In March 2025, E-MAX in Dilsen-Stokkem, Belgium, a specialist in the production of aluminium extrusion profiles, commissioned a new automatic die cleaning installation from PCA Water. With this investment, E-MAX is placing a strong focus on safety, process optimisation and automation.
During the extrusion process, aluminium residues remain in the dies. To allow the dies to be reused, they must be chemically cleaned at regular intervals. This is done using a heated NaOH (caustic soda) solution, which dissolves the remaining aluminium.
Fully automatic cleaning and rinsing in a single process tank
The installation consists of two fully automated process tanks, in which both the chemical cleaning and the rinsing of the dies take place. The process is remarkably simple for the operator: they place a basket of contaminated dies in an empty process tank and start the cleaning cycle. From then on, everything runs automatically. The tank is closed and filled with preheated NaOH, which is continuously circulated over the dies by a circulation pump. This intensive circulation ensures efficient and faster cleaning.
After the chemical treatment, the NaOH is automatically pumped out and the dies are rinsed in the same tank. Once the cycle is complete, the lid opens automatically and the operator can remove the basket of cleaned dies from the empty tank.
Maximum safety for the operator
One of the key objectives of the project was to improve safety on the shop floor. With traditional cleaning installations, operators often have to move dies between different baths, bringing them close to hot, aggressive chemicals and the fumes they give off.
PCA Water's concept makes these tasks a thing of the past. At no point does the operator come into direct contact with the chemicals. The entire cleaning and rinsing cycle takes place in a closed process tank fitted with automatic fume extraction and a gas scrubber.
This not only creates a safer working environment, but also reduces physical strain and the amount of manual labour required.
Efficient use of chemicals and rinse water
Alongside safety and automation, particular attention was paid to the efficient use of water and chemicals.
The installation is equipped with several buffer tanks for storing and reusing NaOH and rinse water. The cleaning solution can be used several times, and the rinse water is also reused wherever possible.
By reusing the rinse water in several stages and using contaminated rinse water to dilute concentrated NaOH, both fresh water consumption and wastewater production are kept to a minimum. With this installation, E-MAX now has a safe and efficient solution that fully automates the cleaning of extrusion dies while making optimal use of water and chemicals.
From dirty to clean dies, with no manual intervention at any point during the cleaning process.
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