Aluminium Rolling Mills & Turnkey Solutions
WORLD-CLASS ALUMINIUM ROLLING MILLS FOR FOIL, SHEET & STRIP
Precision Engineering | Automated Control | End-to-End Turnkey Solutions
About Engineering Services International FZE - LLC
Engineering Services International FZE - LLC is a leading global provider of turnkey aluminium rolling mill solutions. Our expertise spans hot rolling, cold rolling, and foil rolling systems, each engineered with advanced automation, energy efficiency, and high throughput in mind. By seamlessly integrating components procured from renowned international suppliers (Germany, Japan, USA, etc.) and leveraging our in-house engineering capabilities, we deliver complete, custom-tailored solutions that consistently exceed performance benchmarks.
Our Turnkey Aluminium Rolling Mill Solutions
Purpose & Capabilities
- Primary Breakdown of thick aluminium slabs (up to 600 mm) into thinner intermediate gauges.
- Achieves high-volume throughput crucial for large-scale production.
Technical Features:
- Reheating Furnaces rated up to 650°C for optimum slab temperature.
- Hydraulic Screwdowns providing real-time load control and precise thickness adjustments.
- Rolling speeds up to 2000 m/min for maximum productivity.
- Roll Gap Lubrication Systems to reduce friction and improve surface finish
Typical Output:
Intermediate gauges from ~20 mm down to ~3 mm, ready for cold rolling or direct finishing.
Purpose & Capabilities
- High-precision thickness reduction, improving surface finish and mechanical properties.
- Ideal for automotive-grade sheets, architectural applications, etc.
Technical Features:
- 4-High / 6-High Mill Configurations for superior flatness control (work & backup rolls).
- Automatic Gauge Control (AGC) with ±0.01 mm thickness accuracy.
- Integrated Automatic Flatness Control (AFC) adjusts roll bending/shape in real-time.
- Strip Width capacity up to 2200 mm.
Typical Output:
Thickness range from 0.2 mm to 6 mm with consistent mechanical properties.
Purpose & Capabilities
Production of ultra-thin aluminium foils down to 0.006 mm for packaging, insulation, and industrial uses.
Technical Features:
- Multi-Stand Tandem Mills for continuous high-speed rolling.
- Vacuum Roll Cooling to prevent foil wrinkling and maintain gloss.
- Oil Mist Lubrication system to reduce contamination and enhance brightness.
- Special tension control mechanism for stable winding.
Typical Output:
Foils used in pharmaceutical packaging, food wraps, household products, etc.
Purpose & Capabilities
- Primary Breakdown of thick aluminium slabs (up to 600 mm) into thinner intermediate gauges.
- Achieves high-volume throughput crucial for large-scale production.
Technical Features:
- Reheating Furnaces rated up to 650°C for optimum slab temperature.
- Hydraulic Screwdowns providing real-time load control and precise thickness adjustments.
- Rolling speeds up to 2000 m/min for maximum productivity.
- Roll Gap Lubrication Systems to reduce friction and improve surface finish
Typical Output:
Intermediate gauges from ~20 mm down to ~3 mm, ready for cold rolling or direct finishing.
Purpose & Capabilities
- High-precision thickness reduction, improving surface finish and mechanical properties.
- Ideal for automotive-grade sheets, architectural applications, etc.
Technical Features:
- 4-High / 6-High Mill Configurations for superior flatness control (work & backup rolls).
- Automatic Gauge Control (AGC) with ±0.01 mm thickness accuracy.
- Integrated Automatic Flatness Control (AFC) adjusts roll bending/shape in real-time.
- Strip Width capacity up to 2200 mm.
Typical Output:
Thickness range from 0.2 mm to 6 mm with consistent mechanical properties.
Purpose & Capabilities
Production of ultra-thin aluminium foils down to 0.006 mm for packaging, insulation, and industrial uses.
Technical Features:
- Multi-Stand Tandem Mills for continuous high-speed rolling.
- Vacuum Roll Cooling to prevent foil wrinkling and maintain gloss.
- Oil Mist Lubrication system to reduce contamination and enhance brightness.
- Special tension control mechanism for stable winding.
Typical Output:
Foils used in pharmaceutical packaging, food wraps, household products, etc.
From Raw Ingot to Finished Coil: The Production Journey
Alloy Selection & Casting
-Homogenization in specialized furnaces to eliminate segregation
Hot Rolling Stage
-Multiple roughing and finishing passes to reduce thickness
Pickling / Degreasing
Cold Rolling Stage
-Intermediate annealing if needed to restore ductility
Foil Rolling (If Applicable)
-Real-time tension monitoring to avoid breaks.
Final Annealing & Finishing
-Slitting & Packaging into coils or sheets
Key Machinery & Control Systems
Rolling Stands
High-Strength Forged Steel frames
Load capacity exceeding 40 MN
Precision bearing assemblies for minimal runout
Coil Handling Systems
Decoilers & Recoilers with torque capacities up to 500 kNm
Automatic coil car for fast coil exchange & minimal downtime
Annealing Furnaces
Continuous (roller hearth) and batch (bell-type) designs
Temperature uniformity ±5°C with multi-zone control
Atmosphere control (nitrogen/hydrogen) to prevent oxidation
Lubrication & Emulsion Systems
High-pressure spray bars for uniform coolant distribution
Real-time viscosity & temperature control
Automation & Control
PLC/SCADA Integration (Siemens or Mitsubishi)
HMI Touch Panels for user-friendly operation
IoT Connectivity for remote monitoring & predictive maintenance
Maximizing Yield & Minimizing Operational Costs
| Parameter | Specification |
|---|---|
Rolling Speed |
Up to 2500 m/min |
Thickness Accuracy (AGC) |
±0.01 mm across full width |
Width Capacity |
Up to 2200 mm |
Energy Savings |
15–25% via regenerative drives & heat recovery |
Surface Roughness (Ra) |
As low as 0.2 µm (for foil applications) |
Yield Rate |
Up to 98% with optimized rolling schedules |
ROI Highlights
- Lower Scrap Rates: Reduced thickness deviations
- Higher Throughput: Fast rolling speeds, fewer passes
- Predictive Maintenance: Minimizes downtime & emergency repairs
Proven Success & Client Satisfaction
Project Overview
Required a high-capacity foil rolling line (0.006 mm thickness), tight timeline
Engineering Services Intl Solution
- 6-High Foil Rolling Mill with AFC & oil mist lubrication
- Automated control (PLC + SCADA) for continuous tracking
- Custom vacuum roll cooling for foil flatness
Results
- 1,500 tons/month foil production
- Energy consumption reduced by 18% vs. standard benchmarks
- ±0.01 mm thickness accuracy, minimizing scrap
Client Testimonial
Sustaining Productivity & Operational Excellence
Spare Parts Inventory
-Partnerships with OEMs for expedited deliverie
24/7 Technical Support
-On-site interventions within 24–48 hours globally
Training & Capacity Building
-Focus on rolling schedules, optimization, and safety
Upgrades & Retrofits
-Mill stand refurbishments for increased load capacity
