ALUMINIUM NEWS THE VOICE OF THE UK ALUMINIUM INDUSTRY ISSUE 2 SEPTEMBER 2019

WELCOME ADDITIVE GUIDANCE THE EUROPEAN ALFED TO OUR MANUFACTURING ON EU EXIT ALUMINIUM HEALTH, SAFETY NEW MEMBERS RECYCLING & ENVIRONMENT Developments From the INDUSTRY COMMITTEE Coventry University in Net Additive Department for ISC Wales Manufacturing and Business, Energy Aluminum recycling - Sharing best 3M Advanced Alloys and Industrial a vital part of Europe’s practice and Ash & Lacy Finishes Strategy (BEIS) wider aluminium experiences value chain 10 15 18 23 31 KEEPING THE UK AT THE FOREFRONT OF TESTING TECHNOLOGY NEW MATERIALS TESTING HUB FOR THE BLACK COUNTRY

Rubery Owen is delighted to announce that it is developing a state-of-the art testing facility called The Rubery Owen Testing and Research Centre, in the heart of the Black Country, for three of its businesses in the materials testing sectors, Phoenix Materials Testing, Rotech Laboratories and Merlin Powder Characterisation. Whilst maintaining their existing premises, they will enjoy the collaboration of expertise and innovation at a new combined testing facility and laboratory. The Rubery Owen Testing and Research Centre will combine the latest in high temperature, humidity and pressure testing capabilities along with current fatigue and thermomechanical fatigue (TMF) testing. It will also house the Merlin Powder Characterisation test facility, in which the physical properties and compressibility of powders are determined by use of an hydraulic compaction simulator. This unique, cutting-edge facility will help to keep the UK at the forefront of testing technology.

PLEASE JOIN US FOR THE OPEN DAY AND ENJOY A FULL GUIDED TOUR

WEDNESDAY 13TH NOVEMBER 2019

The Rubery Owen Testing and Research Centre 7am – 10am: welcome breakfast D1, The Wallows Industrial Estate 11am – 2pm: working style lunch Fens Pool Avenue 4pm – 6pm: afternoon canapés Brierley Hill If you have any food allergies, please let us know. West Midlands DY5 1QA RSVP [email protected] Please state your preferred arrival time

Find out more about Rubery Owen, Phoenix, Rotech and Merlin by visiting:

www.ruberyowen.com l www.phoenix-mt.co.uk l www.rotechlabs.co.uk l www.merlin-pc.com If it ain’t broke, don’t fix it… It can often seem simpler to keep a product exactly as it is, especially when it receives a consistently positive response from the industry. But because leading precision cutting tool manufacturer KYOCERA SGS recognise the value of constantly upgrading products, they have recently launched the latest versions of their Advance Productivity Rougher (APR) cutting tool, the APR 3 (three- flute) and the APR 4 (four-flute).

For KYOCERA SGS, this is not simply about creating a new product to enhance their portfolio but offering a fresh way to address current and emerging machining The new tools also challenges. resolve issues such as vibration, with Designed for maximum removal rates a three- or four- on aluminium structures, the original flute variable pitch APR tool was first developed to support geometry for reducing a customer project and helped to vibration and load at a metal removal revolutionise metal removal rates. Its rate of between 10 and 12 litres. design has now been updated to make However, the aim for the APR 3 and 4 it even easier for the APR 3 and APR 4 wasn’t only to enhance performance to address specific machining challenges. but to extend the life of the tools So, how do you improve on what is themselves, thanks to a Tinamite-B already recognised as an exceptional coating which provides up to double product? The updated APR tools are the length of the original tool. As with likely to prove great news for companies the first APR, the new versions are under increasing pressure to streamline suitable to run with MQL and coolant, and simplify their processes, thanks to a so no additional work is required on significant reduction in cycle times and them. For manufacturing processes other key advantages. The APR 3 is the where wear and noise are a concern, the next evolution of the original product APR 4 provides an incredibly low level of while the APR 4 provides ultimate sound with less resonance and less wear. metal removal rates on maximum power machines but will also suit other With industry challenges constantly applications. Available at the same price, evolving, it is imperative that cutting both products offer an even wider choice tools keep up. KYOCERA SGS’s goal for of tooling for manufacturers. Ray Gibbs, the latest versions of their APR tool is Aerospace Technologies Manager for not simply to expand their own products’ KYOCERA SGS, explains more: capabilities but their clients’ capabilities too. This approach involves constantly “We looked both at current machining listening to customers, watching the challenges and at issues likely to emerge market closely and identifying new in the future. Then we identified the ways to make high quality products different ways in which the design of the even better. Because creating effective APR 3 and 4 could resolve the concerns cutting tools isn’t a one-off action. that all companies have about reducing It’s an ongoing process. cycle times and costs and increasing performance. By doing this, we were able Kyocera SGS specialises in bespoke to design efficiency into every aspect of and modified tooling and the European an already highly effective part.” Headquarters are in Wokingham, Berkshire, UK. This meant addressing significant multiple machining problems all in one: supporting suppliers under pressure to provide time savings year-on-year, thanks to a significant improvement in metal removal rates on aluminium parts. MORE ABOUT OUR APR APF PRODUCTS ››

For more information on their product range, visit: www.kyocera-sgstool.eu T: +44 (0) 1189 795 200 CONTENTS

IN THIS ISSUE

Quarterly message from the CEO 3 Training Education Aluminium technical The Aluminium Federation Meet the ALFED team 4 training & lectures 11 desert wheel challenge 20 Aluminium technical training 12 How to find us 4 Essential leadership Sustainability & recycling skills programme 13 Earth overshoot day 2019 21 Meet the board members 5 Sustainability 22 Additive manufacturing Recycling 22 From the President 8 Additive manufacturing The European Aluminium networking day 15 Recycling Industry 23 Member spotlight EMR Metal Recycling 8 Working with government Energy G-TEX 8 House of Lords lunch 16 Streamlined energy BEIS master class 17 & carbon reporting 24 Membership BEIS guidance on EU exit 18 Benefits of becoming Exporting is great 19 Aluminium processing an ALFED member 9 ‘Thru-process’ temperature Market report monitoring 26 Welcome to our new members Global primary Coventry University 10 aluminum production 20 Innovation ISC Wales 10 Fronius fourth open house 27 3M 10 Ash & Lacy Finishes 10 Technology Hot form quench sets aluminium lightweighting standard 29 Dissimilar laser welding of aluminium and copper alloys 30

