application, aluminium foils are checked in terms of characteristics such as yield stress (MPA-Rp0.2), ultimate strength (MPA-Rm), elongation percentage (E%) and according to the buyer’s request, the test result certificate are provided.
Quality Control
Specialized laboratory omid alborz Aluminum Complex is one of the most advanced quality control laboratories in this industry in iran and checks and controls all physical, chemical, mechanical and appearance characteristics of products. In this laboratory, the quality of other parameters affecting production and the quality of the final product, such as the quality of raw materials, alloying agents, rolling oil, etc., are also examined. Some of the devices used in this laboratory are:
- Oil density device: determining the specific weight of oil
- Tensile device: device for stretching and determining the hardness of the product
- Spectrometer device: determining the chemical analysis of the product
- Oil viscosity determination device
- Oil level test device
- Thermal oven
- Flash point: test to determine the ignition of oil
- Accurate scales
- Mechanical thickness gauge
- Electronic thickness gauge
- Standard punch for thickness control by weight method
🔵 Standards
The products of Omid Alborz Aluminium Complex comply with the following standards:
- Mechanical standard: BS EN 546-2:2006
- Chemical standard: BS EN 573-3:2013
Equipment
🔵 Main machines
- Primary foil rolling machine: (Roughing Mill)
- Intermediate foil rolling machine: (Intermediate Mill)
- Final foil rolling machine: (Finishing Mill)
- Cold rolling machine: (Aluminum Cold Rolling Mill)
- Continuous sheet casting machine: (Aluminum Strip Continuous Caster)
🔵 Other machines and equipment
🔷 Doppler device:
Opens two rolls of aluminum foil and doubles the opened double layer of foil and rewinds it again. This work is done when it is necessary to roll the final product as one matte side and one shiny side, or the thickness of the final product is less than 10 microns.
🔷 Superfinish Grinder machine:
The polished surface of the rollers is very effective in the quality of the final product, especially for thicknesses less than 20 microns, and it is necessary to periodically polish these rollers. This work is done by stone cutting machines and the experience and skill of the operator of these machines is very important in the final quality.
🔷CO2 production device:
One of the equipment that is used in this factory and helps to reduce the emission of polluting gases and reduce production costs is the technology of converting the exhaust gases of gas annealing furnaces into CO2, which is used to charge the automatic fire extinguishing system.
🔷 Rolling oil distillation and refining system:
One of the factors that plays an important role in determining the production cost is rolling oil. The quality of this oil is very effective in the quality of the final product. Similar factories need to empty about 50,000 liters of rolling oil and replace with new oil every month. Omid Alborz Aluminium Complex has a small-scale refinery that collects all the oil vapors produced in the rolling process by hoods installed on top of the rolling machines and prevents air pollution. Also, this system refines the rolling oil and returns it to the production cycle. With the help of this technology, the rolling oil is changed only once a year and up to 98% of air pollution is eliminated.
🔷 Air conditioner and air purification system of aluminium foil production hall:
On average, in normal air, there are dust particles and pollutants with a diameter of 1 to 100 microns. Particles above 50 microns can limit visibility and cause damage to the eyes, ears, and respiratory system of humans. Pollutant particles with a diameter of less than 7 microns are more dangerous because they strongly tend to deposit deep in the air sacs of human lungs. In the foil rolling hall of Omid albor aluminium factory, an advanced air purification and air generator system has been installed. This system is installed with four goals:
- First goal: Protecting the environment and cleaning the air leaving the factory.
- Second goal: Safety and health of colleagues active in production lines.
- Third goal: Cleaning the indoor air of production halls from oil vapors and other pollutants.
- Fourth goal: Controlling the quality of manufactured products and controlling the amount of precipitating oil on the products.
This factory produces the thinnest foil in Iran and is the only producer of aluminium foil with a thickness between 5 and 10 microns in Iran. Therefore, in order to control the quality of foil, especially foils with a thickness of less than 10 microns, in terms of appearance and number of pinholes, it is necessary to completely control the number and size of polluting particles in the air of the production hall. For these purposes, two advanced air conditioners with air purification systems have been installed. One of these devices sucks the air inside the hall and creates negative pressure in the hall. The second device blows purified air with pressure into the hall. The result of the air pressure sucked and blown in the hall is a small positive value. This positive pressure from purified air first makes breathing easier. Secondly, the unfiltered air with dust particles outside this hall should not be sucked into the enclosed space of the foil rolling hall.
🔷 Separator machine:
This machine separates the doubled rolls in the Doppler machine and rewinds them again, and it has the possibility of cutting along the length of the foils at the same time as the rewinding operation.
🔷 Slitter machine:
This machine specially opens the roll of foil or aluminum sheet, continuously cuts it to the desired width and rewinds it again.
🔷 Annealing furnaces:
Granulation and mechanical properties of aluminium foil and sheets undergo changes in the cold rolling process. After finishing the rolling steps, according to the alloy of the product and the type of application that is intended for the final product, the mechanical characteristics are modified by the heat treatment method. This operation is called annealing. Special furnaces are needed to anneal the products. These furnaces have the possibility to control the amount and timing of the temperature and maintain the thermal uniformity in the entire space of the furnace. Omid Alborz uses the highest quality and most reliable brands of annealing furnaces. These furnaces use the highest technology and the most accurate control sensors. Their heat source is gas and electric.
🔷 Fire extinguishing system:
The oil used in cold rolling operations is highly flammable and during the rolling operation, the rolling foil or sheet must be completely covered with this oil. High speed, high friction, high pressure and tension of the rollers on the product greatly increase the risk of fire and oil ignition. Therefore, the existence of an advanced automatic fire extinguishing system is very necessary. This factory uses advanced automatic CO2 low pressure fire extinguishing system. In addition to this system, different fire extinguishers have been used in different parts of the factory.
🔷 Pools and cooling system:
Continuous casting lines for the production of aluminium coils from ingots require cooling. Due to the lack of water and to prevent wastage and 100% control of industrial water consumption, an advanced cooling system combining RO and ACC methods has been set up in this factory and is responsible for cooling the continuous casting lines.
🔷 Waste recycling furnaces:
Aluminium is one of the metals that has a very high recyclability and if the right method and equipment are used, it can be recycled with a high percentage. Medium-sized ground furnaces are used for foil recycling because, due to the very low thickness of the foil, if large melting furnaces are used, the amount of wastage will be very high.
Omid alborz factory uses these furnaces and foil scraps are turned into 10-pound ingots.
🔷 Melting and holding furnaces:
In this production unit, the continuous casting method is used to convert aluminium ingots into aluminium coils. In this method, aluminium ingot with a purity of 99.7% is first charged in a melting furnace with a capacity of 17 tons and turns into molten aluminium. To alloy and obtain the desired chemical composition, some amines are added to the melt. Then the melt is transferred to the holding furnace and after adding other additives such as aluminium titanium alloy, the molten material enters the casting line by passing through the ceramic molds and finally aluminium coil with a thickness between 6 and 10 mm is produced.
Location
🔵 Address :
Plots 3257 to 3262 and 3275 to 3277, 3nd Sepehr St., Eastern Ghazali St., Eshtehard Industrial Town, Alborz Province, Iran.
🔵 Email: 🔵 Phone Number:
