From scrap treatment to casting, Sistem Teknik advances aluminium production with integrated technologies

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As aluminium producers work to increase recycled metal use while reducing emissions and energy consumption, technology is becoming central to improving production efficiency. Across the aluminium value chain, innovations in scrap treatment, melting, molten metal refining, casting and heat treatment are helping manufacturers improve metal recovery, optimise energy use and support the shift towards closed-loop recycling and lower-carbon aluminium production.

Recent developments have focused on technologies that improve different stages of the production process. Delacquering drum furnaces prepare coated aluminium scrap before melting, while preheating ovens recover waste heat to improve energy efficiency. Camera integration systems are used for efficiency prediction, ultra-low NOx burners help reduce furnace emissions, and fully automated charging and skimming systems shorten melting cycles in aluminium cast houses while reducing manual intervention.

Improving every stage of aluminium production

Technology providers are responding to these industry requirements by developing integrated solutions that span the aluminium production process. Among them is Sistem Teknik, an engineering and technology company that provides turnkey solutions covering every stage of aluminium production, from scrap and raw material treatment to finished products.

The company's aluminium portfolio includes scrap and raw material treatment, charging and skimming, melting and holding, metal refining and alloying, casting, heat treatment after casting and plastic deformation, together with in-house manufacturing and project management. According to Sistem Teknik, these solutions are designed, engineered and manufactured in-house to deliver customised production lines for aluminium plants.

The company states that its mission is to transform aluminium production by supporting closed-loop recycling and net-zero aluminium production through technologies that prioritise energy and material efficiency. Its technology portfolio includes ST Phoenix regenerative burners, ST Magnetica electromagnetic furnace technology, ST LIBS laser-induced breakdown spectroscopy, ST Alupure automated skimming systems and delacquering furnaces, all developed for aluminium production and recycling.

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Metal treatment technologies strengthen casting operations

Molten metal treatment remains an essential stage before casting, as the quality of the metal directly influences downstream processing and the final product. To support this stage, Sistem Teknik offers metal refining and alloying technologies including electromagnetic stirrers, heated launders, ceramic foam filter (CFF) systems, degassing units and rod feeders. According to the company, these technologies are used for molten metal treatment before casting and form part of its turnkey aluminium production solutions.

Together, these technologies support multiple stages of aluminium production, from preparing scrap for melting and recovering waste heat to refining molten metal before casting. Automation systems help shorten melting cycles and reduce manual operations, while ultra-low NOx burners are designed to lower furnace emissions. Metal refining technologies improve molten metal treatment before casting, with the aim of increasing energy and material efficiency, improving metal recovery, supporting higher recycled content and contributing to closed-loop aluminium recycling and lower-emission aluminium production.

Innovation drives recycling and decarbonisation

According to Sistem Teknik, 85 per cent of its research and development budget has been dedicated to reducing emissions from aluminium production. This work has resulted in the development of five technologies for aluminium melting and heat treatment processes, including delacquering drum furnaces, preheating ovens targeting heat recuperation, camera integration systems for efficiency prediction, ultra-low NOx burners, and fully automated charging and skimming mechanisms for aluminium cast houses.

In addition to equipment supply, the company provides lifecycle services for aluminium plants, including spare parts, maintenance, modernisation and furnace revision. Sistem Teknik says its in-house engineering expertise, manufacturing capabilities and turnkey project delivery enable it to support aluminium producers and recyclers throughout the production process.

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