DATES FOR YOUR DIARY Health, safety & environment Health & safety services 30 ALFED Health, Safety & Environment Committee 31 NOVEMBER orkshop LinkedIn One Day W 12 SEPTEMBER ing Event Member news Closed Loop Recycl One Day Basic 5 13 Aluminium extrusions, oup Supervisors Course Extrusion Gr 9 The Effective Team Leader a change of emphasis 32 ALFED Annual Dinner 14 12 Prestigious Gold Medal marks Aluminium for Engineers Working with Your Team 26 - 27 17 oup the distinguished career of HSE Support Gr 26 DECEMBER Prof. Geoff Scamans 33 The Effective Team Leader 6 TWI and ALFED unite to OCTOBER APPG Breakfast Briefing 11 promote aluminium for industry 33 orking withW Your Team oup 3 oup HSE Support Gr Finishing Gr 12 10 APPG Breakfast Briefing Career zone 16 World of Aluminium The importance of productivity 35 24 Advanced Engineering Find out more 30 - 31 ion 2019 Exhibit about our events Partner news and training Your questions answered 36 opportunities: www.alfed.org.uk

All rights reserved. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording or any information storage or retrieval system without the express prior written consent of the Publisher. Aluminium News Magazine is published by the Aluminium Federation Every effort has been made to ensure the accuracy and reliability of material published in this magazine. The Aluminium Federation and its agents do not accept any responsibility for the views or claims made by contributors in the advertising or editorial content.

Front cover image courtesy of Primetals Technologies Ltd © Aluminium Federation 2019

2 www.alfed.org.uk QUARTERLY MESSAGE FROM THE CEO

QUARTERLY UPDATE members of the Aluminium Federation run their businesses and to get a real On the 1st June we moved into our new insight to all the challenges industry offices; a bright and modern new space faces and will face after Brexit. We had that will allow ALFED to grow, develop the pleasure to accompany the Deputy and focus on delivering value to our Director of BEIS and two senior policy members and partners. The move went advisors on a 2-day trip around the UK like a well-oiled machine, teamwork was visiting our members, who represent a the order of the day, packing and moving broad cross section of the UK aluminium boxes and equipment. In any move you industry. The article is on page 17 of this take the opportunity to discard many magazine issue. years of unwanted items that have been hoarded, saved for posterity or hoping I had the pleasure of meeting it has some use or value 20 years later. Chi Onwurah, Labour MP and Shadow Deciding what to discard was a challenge, Minister for Industrial Strategy, Science suffice to say we sent to a recycling centre & Innovation to discuss the impact of Welcome to the second as much as we moved to our new offices Brexit on the UK industry over the last three years, the ramifications of a no-deal issue of leaving us with uncluttered offices and Aluminium News, clear minds. Brexit and the cost to industry because I hope you enjoyed the first of political divisions We are proud to welcome four new issue and found it interesting companies to our membership since LOOKING FORWARD and informative. I would like the last issue of the Aluminium News: to thank our Board of Directors 3M UK, Ash & Lacy Finishes, ISC Wales ALFED and the Aluminium Stockholders Association (ASA) join forces in January for having the belief and and Coventry University, who with their vast knowledge and experience of the 2020 when members of the ASA become supporting the investment aluminium industry add value to our members of the Aluminium Federation. to launch Aluminium News. federation and its members. ALFED have This will make us stronger together, our I would like to thank many signed a Memorandum of Understanding strategic value sets us apart from other (MoU) with the SMMT adding strategic trade associations and our influence organisations for their valuable on government policy and the industry contribution; member companies, value to all parties and the industry. We are planning joint events early in come to the forefront of developing the who advertised, and our partners, 2020 with the SMMT. UK aluminium industry. who supported our journey. As the UK moves closer to the Our association with the University Not least I thank the ALFED staff, 31st October 2019 and our new of Wolverhampton Business School without their determination and Prime Minister is preparing the UK for continues to develop adding an a NO Deal Brexit, we see the pound outstanding training program offering motivation to get this project off a diverse range of opportunities the ground it would have not drop to a new low against the Euro and US Dollar. How does industry prepare in training, upskilling and personal been possible. for a No Deal exit from the EU? There is development. This will offer support to so much uncertainty, contradiction and our members, partners and the industry ambiguity around every element of Brexit. in general and add to their competitive Members of Parliament have consistently advantage through education. failed to agree on a deal to leave, the We will continue to develop as an delay and inability of parliament to agree organisation adding to our strategic to any deal over the last three years has partnership program as the year goes damaged manufacturing, employment on. We are busy planning and organising and investment in the UK. events, supporting members and of ALFED continues to work with government course working with government as across all appropriate departments to Brexit becomes a reality. ensure we are at the forefront of policy development, influence change that benefits members and the UK aluminium industry and supporting government with Tom Jones industrial strategy. One such example CEO was to help BEIS officials understand how Aluminium Federation

2 3 www.alfed.org.uk www.alfed.org.uk MEET THE ALFED TEAM

CEO EVENTS ADMINISTRATOR ADVERTISING OPPORTUNITIES Tom Jones Linda Ford IN THE ALUMINIUM NEWS [email protected] [email protected] MAGAZINE: TRAINING & EDITOR OF The Aluminium Federation EDUCATION MANAGER ALUMINIUM NEWS represents businesses who process, trade and work with aluminium; Kathy Romback Kirsi Lintula we foster innovation, promote [email protected] [email protected] best practice, develop skills and champion member interests. TECHNICAL MANAGER TECHNICAL CONSULTANT This ranges from training and Jan Lukaszewski David Harris networking to research, advocacy, [email protected] lobbying and outreach, we help our members solve problems, capitalise ACCOUNTANT on opportunities and boost their ADMINISTRATION MANAGER Karen Williams competitiveness. Our Aluminium Margaret Lane News magazine will cover all these [email protected] CONTACT US AT topics and more, keeping you Suite 9 abreast of the latest news, views ADMINISTRATOR Alcora Building and reviews in the fast-moving Caroline Jones Mucklow Hill aluminium industry. Halesowen [email protected] Our new, dynamic quarterly West Midlands B62 8DG magazine offers you a great Tel: +44 (0)330 236 2800 COMMUNICATIONS advertising opportunity to promote www.alfed.org.uk EXECUTIVE your products and services to key decision makers and influencers Melissa Beasley within the aluminium industry in the [email protected] UK. The Aluminium News magazine will be available in hard copy and electronic version from our website HOW TO FIND US plus social media platforms. All members will receive a hard copy and electronic version. We will also distribute copies at our events, meetings and industry exhibitions.

