Case Study: How a Jiangsu Aluminum Recycling Plant Achieved Full Automation in 2018

Subtitle: A deep dive into the successful integration of high-efficiency casting and automated palletizing for high-volume recycling.

Project Background

In 2018, a leading aluminum recycling plant located in Jiangsu Province, China—one of the country’s most industrialized and environmentally regulated regions—faced a critical bottleneck. To meet the growing demand for secondary aluminum alloys, they needed to upgrade their aging casting facility.

The primary objectives were clear: maximize production capacity, eliminate manual stacking labor, and ensure strict environmental compliance. After evaluating multiple global suppliers, they selected our High-Efficiency Chain-Type Aluminum Ingot Casting Machine integrated with a Robotic Palletizing System.

Automatic Palletizing Machine (Robot & Gantry Type)

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The Challenge

• Labor Intensity: Manual stacking of hot ingots was dangerous and slow, limiting the line’s overall throughput.

• Inconsistent Quality: Manual handling resulted in uneven stack shapes, which jammed downstream automatic strapping machines.

• High Energy Consumption: The legacy system wasted fuel and generated excessive dust.

The Solution

We delivered a turnkey automated solution that seamlessly connected the melting, casting, and packaging stages.

1. High-Efficiency Casting
We installed a 20-meter chain-type casting machine equipped with 280 premium nodular cast iron molds. The system was configured to produce standard 7kg and 15kg ingots.

• Highlight: The automatic aluminum liquid distributor ensured every ingot had uniform weight, reducing waste.

2. Automated Handling
To replace 3 manual workers per shift, we integrated a FANUC Robotic Palletizing Machine. Equipped with a heavy-duty 150kg gripper and 360-degree rotation, it effortlessly synchronized with the casting line, achieving a perfect demolding rate of over 99%.

3. Sustainable Cooling
We implemented a dual cooling system (water spray and mold bottom overwater cooling), ensuring the ingots were completely solidified before demolding, while minimizing thermal shock to the molds.

The Results: Proven Stability Since 2018

Since its commissioning in late 2018, the line has been operating 24/7 with exceptional reliability. The impact on the plant’s bottom line was immediate:

• Production Capacity: Achieved a stable output of 12 tons/hour, significantly exceeding the previous line.

• Labor Cost Reduction: Completely eliminated manual stacking, saving the factory over $50,000 USD annually in labor costs.

• Zero Downtime for Packaging: The perfectly aligned stacks from the robotic palletizer fed directly into the automatic strapping machine, reducing packaging downtime by 90%.

• Environmental Compliance: The enclosed design and improved combustion system met the strict local environmental standards for secondary aluminum smelting.

“Upgrading to this automated line was the best investment we made in 2018. It not only solved our labor shortage but also future-proofed our plant against strict environmental regulations.” — Plant Manager, Jiangsu Facility.

Why This Matters for Global Manufacturers

• For Southeast Asian Markets: This 2018 case proves that our equipment delivers a rapid ROI. By replacing manual labor and reducing material waste, the investment can typically be recovered within 12 to 18 months.

• For European Markets: The fact that this system has been running continuously for over 5 years is a testament to its durability and precision. It shows that our PLC controls and robotic integrations can withstand the heavy-duty demands of European recycling operations.

Upgrade Your Plant with a Proven Partner

Whether you are planning a new greenfield project or upgrading an existing recycling plant, our engineering team can design a customized layout based on your capacity and local regulations.

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