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Company Profile Alcomet AD is the largest Bulgarian manufacturer of rolled and extruded aluminium products. The company offers a broad range of aluminium semi-finished products – household, technical and container foils, finstock, sheets and strips; standard and customized profiles. 95% of the total production is exported, mainly to Europe and the USA.The company has continuously invested in acquiring new technologies and upgrading existing facilities to the latest technological standards in order to meet the more challenging demands of its clients and step into new markets. Latest investment programme, spanning a period of three years, will double the capacity and expand production premises by additional 13000 m2 upon its completion in 2019. On the rolling side it involves commissioning a new 6-high cold-rolling mill with max. width of 2200 mm, a continuous casting line, heat-treatment facilities and finishing lines, while on the extrusion side a new generation 25 MN HybrEx® extrusion press will enable Alcomet to extrude profiles with a CCD up to 310 mm and wall thickness as low as 0.8 mm.

Investing in the most state-of-the-art equipment available the company targets new markets for high added-value products, such as building and architecture, flexible packaging and automotive. Alcomet is certified to ISO 9001:2015, ISO 14001:2015, BS OHSAS 18001:2007 and EN 15088:2005, and it is strongly engaged in programmes effectively addressing the issues of environmental protection, waste reduction and resource efficiency. Continuous investment in modern technologies and equipment guarantees product improvement and sustainable development of the company.

Today, Alcomet ranks among the top 100 Bulgarian companies in terms of income and growth. It is also among the top 100 biggest employers in Bulgaria.

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ROLLED PRODUCTS DIVISION

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CastingTo cover the needs of its rolling production, Alcomet has a casthouse

equipped with 6 continuous casting lines with a total production

capacity of 65000 tons per year. Main focus is on 1xxx, 8xxx and 3xxx

series alloys suitable for the majority of foil products available on

the market, as well as many kinds of sheets and strips for industrial

applications.

Chemical composition is according to international standards, such as

EN 573-3, or internal standards developed specifically to ensure best

possible quality of the final product.

Strip thickness:

Strip width:

Available alloys:

5 –10 mm

max. 1570 mm

1xxx, 3xxx, 8xxx series

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The main production division at Alcomet is the Rolling plant equipped with a cold-rolling mill, a foil-breakdown mill and 3 foil mills with a total production capacity of 50000 tons per year. Our state-of-the-art finishing lines for slitting, degreasing, cut-to-length and embossing enable the company to produce a wide range of products with a variety of applications in food packaging, construction, automotive, heat exchangers, etc.Company’s primary focus is the household foil with annual production output of over 17000 tons, making Alcomet a leading European supplier of this product.

Rolling

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Household foil is used for wrapping food during cooking or to preserve its freshness. Its excellent resistance to the highest temperatures in cooking, and its role as barrier against light, aroma and steam make it an essential item in every kitchen.

Household foil

Food Packaging

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Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Coil sizes

ID

OD

Core

8011А, 8006

0

0.008–0.02 mm

280–600 mm

150 mm

max. 750 mm

metal

Alcomet has a strong presence on the European foil market.

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Flexible packaging

Container foil, also called lubricated foil, is used for the production of aluminium containers offering some of the most versatile packaging solutions available today. With its unique set of properties – a 100% barrier against light and gas, heat conductivity, formability, food contact ability and decorative appearance – it helps to prevent food waste and provides other great benefits along the food chain to the end consumer.

Container foilA unique combination of physical characteristics makes aluminium foil an essential material for the flexible packaging industry  like aseptic cartons, wraps, pouches, bottle neck, push-thru blister, laminated tubes.

Converter foil

A special type of sheets developed by Alcomet’s predecessor Alumina, used for the manufacturing of Omnia type jar caps for food preservation in home conditions.

Omnia sheets

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Coil sizes

ID

OD

Core

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Diameter

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Length

3003, 8006

H24, H22, H24, 0

0.045–0.120 mm

150–1250 mm

150 mm

max. 800 mm

metal

1235 8079

0 0

8.5–40 9–40

100–1270 mm

ID/OD: 150–750 mm

8011A

H18

0.18–0.25 mm

800–1000 mm

700–900 mm

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Aluminium has a unique set of characteristics that make it ideal for heat exchange. With its key properties – light weight, good thermal and electrical conductivity and corrosion resistance, aluminium finstock has a widespread application in modern HVAC (Heating, Ventilation and Air Conditioning) and refrigeration systems.