Schedule: Issue 3 – to be published 5 December 2019 Issue 4 – to be published 27 March 2020 Issue 5 – to be published 29 May 2020 Issue 6 – to be published 23 September 2020

For further information Please contact Kirsi Lintula, Editor: email: [email protected] mobile: 07768 566 437

4 www.alfed.org.uk MEET THE BOARD

MEET THE BOARD MEMBERS WHO HELP TO SHAPE THE ALUMINIUM INDUSTRY AGENDA AND RELEVANT POLICY AT THE HIGHEST LEVELS

GILES ASHMEAD SIMON BARRON joining the head office team. Clive is Giles is a Director Simon has over 40 currently working on Amari’s ‘industry 4.0 of Powdertech, one years experience in initiatives and supporting the company’s of the UK’s leading the non-ferrous metals acquisitions objectives. Working across all Architectural Powder industry, fulfilling Amari Metals brands, he is also helping Coaters, specialising various senior roles to develop business strategy and new in supplying standard in aluminium and product development. and unique finishes stainless steel As well as sitting on the Marketing onto products and substrates that other oriented companies. & Technical Committee of the British coaters cannot process. Powdertech He considers his current global role as Stainless Steel Association (BSSA), look to differentiate products, lead their Special Advisor - Aluminium, to be the Clive joined the ALFED board in 2016, industry and were founder members of most interesting and challenging to-date. so giving distributors a voice at the table. the Aluminium Finishing Association, so Reporting to Amari’s board of directors Clive is honoured to be ALFED’s President they could influence the direction and based in the US, he provides guidance in 2020. development of the aluminium finishing and support to the various operational Amari Metals is one of the largest industry. Having been with Powdertech client companies located principally in UK, aluminium stockists in the country and for a decade Giles started to represent Europe, USA, Australia and New Zealand. are therefore keen to influence the Powdertech at the Finishing meetings in Simon was on the BSSA Council (2005- development of aluminium within the 2000, becoming Chairman, and therefore 2016), serving as Chairman between UK – an aim that they share with ALFED. an ALFED board member, in 2009. 2012-2014, and presently sits as a Council Amari recognised that the Federation Being on the ALFED Board has member of the Aluminium Stockholders provided great services that members can meant that, not only can Giles lead Association (ASA). take advantage of, not least independent developments in metal finishing by being Simon understands that ALFED represents technical advice, market insight and close to new technologies and improved companies involved in the entire aluminium training as well as the opportunity to standards, but he can also understand supply chain from liquid metal through meet with other industry professionals. the entire aluminium supply chain and to line-side delivery of components to With Brexit looming, Clive and Amari have input into the many initiatives that manufacturers. He believes it is uniquely Metals feel that ALFED will give the ALFED lead both inside the industry and placed to encourage and support growth industry a seat at any discussion that in the wider world. In the past decade in the use of aluminium in the UK. could affect their – and other ALFED the aluminium industry has seen many The depth and breadth of ALFED’s members’ – business. changes, and ALFED had to change with membership adds credibility to it being it; a strategy change that Giles was very the voice of the industry, representing and COLIN DAVIES involved in. As a result of this involvement, lobbying members’ interests within central Giles was asked to take up the role of Colin has 35 years government and civil service departments, President in 2017; a role that he will experience in the and providing access for its members to continue with until the end of this year. aluminium industry knowledgeable experts. and is currently For Amari Metals and other ALFED Commercial Director - RUSSELL BARR members, this access is proving invaluable Aerospace and Defense Russell is the Executive as it navigates through the fallout of - at Arconic Global Vice President & Brexit, EU retaliatory import duties, Rolled Products and Managing Director Rules of Origin queries and so on. Extrusions. Europe for REAL ALFED provides Simon and his colleagues Colin joined the Kitts Green Rolling Mill ALLOY who are the with the opportunity to network with (then under the ownership of Alcan) as largest independent other complimentary (and sometimes Product Manager for Aerospace and Aluminium Recycler in competing) companies and their HT Plate and progressed via various Europe. Before joining executives involved in the supply chain. Marketing and Sales Management roles REAL ALLOY’s leadership team in 2015, (under British Aluminium, Alcoa and now Russell served as Vice President at Aleris Arconic). He has been Sales/Commercial Recycling Europe for two years. Between CLIVE BUSH Director for past 20 years, looking after 2010 and 2012, he was Vice President Clive’s route to the division’s aerospace and defence of Aleris Extrusions and also spent two becoming Amari sales in Europe, Middle East and years as their European Director of non- Metals’ Business South America. metal purchasing. Prior to this, he was Development Director Managing Director and joint owner of the took an interesting I was proud to stand as ALFED President automotive supplier Triplex Components direction, starting with in 2010/2011 and have been on the and held various positions at De La Rue HM Customs & Excise ALFED Board ever since during which and the BMW/Rover Group. He has a as an enforcement the association has undergone significant BA honors degree in business studies officer, via a stint at General Foods as strategic reviews and changes, further from Oxford Brookes University and an a ‘Space Dust’ then ‘MAXPAX coffee increasing its effectiveness in supporting engineering management diploma from machine’ salesman before entering the its members across the UK aluminium the University of Warwick (WMG). metals industry. He Joined Aalco in 1984 supply chain. and progressed to be General Manager “It’s been a huge honour to be ALFED of Aalco in Romford and Swanley before President and to sit on the ALFED

