Exlabesa is set to expand its aluminium recycling operations at its plant in A Coruña, Spain, by increasing its production capacity with the installation of new technology supplied by Hertwich Engineering, a company under the SMS group. The upgrade includes the addition of a continuous homogenising furnace, complete with an air cooling station, a long-billet stacker, and a semi-automatic PET strapping system. This new equipment complements an existing second melting furnace, which is dedicated to producing recycled aluminium from post-consumer scrap.
Previously, Exlabesa commissioned a second continuous homogenising plant at the same site in 2018, followed by the installation of a multi-chamber melting furnace, both also supplied by Hertwich. The latest expansion will boost the plant’s capacity for continuous homogenisation by an additional 30,000 tons per year, bringing the total to around 80,000 tons annually.
The state-of-the-art melting furnace recently put into operation is specifically designed to produce recycled billets from aluminium scrap that has completed its lifecycle. The expansion, featuring the new continuous homogenising facility from Hertwich, will significantly enhance the plant’s ability to process production scrap. This development allows Exlabesa to reduce its reliance on primary aluminium, promoting resource conservation and sustainability.
Exlabesa’s investments highlight its commitment to sustainability and the reduction of CO2 emissions by fostering a cleaner and more efficient industry rooted in the principles of the circular economy. These upgrades further strengthen Exlabesa’s capacity to meet the rising demand for recycled aluminium products, reinforcing its position as one of the leading foundries globally.
Gerold Keune, CEO of Hertwich Engineering, emphasized the importance of tailored solutions in their partnership with Exlabesa. “Our expansion of continuous homogenisation operations at the Exlabesa plant aligns seamlessly with their existing production environment. It is not just an investment in aluminium production; it’s a commitment to sustainability and long-term cooperation,” Keune said.
The new system is engineered to process aluminium billets with diameters ranging from 178 to 406 millimeters and lengths of up to 7.0 meters, suitable for all alloys in Exlabesa’s portfolio. Hertwich’s continuous system offers advantages over traditional chamber homogenisation by ensuring uniform treatment of the billets. In the homogenising furnace, billets undergo continuous heat treatment at temperatures up to 590 degrees Celsius, ensuring a consistent microstructure before entering the air cooling station. This process not only guarantees high billet quality with optimal metallurgical properties but also reduces the energy required for homogenisation. After processing, the billets are stacked and secured with plastic straps, ready for further use. 