Strips for heat exchangers/Finstock

Industrial Applications

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Coil sizes

ID

OD

Core

8006, 8011A

0, H18, H22

0.060–0.350 mm

200–1280 mm

150 mm

max. 1000 mm

metal

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With its specific physical properties – reflectivity, thermal conductivity and corrosion resistance – aluminium is the perfect heat shield material offering excellent protection against excessive exhaust system heat. Alloy 1050A in soft temper is widely used for its good formability, adequate corrosion resistance and energy absorption providing for ease of fabrication and good performance.

Strips for heat shields

Automotive

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Coil sizes

ID

OD

Core

1050A

0

0.4–1.0 mm

100–1500 mm

400, 500, 600 mm

max. 1500 mm

without

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Aluminium’s excellent formability, insulating properties, high strength-to-weight ratio often make it the architect’s material of choice in modern building design. Aluminium strips are used for sandwich panels, insulation, roofing, gutters, etc. offering an eco-friendly and cost-effective solution to the most innovative and ambitious projects.

Strips

Due to its barrier function, heat and corrosion resistance and reflective surface, aluminium technical foil has a number of applications in buildings, electrical cables, pipe work and ducting, adhesive tapes.

Technical foil

Building & Construction

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Coil sizes

ID

OD

Core

1050A, 3105, 3003

H12, H14, H16, H18, H22, H24, H26, O

0.4–3.0 mm

250–1500 mm

400, 500, 600 mm

max. 1500

without

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Coil sizes

ID

OD

Core

1050A, 8011A

0, H18

0.020–0.200 mm

100–1250 mm

150 mm

max. 1000 mm

metal

Stucco embossed surface is available for thickness range 0.4–1.2 mm and width max. 1250 mm.

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Aluminium’s light weight, good corrosion resistance and formability make it an excellent engineering material with a variety of applications in all industrial sectors. Standard aluminium strips and sheets are usually supplied to distributors and service centers for subsequent use in construction, electro-technical industry and other industrial sectors.

Stucco embossed surface is available for thickness range 0.4–1.2 mm and width max. 1250 mm.

Standard strips and sheets

Distributors

Technical specifications

Alloy

Temper

Dimensions

Thickness

Width

Length for sheet

Coil sizes

ID

OD

Core

1050A, 3105, 3003

H12, H14, H16, H18, H22, H24, H26, O

0.4–3.0 mm

max. 1500 mm

1200–4000 mm

500, 600 mm

max. 1500

without

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EXTRUDED PRODUCTS DIVISION

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Billets used in Alcomet’s extrusion shop are produced in the company’s own casthouse utilizing one of the most advanced technologies available on the market – Wagstaff Hot Top Billet Casting System. The line is dedicated to “soft alloys” production covering 1xxx and 6xxx series alloys. Chemical composition is guaranteed according to international standards or customer specification.

Billet Casting

Billet diameters:

Annual capacity:

4”, 6”, 7”, 8”

25000 tons

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Alcomet operates an Extrusion plant with five presses ranging from 600 tons to 2500 tons, with an overall production capacity of about 36 000 tons per year. The main focus is on soft alloys for the ABC (architecture, building and construction) sector, advertising, transportation and machine-building. The latest addition to the company’s extrusion facilities is a new generation 25 MN HybrEx®

extrusion press which enables Alcomet to extrude profiles with a CCD up to 300 mm and wall thickness as low as 0.8 mm.

Extrusion

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Press size

600 1300 1800 2000 2500

4” 6” 7” 8” 8”

Alloys6060, 6063

1200, 6060, 6063, 6005

6060, 6063, 6005

6060, 6063, 6005, 6082

6060,6063,6005,6082

CCD (mm) – solid profiles

MAX. 90

MAX. 150

MAX. 170

MAX. 200

MAX. 300

CCD (mm) – hollow profiles

MAX. 70

MAX. 130

MAX. 150

MAX. 180

MAX. 280

Weight (kg/m)

0.05–0.7

0.1–1.8

0.2–2.3

0.35–9

MAX. 0.5 – 10

Length at the press (mm)

1000–7000

1000–8000

1000–8000

1000–11500

1500–8000

Wall thickness (mm)

MIN. 0.8

MIN. 1.0

MIN. 1.0

MIN. 1.2

MIN. 1.2

Creating SolutionsAluminium profiles make it possible for designers to create unique shapes that satisfy any customer’s expectation and demands. The main characteristics of aluminium – good corrosion resistance, formability, light weight, good conductivity – play an essential part in the development of new shapes and applications.With its 35-year history in extrusion production, Alcomet has the capability and experience to create tailor-made solutions according to the needs and expectations of each client.

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Over 7500 different shapes and600 new dies annually.