4 5 www.alfed.org.uk www.alfed.org.uk MEET THE BOARD

Board for over a decade as one can get The company is diverse in its activities a solid sales platform Latchford is now engaged to help manage and influence that are all associated around metal in a central position within the group the significant issues and factors that will recycling. At the Congleton site the supplying high recycle content shape our industry in the future”. company manufactures Aluminium Alloys, aluminium ingots for the automotive Arconic is a global leader in lightweight Master Alloys and De-oxidants. It also and can markets. metals engineering and manufacturing, processes large volumes of aluminium At the end of 2017 Steve moved into employing over 40 thousand people packaging material including UBC. Apart a Global Account management role across more than 25 countries. One from the furnaces the other processing primarily for the UK automotive markets of Arconic’s largest and fastest equipment on site include a full shredding for Novelis Europe. line, dross plant and balers. Additionally, growing market is aerospace, where His aim within the ALFED Board is to help the company handles and sorts a large they have had a major presence since grow and develop the aluminium sector range of Nickel and Stainless steel alloys. the Wright brothers’ first flight. Besides by promoting training, the advantages The new site in Brownhills handles and aerospace, Arconic’s products support of the material properties, particularly its process all the range of non-ferrous the further development of key sustainability, and create opportunities for scarps including aluminium, copper and automotive, commercial transportation, strong sector communications. industrial and building & construction the yellow metals. Over 110 people are markets worldwide. employed by the two companies and they deal with customers and suppliers RICK HINDLEY Within the UK, Arconic employs around all across the globe. Rick took up the 2800 people at 16 manufacturing locations mantle of Executive producing aluminium rolled plate, He started work as a drawing clerk in Director at Aluminium fastening systems, building & construction an engineering office before moving to Packaging Recycling products and investment castings. a laboratory where thet analysed sand, this then led into the laboratory for an Organisation (Alupro) The Arconic Kitts Green aluminium Rolling aluminium company and his connection in 2007, following roles Mill near Birmingham supplies aerospace to recycling. at Alcan/Novelis and products to leading global aerospace Valpak. The past 30 years of Rick’s career He has held following positions during manufacturers, as well as high technology have been dedicated to highlighting his career: Works Chemist, Production products to the defence, tooling and the importance of aluminium packaging Manager, Purchasing Director, Commercial industrial markets worldwide. recycling – there are few as enthusiastic Director and Managing Director. or as knowledgeable on the subject. Mike believes that it is important to be HENRY DICKINSON Rick has been a Board Member of ALFED part of the Aluminium story in the UK and Henry is a Past President since 2007 and a member of the UK ALFED gives them that platform from of the Aluminium Government’s Advisory Committee on which they can hopefully shape its future. Federation 2008-2009. Packaging (ACP) since 2014. He has been associated with ALFED for He is also a Past There are clear synergies between the a number of years, first serving on the Chairman of the organisational aims of Alupro and ALFED Analytical Committee of ALARS in Aluminium Alloy maintaining a close working relationship the early 1980’s. He was the Chairman Manufacturing & allows both organisations to thrive. of ALARS and then AMARA in its Recycling Association 2003-2004. Henry Most recently they worked together on founding year. is the owner and Managing Director of the ‘Alu D & T Challenge’, a competition Norton Aluminium, an aluminium recycler which tasked young students aged and foundry alloy producer. He also STEVE HEDAR 11-14 to create sustainable products owns Hytec Castings and Norse Precision Having graduated in out of aluminium; the challenge received Castings, manufacturers of aluminium Engineering Steve over 1600 entries from 200 schools, over sand castings, and Kiveton Park Steel, initially started his the course of four competitions between a bright bar producer. career with British Steel. 2012 and 2017. Henry has been a strong supporter Then following a “At a time when drastic changes in of trade associations and interaction Post graduate in Government policy mean that the between industry and academia. He is Manufacturing and landscape of packaging recycling for the actively involved not only in Operations management he worked future is uncertain, I’m sure many within ALFED activities, but also the Non-Ferrous in various industry sectors including the industry share my frustration that Alliance, UK Steel, The Liquid Metal construction, electronics and railway the disproportionate attention received Engineering (LiME) umbrella research vehicle manufacture before spending by plastic packaging is overshadowing project, IOM3, and various KTN Innovate eight years working for Alcan/Novelis in the ongoing success stories within our funded research projects. the aluminium packaging divisions at the sector, for example the consistently Bridgnorth plant where he held several rising recycling rate of aluminium drink MIKE DINES positions, finally as Site Manager. cans, which currently stands at 75% Mike has been involved More recently, he was the Supply Chain (2018 figures). We hope that working over 40 years in and Operations Director for Tullis Russell collaboratively through partnerships such aluminium recycling Coaters UK/South Korea, an employee as our membership of ALFED, will enable and he is currently a owned company and manufacturing us to take back a share of the narrative on director at Tandom specialist of paper products for the packaging and help us to shine a spotlight Metallurgical Group securities markets. on the sustainability of aluminium.” Ltd. The company was Having worked for Novelis previously, established in 2008 and gone from strength Steve returned in 2013 as Plant Manager STUART IRVINE to strength over the years. Now operating for the Latchford and Crick facilities. out of two sites with its sister company Following a period of recycling Tandom Metallurgical (Midlands) Ltd. investment and the development of

