Six modern tandem continuous casting lines produce brass and bronze bands in a continuous process. A permanent stock of approximately 5,000 tonnes of raw materials is kept on hand to ensure that the casting lines can be continuously operated. The casting capacity is approximately 22,000 t/a.

The raw materials for the casting process (copper, zinc, tin and punching waste from the customers) are subjected to an acceptance test, weighed into metal containers and stored in a fully automated high-bay warehouse. The casting line managers supply the casting line with the raw material stored in this warehouse to ensure that the flow of the melt is not interrupted. The furnace is automatically supplied from the high-bay warehouse via a rail system.

The furnaces are arranged vertically above the casting line, while the finished melt leaves the furnace in a horizontal direction. Once the bands have cooled down, they are wound into coils. A coil weighs approx. 6 tonnes and has a band width of approximately 360 mm.

After casting, the raw master coil is covered in black oxide layers that have formed on the surface during cooling. The scale must be removed before rolling, otherwise the oxides will pollute the material during the subsequent processes.

A surface milling machine is available for this purpose. After milling, the bands have a thickness of approx. 14.2 mm. After this initial processing step, the coil is moved to the first roller mill - the roughing mill.

During the first reduction stage in the roughing mill, the bands are reduced in several rolling steps from a thickness of 14.2 mm to approx. 3.3 mm. Reducing band thickness leads to a proportional increase in their length.

Several rolling processes are carried out in succession to achieve the desired final thickness. However, rolling changes the metal structure. The material becomes brittle and very hard. Before rolling, the metal must be reheated in various annealing furnaces to make it soft and pliable.

The largest batch-type annealing furnace made by Ebner holds up to approx. 100 t at one time. This corresponds to approx. 25 coils. The loading and unloading processes as well as the annealing process are handled by this unit in a fully automated manner. Annealing takes place in an inert gas atmosphere to prevent reoxidation of the band surfaces.

Approx. 10-12 rolling processes with multiple intermediate annealing steps are necessary to change the initial thickness of 3.3 mm to 0.15 mm. The ultimate hardness of the band after the last rolling process is usually determined by a final annealing process.

All bands up to a thickness of 1.0 mm run through the stretch-bending alignment line. This work step releases tension in the band that built up during the rolling processes. The stretch-bending alignment line reduces curving, deformation of the bands and buckling along the edges during cutting. This work step improves the accuracy and alignment of the bands in high-speed pressing systems.

After stretch-bending alignment, an additional heat relaxation step can be performed, if required.

A team of specialised engineers can quickly analyse and eliminate any problems that may arise within the complex production processes. The specialised workers on site can deal with the electronic, hydraulic, pneumatic or mechanical systems to ensure an uninterrupted production run.

The company's internal tool department maintains tools such as cutting heads, circular blades and ejector rings. Rollers and other machine parts can be maintained by the modern machinery of ILNOR SpA.

The quality assurance department is responsible for ensuring and documenting the quality of the band products. The specialised engineers in this department are regularly trained in quality management. An in-house laboratory with measuring and analysis facilities is available at all hours. The mechanical, physical and chemical analysis results are documented and each customer can request a detailed factory certificate for his product. Quality assurance guarantees that the conditions for certification as specified in UNI-EN-ISO 9001, ISO/TS 16949 and UNI-EN-ISO 14001 are adhered to at all times.