Process manufacturing aluminum cans

Brazil 03-31-2024

Alonso Consultant

Process manufacturing aluminum cans

Today we will talk about the process of manufacturing aluminum cans (speed x quality x spoilage).

The process of manufacturing aluminum cans is very dynamic and a lot of variations of the process will damage your final goals.(spoilage)

Team process needs to be checked all the time each process and identify problems and solve them. These methods can help the team understand expectations, improve their performance, and align their actions with the Company's goals. (quality)

-Front End

-Cupper Press and Bodymaker (speed)

The process of creating an aluminum can body typically starts with coil aluminum being fed into a cupper press to form cups. These cups are then transferred to a bodymaker, where they are reshaped into the final can body. The bodymaker applies pressure to the cup to stretch and shape it into the desired cylindrical form, creating the body of the aluminum can. This process ensures that the can body is uniform in shape and size, ready for further processing cut after cleaning the surface of the cans.

To each of process the aluminum coil we have a lot of shapes:

coil →blank→cup→re-draw→1st iron→2nd iron→3rd iron→form dome→trim→neck flange.

-Trimmer (speed and spoilage)

The trimming process typically involves feeding aluminum cans into the machine, where they undergo precise trimming of the high cuts to remove excess material. The trimmed cans then continue through the production line for further processing, such Washer.

List of main points to check every day:

? Quality of aluminum canbody (AA3104-H19 raw material is commonly used in applications requiring moderate strength and good formability).

? Quality of cup (cupper press, tooling die set)

? Control oil soluble (PH, temperature and tramp)

? Control short cans (raw material, alignment of tooling)

? System control quality (quality control automatic and manual)

? Variation of the top wall/think wall (thickness, raw material, tooling dies, alignment of bodymaker)

? High can (Tooling dies, alignment of trimmer).

-Washer (quality and spoilage)

The washer’s function is to clean the cans and apply a treatment to its surface, preparing it for the following steps. The process of cleaning and to have four variations: mechanical, chemical, speed and temperature.

?System of risers (control of nozzles)

?Control the addition of products and cleaning the surface of the can (automatic control)

?Control the temperature of baths and oven

?System control blower and brushes.

Note: Training is essential for ensuring that team members are equipped with the necessary knowledge and skills to perform their tasks effectively and safely. For a manufacturing process like producing aluminum cans, training should cover various aspects such as operating machinery, quality control procedures, safety protocols, troubleshooting common issues acquiring a high level of knowledge and adherence to SOP (Standard Operating Procedures).

By providing comprehensive training, employees can enhance their understanding of the processes involved and contribute to the overall efficiency and quality of production. Regular training sessions and refresher courses can also help keep employees up-to-date with any changes or advancements in the manufacturing process.

?Alonso, Marcos

Consulting and Project

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