6 www.alfed.org.uk MEET THE BOARD

TOM JONES SPENCER MELIA of key matters, for example the revision Tom was appointed I joined Aluminium of BS EN12206-1:2004 superseding to The Aluminium Shapes Ltd in the well-known BS 6496 1984. Also, the Federation as chief September 2017 as authorisation for the continued use of executive officer and the Sales Director after hexavalent chrome beyond the sunset joined the board in previously working in date of Sept 2017 whilst considering the January 2018. He sits as the industry for over alternative non-chrome technologies a director on the board 25 years and now I am available in the market. ALFED of the UK Metals Council and co-chairs proud to say I am also member of the membership offers excellent opportunities the government thematic business panel ALFED team after becoming the Extrusion to network, build relationships, an insight for aluminium. Between 2007 and 2017, Group Chairman back in January 2019. into the market, sharing of knowledge and they all have a contribution. he was the Managing Director of Aluminium Shapes are a privately owner Mitsubishi Materials Group UK and the extruder of aluminium profiles based in General Manager of Mitsubishi Hard Corby in Northamptonshire. They operate DR REMI ZANTE Facing Alloys UK division and headed from a 70,000 Square foot facility and have With a background up Mitsubishi’s UK Aerospace strategic two six-inch presses that offer a range of in Product Design growth partnership. He holds a BA (Hons) bespoke extrusions from 0.03 kilos per Engineering, Remi 1st Class from the Loughborough metre up to 4.00 kilos per metre. On site worked for several Centre for Leadership & Management, they also have a full range of fabrication years in the automotive Nottingham Trent University. machinery which they use to offer mitre sector with design cutting, standard cutting, punching and responsibility for a SIMON MACVICKER CNC machining up to 6500mm lengths. range of commercial vehicle axles at Simon joined the In a market that has many tiers to the a global T1 supplier. Following a PhD aluminium industry supply chain they pride themselves in in mechatronics he joined the AFRC prior in 1997, at Bridgnorth, being the local extruder that offers to its formal launch in 2009 where he led at the time owned a fantastic speedy service aligned with the development and delivery of a wide by Alusuisse. Elval good quality at an affordable price. variety of industrially focused research acquired the company Their flexible approach means that they projects related to metal forming. As part in 2001, and Simon has can take on one off projects for as little of the AFRC since its earliest days, he has served as Managing Director since 2004. as 50 kilos and major contracts in the seen the centre grow to 140 people and is now Head of Strategic Planning. Bridgnorth Aluminium is the UK’s only hundreds of tonnes. He is leading the process of ensuring rolling mill supplying coils, operates Recently Aluminium Shapes have been the AFRCs technical developments a casthouse, hot and cold rolling acquired by the Anglo European Group. target industrial sector challenges and finishing facilities all on one site in They are a steel section roller based in and are focused on delivering impact Bridgnorth, employing around the Greater Manchester area who supply into the UKs manufacturing industry. 400 people. The company serves into the fenestration industry. Dr Zante has also chaired the High the graphic arts (litho), packaging, The acquisition will allow the group to Value Manufacturing Catapult’s (HVMC) automotive, electrical and distribution be the only company to be offer both Metals forum and has been instrumental sectors. Bridgnorth Aluminium is a steel sections and bespoke aluminium in mapping the UKs metals manufacturing joint venture company, 75% owned by extrusions from source, rather than capability for key industry sectors. Viohalco, and 25% by UACJ Corporation. through distributors and they see this ALFED board membership allows the Membership of trade associations has as a massive advantage going forward. AFRC to connect directly with the always been important for the company leading companies in UK aluminium and its Group, because it allows GARY MOTHERSOLE manufacturing and provides added opportunities to network with other Gary works for BASF reach in supporting manufacturing industry players, understand best practice Chemetall Ltd as innovation in the UK. and industry trends, and to have a better Aluminium Finishing voice when talking with legislators. The Sales Manager for company under previous ownership was BECOME AN ALFED UK & Ireland. a founder member of ALFED in 1962 BOARD MEMBER and has remained in membership ever BASF Chemetall Ltd since. Simon has served on the ALFED are the global market ALFED board members have board since late 2007, and from 2014-15 leader in the manufacture and supply of a unique opportunity to shape as President. He also represented the surface treatment chemicals for a range of the industry agenda and industry as Chair of UK Metals Council business segments including aerospace, relevant policy at the highest levels. from 2016 to 2018. aluminium finishing, automotive, can, coil, Contact Tom Jones, CEO, general industry and metal forming. He at [email protected] Simon is a non-executive director of joined BASF Chemetall Ltd in 2007 having to learn more about serving Cenergy Holdings SA, and Shropshire previously working for a local competitor. Chamber of Commerce. on our board. He is Chairman of the ALFED Finishers Prior to his career in aluminium, Simon Group and have been in the role since Contact us to discuss how ALFED held various commercial positions at 2016. The Finishers Group members are membership can help your business British Steel for 10 years. He holds an a good mix of applicators, pre-treatment www.alfed.org.uk MBA from Warwick Business School suppliers and powder paint suppliers. and a bachelor’s degree in modern Being passionate about the Aluminium languages from the University of Leeds. Finishing business he was delighted to be asked to become Chairman and represent ALFED members in a variety

6 7 www.alfed.org.uk www.alfed.org.uk THE PRESIDENT

FROM THE PRESIDENT Giles Ashmead, ALFED President and Director of Powdertech

Since becoming President in May and also issues with sanctions on Rusal, more suitable 2017, I have overseen a period which could have had a major impact on offices. the supply chain if not resolved. As a These changes of unprecedented change to the Federation we have probably had more have all been Aluminium Federation. As this meetings and contact with Government made with a focus was approximately twelve months officials in the last two years than in on engaging with the preceding decade, and we have a wider range of after the UK had voted to leave represented our industry and our other industry Europe, we were just starting members robustly in getting our points bodies and to understand what the process and priorities across to people who have developing the influence. I have found this opportunity variety and level involved and how it could affect very rewarding as I feel I have been able of services, so we can offer more value to our industry. to make a difference. our members. During my Presidency we have also Being President has not been without its witnessed major change internally within challenges, particularly during the period the Federation. Soon after I became when we didn’t have a CEO, but I took on Once the Brexit process reached the trade President our long-standing CEO left, the role to stretch my comfort zone, widen negotiation stage, we suddenly gained to be replaced by Tom Jones. We have my experience and challenge myself, and huge attention from the Department of welcomed Kathy Romback, Melissa whilst I have had the honour of carrying Business, Energy and Industrial Strategy, Beasley and Linda Ford to the team, whilst out the role, it has certainly done that. who wanted to understand our industry, a couple have left. We have introduced My Presidency will come to an end how we deal with Europe and how new Management Training courses, taken later this year when Clive Bush from tariffs would affect our business. Thrown over the running of the schools challenge, Amari Metals will take over this role. into this mix was Section 232 and the gained many new members from all areas threat of tariffs from the US, which of the industry and beyond and most developed in a US trade war with China recently have relocated ourselves to much