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Powder coating is a type of surface treatment providing a decorative finish to aluminium products. Its main benefits are good resistance to high impact abrasion, flexibility, high UV radiation and corrosion resistance.

For products demanding decorative appearance or improved corrosion resistance, Alcomet can offer a wide range of finishing services on its in-house anodizing and powder coating lines. Available anodizing colours are silver, gold, bronze and black in standard mat finish or with additional pretreatment, such as sandblasting or brushing. Powder coating, on the other hand, offers an infinite variety of colours based on RAL standard or customer’s specifications.Both lines operate in full compliance with ISO14001.

Powder coating

Surface Treatment

Maximum length

Coating thickness

Powder coating capacity

6500 mm

60–200 microns

2500 tons per year

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Electrochemical anodizing is the process of covering the surface of the product with a transparent oxide layer. This process is carried out on a computer-controlled automatic line in four distinctive stages: pre-treatment with satin finishing, anodizing, colouring and hot sealing. Key features of the anodized products are increased hardness, attractive appearance and corrosion resistance.

Anodizing

Available colours:

Pre-treatment

Max. length

Coating thickness

Anodizing capacity

E6 (matt finish)

6500 mm

10–25 microns

2500 tons per year

Natural (C0)

Champagne (C2)

Gold (C3)

Sandblasting (E6/C0 SB)

Light bronze (C32)

Dark bronze (C33)

Black (C35)

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Strong demand for profiles with additional fabrication has urged

Alcomet to invest in own fabrication facilities. The company is able

to offer a wide range of services to its customers: CNC-machining,

drilling, milling, punching, cutting. The latest acquisition is a state-

of-the-art 5-axis CNC-line ensuring highest quality and precision in

profile processing for lengths up to 7300 mm.

Positive market response means the company will continue to expand

its range of fabrication services thus optimizing customers' value

chain and logistics.

Fabrication

7300 mm

40 mm +/- 0.15

100 x 80 mm

CNC Machining

2 CNC lines (5-axis and 3-axis)

Drilling, tapping, milling, notching, sawing

max. length

Cutting

2 automatic saws

min. cutting length

Angle cut 45°

Punching

2 eccentric presses (25 tons and 65 tons)

Bending

Profile dimensions app.

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Offering the best possible quality to our customers is an essential part of our corporate strategy. With precision and care we monitor every parameter of the production process – from the quality of the raw material at the very beginning to each and every aspect of the finished product. Working closely with our customers on product improvements and process optimizations, our dedicated team develops tailor-made solutions to their specific needs, always ready to go the extra mile to ensure highest customer satisfaction.As evidence of the company’s commitment to quality improvement, Alcomet has been certified to international standards such as ISO 9001 Quality management systems, ISO 14001 Environmental management systems, OHSAS 18001 Occupational health and safety management systems, and EN 15088 Structural products for construction works.

The company has two laboratories: one in Casting shop dedicated to controlling the chemical composition during production and a main laboratory equipped for mechanical, metallographic and chemical testing and monitoring.

Always striving for perfection, Alcomet is continuously upgrading its laboratory equipment keeping it up to date with the latest technological standards.

Quality

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Environment protection and the effective use of natural resources have always been among the top priorities in the development of Alcomet AD. For the past few years, all investments in the modernization and expansion of production capabilities have invariably been accompanied by the installation of modern purification facilities.

The company has developed a number of programmes to manage production waste, the greater part of which is delivered for utilization by other industrial sectors. The existing melting furnaces enable the recycling and reuse of aluminium scrap generated in Bulgaria, thus reducing high energy costs and limiting the harmful emissions resulting from the production of primary aluminium. Consistent with its environmental policy, the company has developed and introduced an Integrated Management System in compliance with the requirements of EN ISO 14001:2004.Through recycling, Alcomet manages not only to preserve the natural resources but also to achieve energy saving and thus reducing carbon footprint.

Environment & Recycling

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The technical and technological solutions employed are of the highest quality and ensure a high degree of purification of the air emissions and the water used in production.

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Aluminium dross

Aluminium scrap

Aluminium dross is formed on the surface of molten aluminium as a valuable byproduct of the aluminium smelting process. It can be mechanically recycled to recover the aluminium content for the secondary aluminium industry.

Aluminium scrap generated in the production process is completely reused in Alcomet’s foundry. Sheet and coil scrap, as well as scrap from extrusion, can be remelted directly in the casting furnaces while foil scrap must first be melted into secondary ingots. Alternatively, foil scrap can be baled and supplied as a raw material to manufacturers of aluminium pigments, powders and flakes.

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