Hindalco Industries Ltd, Mouda

Introduction

Hindalco Industries Limited, a flagship company of the Aditya Birla Group, is one of the world’s leading aluminium manufacturers. Renowned for its commitment to quality and technological advancements, Hindalco operates state-of-the-art manufacturing facilities. Among these is the Mouda plant, which specializes in producing ultra-thin aluminium foils, catering to both domestic and international markets.

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Problem Statement

At the Hindalco Mouda plant, aluminium foils with thicknesses as low as 6 microns are produced using precision foil mills. The quality of these foils is heavily reliant on the accuracy and surface finish of the rolls used in the mills. Maintaining such standards necessitates a Roll Grinding Machine with exceptional accuracy, stability, and performance.

The plant faced a challenge with an aging Naxos Union conventional Roll Grinder, transferred from a European facility. The machine's outdated technology, reduced reliability, and limited functionality hindered productivity and affected roll quality. Hindalco sought a comprehensive solution to modernize the machine and restore its optimal performance.

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Solution Approach

Hindalco partnered with Maxis, an industry leader in machine retrofitting and modernization, to upgrade the Naxos Union Roll Grinder. Maxis delivered a complete, end-to-end modernization solution that included:

1. Advanced CNC System Integration

Implementation of a Siemens Sinumerik 840Dsl CNC system equipped with cutting-edge functionalities such as:

• Short Stroking: Enhancing grinding precision by optimizing stroke movements.
• Constant Current Grinding: Ensuring consistent material removal and surface finish.

Integration of Sinamics S120 Drives and high-performance servo motors (1FT7/1FK7/1PH8 series) for precise motion control.

2. Electrical System Overhaul

• Complete replacement of electrical cabinets with modern enclosures.
• Installation of new electrical accessories, power distribution systems, and advanced control cables.
• Implementation of modern field elements, including sensors, limit switches, and safety mechanisms for enhanced reliability and operational safety.

3. Mechanical Reconditioning

• Reconditioning of the machine base, ensuring proper leveling and structural integrity by placing it on a newly constructed foundation.
• Machine Alignment and Bed Scraping: Achieving micron-level precision for critical components.
• Spindle Assembly Replacement: Installation of a new grinding spindle and bushes to restore accuracy and stability.
• Integration of new transmission mechanisms, including ball screws, transmission pulleys, and other key mechanical components.

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Conclusion

Following the successful completion of the modernization project in 2018, the upgraded Roll Grinder has been delivering exceptional results. The machine now consistently produces ground rolls with the precision necessary for rolling export-quality aluminium foils. Hindalco has benefited from improved operational efficiency, reduced downtime, and enhanced product quality.
Maxis continues to provide ongoing support, ensuring the machine's sustained performance through regular maintenance and technical assistance. This collaboration exemplifies how technological innovation and expert engineering can rejuvenate legacy equipment, extending its operational lifespan and contributing to business success.
Hindalco’s dedication to quality and innovation remains evident in its choice of reliable partners like Maxis, solidifying its position as a global leader in the aluminium manufacturing industry.