Production Cycle

In our plant we perform the secondary smelting of copper alloys for the production of ingots. We purchase our raw materials principally from the EU, including: scrap metal, powder, chips, sheets, tubes, valves, fittings, plumbing, sanitary and artistic items, handles and hinges, and all processing waste. All incoming raw materials are subjected to an initial radiometric inspection, performed in two steps:

Outdoors, each container used for shipping is tested for its irradiation before being unloaded.

When unloaded, or prior to processing, a visual inspection is performed in order to identify any shielded sources.

Before raw materials are placed in the furnace, they undergo important pre-treatments:

TUMBLING: this is the percussion of metal materials that are not very consistent in size. This treatment reduces the mass of the individual pieces.

VIBRATING SCREENING: this process sorts the scrap metal using a mobile screen that separates the tiny pieces from the larger ones.

DE-IRONING: this process consists of placing the material inside very large, powerful magnets that remove the iron, which significantly increases the yield of the ingots.

WET MULLING: this process washes and reduces the size of the foundry slag, removing the impurities.

DRYING: in this process the washed materials are dried using a pan mill to obtain the oven-ready granulate.

Thanks to these treatments, our company can purchase a wide range of raw materials, promoting the RECYCLING of metals for environmental reasons.
All of the pre-smelting treatments allow us to guarantee our customers excellent quality. The ingot yield is improved, as is its processability. Furthermore it results in less mould fouling, saving time and money.

Smelting

Production includes the analysis of the smelting furnace molten material. Sampling is performed using a ladle to remove a sample of molten metal from the furnace and filling a small cylindrical iron mould. When the metal solidifies, it can be analysed in the laboratory using an X-ray spectrometer.

This sampling is performed in a number of phases:

Half-way through the smelting, when all the metal in the crucible is melted and a half-hour before the molten material is poured into the ingot mould.

Before pouring the molten material into the ingot mould, to correct any last minute imperfections.

Before completely emptying the furnace, to verify that the metal quality is constant.

Melt samples are identified with the date and batch number, type of alloy, and a filled-in card is placed on the package of ingots for guarantee. All melt samples and their quality certificates are kept in the company for 1 year.

After the melting, a third radiometric test is performed on all samples and a fourth test is performed on our slag and the chimney smoke.