Kaye Aluminium - part of the Exlabesa Group

Our Doncaster Factory
Our Doncaster site consists of several key areas that are integral to the way we do business. Read on to find out more about the way we work and what benefits each stage in our production brings to our finished products.

The Vertical Paint Plant
	As the vast majority of extrusion suppliers have abandoned in-house painting, Kaye Aluminium sees this investment as an opportunity to establish a niche for itself. The vertical paint plant reflects the way in which we hope to be able to provide our customers with the most modern and leading edge technologies that will uniquely identify our products from others on the market. The vertical paint plant allows us to do just this with better throughput, better quality and finish to the profiles.

Sections are loaded onto the paint line prior to entering our specialist pre-treatment centre which cleanses the aluminium of any impurities that may be on the surface of the metal. A specialist chromate wash is applied to the profiles to assist with the adhesion of the powder coating.

The treated aluminium profiles are then sprayed with a powder coating that is electro-statically bonded to the aluminium providing a smooth and flawless finish.

Once oven cured, the finished painted sections are removed from the paint line ready for packing.

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The Presses

The presses produce the aluminium extrusions from its raw material log form.

Log cut into billets are forced under extreme pressure through dies that shape the metal to produce the required length and shape of the new profile or section.

	A pulling machine collects and carries the profiles along the 50m length table allowing a moving hot saw then to electronically calculate the length of the profiles needed to be cut. A puller is then used to dispatch the metal onto a transfer belt for cooling. After sufficient cooling, sections are stretched and cut to match the requirements of the customer.
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The Scrap Processing Bay
By many industry standards, the aluminium extrusion world accepts quite a high wastage figure of around 30 %. At Kaye Aluminium, we find this unacceptable and work hard to bring this down to around 20 % and lower. Unused or scrap metal is collected and either bundled together or compacted into blocks, ready for dispatch to our smelting centre. This enables us to recycle as much product as possible and take care about our environment.
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	Ageing Ovens

	Aluminium profiles are arranged in trays as they leave the presses in preparation to be artifically heat aged. This is done to harden the metal and is performed at different temperatures for different time spans depending upon the alloys used.