The year 2024 has marked the beginning of a new era for Felgenhauer. A company whose heart has been steel for over half a century has now expanded its operations to include the production of aluminum components. “This is our response to the changing needs of the market. We believe that aluminum has a promising future ahead,” says Adam Stróżyk, Head of Production at Felgenhauer. What does this mean for the company’s clients?
Why Aluminum?
Aluminum is the most commonly used non-ferrous metal in the world. Industries such as renewable energy, transportation, automotive, and construction all use it. It is also found in everyday items, for example, in packaging. Its popularity comes not only from its properties, but also from its high recyclability – aluminum can be recycled multiple times. As a result, three-quarters of all aluminum ever produced is still in circulation today.
The ability to recycle and reuse aluminum supports the development of a circular economy and helps achieve global climate ambitions. Aluminum aids in the decarbonization of other sectors, including transportation. Lighter vehicles require less energy to move, which results in lower emissions and cost reductions for companies.
“Over 90% of the metal is recovered after a vehicle’s end-of-life phase and reused to create new aluminum products, using only a fraction of the energy needed to produce primary aluminum.”
— European Aluminium
The railway industry is increasingly turning to aluminum. Metros, trams, and trains are becoming lighter, cheaper to operate, and faster, all without compromising their durability.
New Material, New Equipment – ELUMATEC SBZ 151
Working with aluminum can mean shorter lead times, as it often requires fewer man-hours than producing the same part from steel. However, in both cases, production processes must be adapted to ensure the highest precision and reliability. Past steel projects completed by Felgenhauer for the railway sector have been met with positive feedback. The company is therefore able to meet the industry’s requirements, and working with a different material required only the right preparation and investment.
In December 2023, Felgenhauer acquired a new machining center – the ELUMATEC SBZ 151 – dedicated to aluminum and thin-walled steel profiles. Currently, the company uses the machine to process two types of aluminum profiles: floor and roof profiles.
The device performs many processes simultaneously and from as many as six sides. It enables milling, drilling, thread cutting, tapping, undercutting, and cutting profiles over 20 meters long. This significantly streamlines production. Unsurprisingly, after a year, there are already two such machines in the plant. “The advantage of the ELUMATEC is that it can be retooled and optimized very quickly,” notes the Head of Production.
Initially, Felgenhauer’s experienced staff, who received training on the new equipment, worked on aluminum processing. Later, new employees were hired. A major advantage is the company’s own tool shop. Until now, this department produced tooling for steel components, but it now also supports aluminum production. Welding aluminum profiles is a semi-automatic process using a robot operated by an employee. This process is different from that of steel, which is why expanding skills related to tooling was necessary.
“But this is not our only potential in aluminum. We also manufacture tram sidewalls and are ready to take on other projects,” emphasizes Adam Stróżyk. At the same time, the company continues to develop its steel operations. “We are expanding our offer to give customers more choices and possibilities,” he adds.
Sources:
https://european-aluminium.eu/about-aluminium/aluminium-in-use/