MEMBER SPOTLIGHT EMR METAL RECYCLING G-TEX With a UK network of over 65 sites across the UK, EMR G-Tex supply an exclusive range of decorative Metal Recycling is the recycling partner you can count on. aluminium finishes. Developed from a single UK site in the 1950s, EMR is a world Our Chemetal range is a massive collection of over 200 metal leading metal recycler with over 170 facilities globally. and laminate designs. We make many of them by deeply EMR can recycle everything from a toaster to an aircraft carrier. brushing, aging and adding patinas by hand and machine. They handle around 10 million tonnes of metal and plastic Our designs are unique works of art, created with a manufacturing every year from a variety of sources - from end of life consumer consistency to ensure repeatability. We also source some of the products to large industrial projects, saving over 10 million best metal designs the world over. tonnes of CO2 compared to using virgin materials. It adds up to what we consider the most expansive collection of From a one-off clearance project to a waste disposal contract metal designs for interiors that you’ll find anywhere. We back it handling several thousand tonnes, EMR specialises in delivering up with exceptional sales and customer service that cares about more value from customers’ waste streams, paying great prices for metal of all grades, shapes and sizes – cars to cables, getting it right. aluminium to zinc. Chemetal is a great and relatively easy way for design professionals No job is too big or too small. With a range of services to meet to use metal in their interior design projects. We have one of the customers’ needs including; total waste management solutions, world’s largest collections of metal designs and laminates. They authorised treatment facilities to process end of life vehicles, are sold in standard laminate sheet sizes. state of the art plastic recycling facilities, specialist plants for Our decorative materials are specified and installed in the recycling of refrigeration products, tailored environmental commercial interior projects in hospitality, retail, corporate, consultancy services and the provision of business training and signage, furniture, restaurant, stadium and arena environments. vocational qualifications, EMR can handle it. Chemetal is ideal for vertical and light duty horizontal use. EMR creates social value by supporting local communities and www.g-tex.com creating sustainable employment opportunities. They encourage sustainable thinking in children by working with local schools to deliver a free programme about the importance of metal recycling. For more information, or to find your nearest site, visit emrgroup.com.

8 www.alfed.org.uk MEMBERSHIP

BENEFIT FROM A RANGE OF SERVICES THAT HELP YOU DEVELOP YOUR BUSINESS, WORKFORCE AND SUPPLY CHAIN

As the voice of the Opportunity: “As an ALFED member, you get your We give you a unique opportunity to voice heard. We’re a small metal finishing UK aluminium industry, get your voice heard - within the industry company, but I get my voice heard very loudly. I’m currently the ALFED president, and in government. Whether you’re our mission is to expand and this gives me influence at a high level a global company or an SME, you can within government – I’m routinely on the market for aluminium advocate and influence to improve market calls with ministers and civil servants. And conditions for your products and services. products by helping I had my voice heard even before I was companies solve problems, president. In 2004, the British standard MEMBER BENEFITS: changed to an EU-wide one that was lobby government and much weaker. I campaigned to change it, boost their competitiveness. From technical support to lobbying, and as an ALFED member, I had a say via we support members working across the Finishing Group. I got my opinions all aspects of production and supply. over, and the standard is now changing. Whether it’s providing technical support, Here are some of the many you get as It was a real success for our business.” delivering market insight, informing part of your membership: Giles Ashmead, Director, Powdertech trade policy or offering networking “There are lots of great opportunities as opportunities – everything we do focuses • Advocacy & lobbying an ALFED member. I read all the market on helping UK aluminium businesses • Market insight reports as they come in and use the stats capitalise on opportunities. • Training in my management reports – the directors As a member, you become part of an • Technical support find them very useful. The events are great influential community, getting your voice • Consultancy from energy because I talk to people that aren’t just heard within the industry and at the management support to bespoke in extrusion like us. It’s good to go along, highest levels of government. Working training, coaching and e-learning have a chat and see how the market is together, we’re actively driving UK progressing for everyone else. I go to aluminium forward – and we look forward • Events the Extrusion Group meetings, and my to working with you in this endeavour. • Influence & Policymaking colleagues go to others like Automotive • Shared Learnings & Networking and Innovation. That way the whole Collaboration: business benefits.” • Savings & Partnerships Steve Nash, Sales We bring together recycling and Director, Hydro Aluminium Profiles secondary producers, extruders, finishers and stockholders – helping WHY JOIN THE Contact us to discuss how ALFED everyone involved in UK aluminium ALUMINIUM FEDERATION membership can help your business make connections for mutually beneficial business and supply development. Whatever your company size or speciality Membership levels are based on within the industry, we help you access business size, so it’s both affordable Innovation: the technical expertise, market insight, and valuable. T: 0330 236 2800 You benefit from a range of services that business support and government www.alfed.org.uk influence you need to boost your help you stay at the cutting edge. From competitiveness. research and development through to industry benchmarking and technical We offer different levels of membership support, you get insight that assists based on your business size – so it’s both you to develop your business. affordable and valuable.

8 9 www.alfed.org.uk www.alfed.org.uk WELCOME TO OUR NEW MEMBERS

COVENTRY UNIVERSITY ISC WALES

The school of mechanical, automotive and aerospace ISC Ltd is a world-renowned company specialising in the design, engineering at Coventry University fundamentally integrate development and manufacture of innovative engineered both the technical and sustainability aspects of lightweight components and other ‘Solutions in Metal’. materials and manufacturing into both their research and ISC supply products globally to the ‘Working at Height’ industry teaching, much of their work being related to transport which includes arborists, fire & rescue, rope access, and other and associated structures. Forefront within that field is the industrial fall protection users, as well as the motor racing, understanding, use and integration of aluminium alloys into military and other specialist markets such structures. With the future of many transport structures moving towards the use of mixed materials, the design and manufacture of said structures must take into account www.iscwales.com the many nuances of integrating sophisticated lightweight materials into functional engineering components and systems. At the foreground of this field is the appropriate use and understanding of aluminium and its alloys. It is anticipated that Coventry University’s membership of ALFED will aid proliferation of the use & understanding of such materials in to teaching, research and product development at the University and associated commercial partners. www.coventry.ac.uk

3M ASH & LACY FINISHES

Productivity on the line. Safety in the workplace. Technology For over 140 years, the Ash & Lacy Group has been to stay ahead. For over 100 years, 3M has designed solutions manufacturing an exciting range of products and systems specifically for the metalworking industry. Their industrial for the construction, automotive, acoustic and audio markets, abrasives are built to withstand the toughest substrates, exporting around the world and currently with an annual group finish metals to precise fine finishes and get you through turnover above £50 million. Always committed to innovation all the stages in between. 3M personal safety equipment and high engineering standards, Ash & Lacy’s in-house, helps ensure that your people are protected whether state-of-the-art Polyester Powder Coating line adds welding, cutting, grinding or crossing the factory floor. considerably to the range of finishes available on fabrications, And armed with a variety of industrial adhesives and tapes, facades and other products and simplifies the production chain. your team can be prepared for whatever challenge comes their way. Their industrial adhesive tapes are built to withstand the toughest conditions, protect critical areas and still remove www.ashandlacy.com/construction cleanly. Whether you are powder coating parts or bundling rebar 3M have a solution. They’ve engineered their masking solutions to withstand intense and difficult conditions associated with electroplating and anodizing processes. And 3M has developed market leading products such as 3M™ Scotch-Weld™ and 3M™ VHB™ which helps engineers and designers to remove the need for welds and mechanical fixings. www.3m.co.uk/3M/en_GB/company-uk/

