Granco Clark is a leading manufacturer of automated equipment for aluminium extrusion operations, offering innovative solutions that enhance production efficiency and reduce downtime. With a strong focus on engineering excellence, the company designs and builds advanced handling systems, heating equipment, pullers and saws tailored to the needs of aluminium extruders worldwide. Their turnkey systems are trusted by top-tier producers for delivering high performance and reliability. Granco Clark's commitment to innovation and customer service sets them apart in the aluminium industry. They shared insights on their automation technologies and industry approach in our latest e-Magazine "Advanced Industrial Technologies in the Aluminium Industry (Part II)".

AL Circle: What are the next major technological breakthroughs that Granco Clark is working on to redefine aluminium extrusion in the coming decade? How do you see your R&D investments aligning with the evolving requirements of sustainability, lightweighting, and high-strength aluminium applications?

Granco Clark: Potential areas of focus for Granco Clark include the following: Smarter and more autonomous extrusion lines: Integrating advanced sensors, AI, and robotics for self-optimising processes, reduced manual intervention, and improved quality control. This will reduce workforce requirements while improving process efficiency and accuracy. Energy-efficient extrusion technologies: Innovations aimed at significantly reducing energy consumption during billet heating, extrusion, and cooling processes. This could involve new heating methods, press designs, and heat recovery systems. Enhanced material handling and automation: Solutions for more efficient and safer handling of billets and extruded profiles. Digital twins and simulation: Creating virtual representations of extrusion processes for better design, optimisation, and predictive maintenance. Sustainable extrusion practices: Technologies that minimise waste, reduce emissions, and facilitate the use of higher percentages of recycled aluminium.

AL Circle: What is the estimated global annual demand and consumption of extruded aluminium products? Which regions are currently the largest consumers, and what factors (such as infrastructure growth, EV adoption, or sustainability policies) are driving demand in these markets? How do you see regional consumption patterns evolving over the next five years?

Granco Clark: The global demand and consumption of extruded aluminium products are substantial, expected in the tens of millions of tonnes annually. Refer again to recent market research for timely and precise figures. Currently, the largest consuming regions include Asia (particularly China), which is driven by rapid infrastructure development, industrialisation, and increasing automotive production. North America continues with strong demand from the automotive, construction, and aerospace sectors. EV Adoption continues to increase demand for lightweight aluminium components in electric vehicles. (This is true for traditional I.C.E. vehicles also.)

AL Circle: Downtime in extrusion operations can be extremely costly. How does Granco Clark integrate real-time data monitoring, predictive maintenance, and AIdriven diagnostics into its systems to enhance equipment reliability and minimise unplanned shutdowns? Could you share real-world data demonstrating downtime reduction and maintenance cost savings?

Granco Clark: Granco Clark integrates the following: Real-time sensor data and monitoring systems: Providing operators with live data on critical parameters like temperature, pressure, vibration, and energy consumption. Predictive maintenance algorithms: Analysing historical and real-time data to identify potential equipment failures before they occur, allowing for pre-emptive maintenance scheduling. AI-driven diagnostics: Utilising AI to analyse complex patterns in equipment data to diagnose issues quickly and provide insights into root causes. Remote monitoring and support capabilities: Enabling remote access for diagnostics and troubleshooting by Granco Clark’s service and engineering teams. User-friendly interfaces and Maintenance Scheduling Tools make it easier for customers to monitor equipment health and plan maintenance activities. By utilising our custom SCS4.0 software (Industry 4.0), there will be a significant reduction in unplanned downtime (measured in hours or percentage). This will also result in lower maintenance costs due to pre-failure interventions and reduced emergency repairs. The goal is to increase the overall equipment effectiveness (OEE).

To explore the full interview and gain deeper insights into the global aluminium extrusion technology and equipment market, click here.