The new entry of Panizzolo Recycling Systems
FROM SCRAP TO FURNACE-READY ALUMINIUM: THE NEW RECYCLING PLANT AT DERAL SPA
Starting from aluminium scrap, Deral Spa produces high quality billets for the national and international markets. In order to ensure high production quality, the material loaded into the furnaces must be carefully treated for any impurities. For this reason the company has its own grinding and selection plant, recently upgraded by Panizzolo Recycling Systems with the Mega 1100 hammer mill.
Deral was founded in 1986, initially dealing with scrap metal discarded from extrusion production cycles and from which we produced new billets. Over the years, the evolution of production has led us to expand the range of incoming aluminum, arriving today to be able to include in the smelting cycle material from the demolition of windows and doors and aluminum profiles. This evolution has introduced greater attention to the quality of recycling and valorization of the raw material from scrap. In 2015 this process saw the replacement of the old line with a first Flex 1000 mobile durm plant by Panizzolo complete with eddy current. Over the years we then also implemented with an x-ray sorter, allowing us to effectively identify and separate secondary alloys from primary furnace-ready aluminum.
Deral today boasts a production of about 40-45,000 tons/year of finished product, and foresees an increase in the company's production over the next ten years, thanks both to the new Mega 1100 and to a rapidly expanding Italian market.
Mr. President Mauro Cibaldi & CEO Giulio Vincoli
CEO of DERAL S.p.a. Giulio Vincoli: "At the beginning of the activity we worked with shear balers and manually performed the selection and cleaning phases. In particular, our twin-shaft shredder produced a very large piece of aluminum (50-60 cm) and forced us to slow down production. Moreover, the quality of the product was not perfect, with clear repercussions at the time of casting. For this reason, in recent years we have opted for complete and more efficient plants such as the Panizzolo line, up to the new x-ray selection. One of the first Panizzolo machines installed, for timing reasons, was the Flex 1000 mobile drum mill, started up in a very short time while now we have moved to a Mega 1100 stationary mill. Our first need was to increase the production capacity of the grinder and from the first accounts of the new production cycle we have already seen a clear improvement. With the grids set for our scrap we calculated a productivity of about 15/16 tons per hour. A high level of control is important in a good machine. Alongside the operators we want to add new technologies for monitoring production, so that the plant operates at its maximum potential every day. The new software, which operates under Industry 4.0, will analyze all the machine's operating data and bring us the feedback we need to understand where we are going and how we can improve."
THE CHOICE OF PANIZZOLO RECYCLING SYSTEMS AS TECHNOLOGICAL SUPPLIER
Mauro Panizzolo has a long experience with grinding and hammer mills, he has created a product based on his own experience. There are other hammer mills of this size but they are not up to the task of processing our ferrous scrap. "The structure of the Panizzolo mill at the carpentry level is good" - continues Vincoli - "I have personally visited the factory where all the machinery is built, noting that the carpentry is also part of an international high quality content in railway supplies. This is further confirmed by the fact that our Flex 1000 Mobile has had no problems whatsoever, even though it has been working for many years under intense production conditions. What also distinguishes the Panizzolo system is both its simplicity and its low running costs, avoiding the need to employ highly specialized or constantly present personnel. Following the simple ordinary maintenance, the Panizzolo mill does not give any problem, with costs undoubtedly lower than the hydraulic twin-shaft shredders on the market".
ITALY AND ABROAD
The President of DERAL S.p.a Mauro Cibaldi, on the other hand, underlines the differences between Italy and abroad: "Mainly as regards the input we have to make two major distinctions. Scrap has an Italian prevalence, with 10% less coming from abroad. Vice versa, pure aluminum ingots are all produced outside the EU. As far as our sales process is concerned, 60% of our turnover goes to our parent company Estral. The remaining 40% is almost all destined to the Italian market, where there is the presence of about 45 extruders and a small part to the European market (about 2-3%). Italy is the European leader in the field of extrusion, both in terms of production and quality, and in this panorama Deral is among the top five national foundries producing billets. The strong propensity to recycle has allowed Italy to develop more than other European countries where, on the contrary, there has been a preference for the birth of a few large foundries. Italy has therefore a great productive and qualitative capacity with an export trend growing every year. As far as the final purchasing basin of our products is concerned, we can say that the German automotive sector is the master. Many vehicles of German brands are built with Made in Italy aluminium".
At a European and national level, a whole series of incentives for products and materials that have a particular value within the circular economy are flourishing. Among these materials, aluminum plays one of the most important roles. Aluminum is 100% recyclable, its recycling process requires 1/20th of the energy that would be used starting from the raw material. It is used more and more because of its lightness and resistance and involves very little CO2 emissions during the melting process. All these are elements on which we are focusing in a predominant way and will ensure that aluminum will become the material of the near future.
Mulino Mega 1100