10 www.alfed.org.uk TRAINING

ALUMINIUM FEDERATION TECHNICAL TRAINING COURSES AND LECTURES

Sadly, the reality is that the basics World of Aluminium: Aluminium is rapidly of aluminium are not taught in A broad-based introduction to all becoming societies apprenticeships, colleges or universities, aspects of aluminium most likely to metal of choice with its nor indeed is its engineering potential, be encountered in manufacturing. basic metallurgy or even its unique Aimed at people who need to ease of application, processability such as “extrudability”. understand the basics, such as lightweight, strength, To fill this knowledge gap the Aluminium production supervisors, managers, Federation with universities, specialist production engineers, salespeople, corrosion resistance manufacturers and experts in the industry purchasing and process technicians. and not least infinite has developed and offers a full range of technical support and training courses Aluminium for Engineers: recyclability. Dominating in aluminium, from simple introductions An intensive two-day course that creates metal innovation in to the equivalent of the second year of the foundation and builds up knowledge a metals technology degree. from a basic introduction to metals automotive, architecture to the wide application of aluminium. Each course is specifically tailored to Aimed at metallurgists, designers, and aerospace sectors, the needs of the audience, the level manufacturing engineers and of students’ knowledge, their industry substituting for steel and companies transitioning into aluminium. plastics, and awakening sector and processes. In-house courses for both members and non-members are Aluminium Casting Metallurgy: the packaging industry to specifically written to agreed syllabuses A one-day course providing an its possibilities. From the and courses can supplemented by introduction into aluminium for specialists and experts, e.g. welding or casting technicians, designers, turn of the century primary “Additive Manufacturing” from within and casting companies. the whole industry. aluminium production has ALFED offers over eighty technical tripled to 60 million tons Specific courses can be written for teaching modules, ranging from universities and educational bodies as 10 to 60 minutes duration, covering with recycling predicted an integral part of their own teaching virtually all the topics encountered to reach 26 million tons. programmes. with aluminium, such as; forging, Given the heavy demand ALFED offers heat treatment, casting, corrosion, throughout the year scheduled courses, joining, pressing, machining and which although having a central theme are coating. All aspects of health and still tailored to the students’ requirements. safety are also covered in the lectures.

10 11 www.alfed.org.uk www.alfed.org.uk TRAINING

Aluminium Technical Training Courses:

WORLD OF ALUMINIUM Thursday 24 October 2019 One day workshop gives an introductory and practical understanding of aluminium production, processing, application and markets.

ALUMINIUM FOR ENGINEERS Tuesday 26 & Wednesday 27 November 2019 This intensive two-day technical workshop focuses on developing a practical understanding of aluminium production, processing and engineering applications. The syllabus covers metallurgy, specification, heat treatment, wrought processing, joining, testing, corrosion, coating and more. All participants get a complimentary copy of the Aluminium Federation’s book The Properties of Aluminium and its Alloys.

Please contact us on 0330 236 2800 to discuss your specific course requirements.

12 www.alfed.org.uk TRAINING

ALFED ESSENTIAL LEADERSHIP SKILLS PROGRAMME

Our courses are practical and engaging THE EFFECTIVE TEAM LEADER The development of the for all levels: ‘How to become a competent leader’ future leaders is essential • Proven and popular programmes An effective team leader has a variety of for business planning focused on learning that can be traits and characteristics that encourage immediately applied in the workplace and the associated team members to follow him. Team • Cost effective leaders naturally possess certain qualities, supply chain. • Accredited by the CPD Certification such as compassion and integrity, or learn It is important to our Service, the UK independent leadership skills through formal training continuing professional and experience. members and to the development scheme This course is designed to provide wider industry - we all In addition, industry takes the health the foundation on which a successful management career can be built. seek to nurture talent and safety of the workforce seriously. We have a range of courses available to the Who it’s for: and foster a culture of industry, designed for all levels and any Those who’ve only been managing continuous improvement. size of company. for a short time, are very new to Our Leadership and Management Courses management or who may be taking cover two levels: on a management position in future. FRONTLINE: for those new to It’s also ideal for managers who want management or who have been managing a broader perspective on identifying for a short time, or who may be taking on and overcoming business challenges. a management position in the future. Course duration: 2 days MIDDLE LEVEL: for those managing Thursday 14 November departments or teams and who take Friday 6 December responsibility for delivering business 9.15am – 4.30pm objectives through other people. Also useful for managers who want to learn Cost: Members £560+vat per person more about leading & managing and Non-Members £695+vat per person getting the best from their people. Venue: The Earls Suite, Halesowen B62 8DG

12 13 www.alfed.org.uk www.alfed.org.uk TRAINING

WORKING WITH YOUR TEAM ONE DAY BASIC Course duration: ‘Using emotional intelligence’’ SUPERVISORS COURSE Wednesday 13 November 9.30 - 3.30pm Research shows successful teams are This one-day course is designed made up of a diverse mix of behaviours. to provide a foundation on which Cost: Thanks to the advances in understanding a successful supervisory career £220+ vat per person human behaviour and neuroscience, we can be built. Venue: know what it takes for people to perform The Earls Suite, at their best and for strong, resilient Who it’s for: Halesowen B62 8DG teams to form. Anyone new to supervising or already supervising in the workplace and Please note: Includes course notes, lunch Who it’s for: would like some further training. and refreshments Whether you are the office junior, chief executive or anything in between, this What will I learn? workshop is for you. Knowing yourself, We begin with understanding the basics your team, your manager and your of the supervisor’s role in the workplace organisation are keys to personal and and lead on through to diversity in the business success. What were once 21st century workplace. FOR FURTHER INFORMATION labelled soft skills are now modern requirements in today’s workplace, You will leave the course not only with OR TO BOOK A PLACE: knowledge of their role but also with especially if you are new to or are Please contact already leading a team. worksheets and templates to help you function well in the role. Kathy Romback Course duration: 2 days Tuesday 17 September • Basics of Supervision Training & Education Manager Tuesday 3 October • What makes a Good Supervisor? on 9.15am - 4.30pm • Required Skills 0121 281 2281 Cost: • Communication or email Members £560+vat per person • How to Monitor [email protected] Non-Members £695+vat per person Employee Performance or visit Venue: • Basics of Management www.alfed.org.uk The Earls Suite, Halesowen B62 8DG

