SMS group delivers high-efficiency HybrEx® extrusion line with fully electrical shear to Hydro Gainesville

• HybrEx^® extrusion technology offers efficient production, increased safety, and long-term reliability with lower hydraulic oil consumption
• SMS group’s patented fully electrical scrap shear creates an oil-free hot zone, enhancing safety and reducing environmental impact
• Hybrid drive technology means significantly less energy consumption and shorter dead cycle times

Hydro Extrusion North America, a producer of high-quality aluminum extrusions, has placed an order with SMS group and OMAV, a brand of SMS group and specialist in the field of aluminum extrusion systems, for a complete eight-inch, 25-meganewton extrusion line to be installed at the company’s Gainesville, Georgia, facility.

The new HybrEx^® line, engineered to Hydro’s high operational standards, features the innovative HybrEx^® press and the patented electric scrap shear, which are designed to significantly enhance production efficiency, operational safety, and sustainability in the production of extruded profiles.

SMS is replacing an existing press line in Gainesville with a next-generation HybrEx line, which comes with a high-efficiency gas furnace. Standout features of the HybrEx^® press include a significant reduction in hydraulic system oil usage, as traditional oil tanks and high-temperature cylinders around the hot billet container are no longer required. With the HybrEx^® press, a reduction in the oil volume is achieved by combining the use of hydraulics to generate the press force and the electrification of the travel paths, which ensure safe operation and consistent performance without any temperature-related fluctuations. This intelligent combination of hydraulic and oil quantity reductions means that over 30 percent less energy is consumed compared to conventional extrusion presses.

To deliver high precision and reliability in cutting processes, which are crucial for efficient production, SMS is supplying its patented electrical scrap shear. The fully electrical shear eliminates the need for hydraulic systems, creating an oil-free hot zone, which enhances operational safety and reduces environmental impact. This system incorporates a self-adjusting, moving scrap shear, which automatically adapts to the height of the material, ensuring optimal, clean cuts. Furthermore, electric shear technology addresses the wear challenges commonly associated with conventional systems, enhancing longevity and performance.

A special focus of the close collaboration with Hydro on the new extrusion line was placed on safety, aimed at protecting and securing both personnel and machinery. This emphasis on safety reflects Hydro’s commitment to creating a safe working environment and minimizing the risk of accidents.

“This project underscores our longstanding partnership with Hydro,” said Massimo Marinelli, CEO of OMAV, “By combining SMS group’s technological leadership with OMAV’s automation expertise, we have delivered a future-proof solution that meets Hydro’s high standards in efficiency, safety, and sustainability.” 

Ralph Westphal, Vice President and General Manager of Hydro Extrusion North America’s South and East regions, adds “At Hydro, we are committed to modernizing our operations with equipment that improves our safety, efficiency, and capacity. This investment in Gainesville represents a significant step in our modernization strategy and we are excited to implement these cutting-edge technologies.”

Hydro’s Gainesville plant in Georgia has 350 employees and provides extrusion, fabrication, and finishing services to the building and construction industry and other key markets in North America.