MANAGING TO LEADING

The course also covered developing skills. Gary Cook presented our Managing to Leading workshop in May and June. We had a range of experience within the group and all contributed to our lively discussions. They examined the purpose of business and what their particular business is looking to achieve and deliver. Recognising the changed role, purpose and requirements when transitioning from operator/worker through to manager/supervisor. The course also covered developing, knowledge and behaviours that will enable immediate improvements to the individual and organisational management performance. Finally, they created an action plan to deliver changes to their management approach, style and influence.

It got me thinking about things differently and have since tried to implement certain aspects already (mainly delegation). One of the main things I took away from the course wasn’t actually to do with the content. It was good being in a room full of people at different levels with different experience, some directors, some new to management, but all speaking openly and honestly about the day to day struggles that are presented within the workplace, it was reassuring.

Paul Plunkett (Aluminium Shapes)

14 www.alfed.org.uk ADDITIVE MANUFACTURING

ADDITIVE MANUFACTURING NETWORKING DAY

Additive Manufacturing more correctly Stuart Jackson, Renishaw plc, introduced We are continuing our known as “3D-Printing” were layers of Multi-Laser Metal Additive Manufacturing – program of introducing a powder, 20 to 100 µm thickness are “The road to economic AM Production”. spread onto a substrate plate and then Renishaw have developed and released disruptive technologies a 2D slice melted together, typically using to market amid-size multi laser metal AM to our members; we a high-power laser, is now commercially machine, a first move towards bringing hosted on Tuesday well-established. State-of-the-art systems affordable AM product to market. can use two or more lasers with different Delivering increased production rate gains 2nd July in conjunction with power and depending on the metal achieved by applying multiple lasers into Wolverhampton University or substance being deposited an inert a bed area previously processed with one gas atmosphere. laser and the effects on cost-per-part with a networking day focused Aluminium with its high thermal the focus on aluminium alloys. on “Developments in conductivity, low melting point and Valerion Carollo, The Welding Institute, Net Additive Manufacturing high affinity for reacting with oxygen provided an overview on the numerical to form alumina, a ceramic, has always modelling strategies for the simulation of and Advanced Alloys”. being regarded as a difficult subject additive manufacturing processes, based for “3D-Printing”, but developments in on applications of aluminium additively powder metallurgy, alternative additive manufactured parts and included: models processes and laser sintering are truly for the prediction of residual stresses and transformational! distortions, microstructure and mechanical Paul Unwin of “Additive Manufacturing properties, and design optimisation. UK” and the Industrial Chair of the Garth Stevenson, Electro Optical Systems “Additive Manufacturing Strategy Ltd, presented Aluminium – Additive Steering Group” outlined how additive Manufacturing at scale considering manufacturing is impacting design, size, volume and cost, comparing with manufacturing, infrastructure and conventional casting, outlining serious business models. How this fully digitally consideration for AM to be part of a enabled process is revolutionising conventional supply chain. businesses by providing a radically Richard Kellett, DMG MORI, have new method of production that developed an innovate additive enables new, functionally superior manufacturing portfolio including directed designs to be realised at lower cost energy deposition as a hybrid solution with enhanced function, productivity within 5 axis mill turn platforms, and highly and greater sustainability. flexible powder bed SLM systems. Dr. Russell Goodall, of the University of Paul Conquest, Fronius UK, presented Sheffield introduced High Entropy Alloys. Fronius Cold Meta Transfer single The use of powder metallurgy allows wire & twin wire process for additive the creation alloys that use metals with manufacturing. vastly different melting temperatures John Robinson, Senior Engineering and gravities. Potentially such alloys Technician, University of Wolverhampton, based on lightweight aluminium can presented the ALM activity at the create innovative materials specifically for University and introduced the research additive manufacture. Materials that will being done involving aluminium. enable new performance levels, in terms of high temperature, electrical conduction An intensive full day with balanced magnetic properties and both high presentations covering the entire range Strength and Youngs modulus. of Additive Manufacturing Technologies. Stuart Godfrey, Materion AMC, for the last 25 years Materion have been producing aluminium silicon carbide reinforced metal matrix composites (MMCs) via a unique powder metallurgy process from its Farnborough facility. These MMC materials are used in a range of industries including performance automotive, commercial automotive, space and defence, niche engineering and consumer electronics. The presentation outlined the production, mechanical properties and application of these materials, particularly their high strength and stiffness.

14 15 www.alfed.org.uk www.alfed.org.uk WORKING WITH GOVERNMENT

The Minister spoke about the strategic Our House of Lords lunch importance of the UK aluminium industry in June was attended by and the work within government to support it. He also spoke about Brexit, ALFED Members, MPs, the opportunities and the support for Lords and Ladies, who the aluminium industry after the UK exit European Union. Our President Giles support the UK aluminium Ashmead spoke on the impact of MPs industry. Our key speaker not agreeing on a deal for Brexit and from government was the impact on our industry over the last three years since the Brexit referendum. Andrew Stephenson MP Our last speaker Murat Bayram from Lord Paul (right) receives Murat Bayram and Bruce Miller and Minister at the European Metal Recycling (EMR) gave from EMR to the House of Lords a very entertaining and informative speech Department for on sustainability and recycling Business, Energy all without any notes. and Industrial The Aluminium Federation All Party Strategy (BEIS). Parliamentary Group (APPG) strengthens its membership by welcoming Lord Horam as a new member. Lord Horam brings with him a wealth of knowledge and experience from industry and the political world making a valuable contribution on the strategy and growth

of our APPG. We invite Members of Keynote speakers: Andrew Stephenson - Minister, Parliament and Members of the House Giles Ashmead - ALFED President and Murat of Lords to join our APPG, all are Bayram - European Managing Director at EMR welcome to join and participate.

Mr Mark Stuckey VP at Arconic USA & Mrs Jan Stuckey with ALFED board member Colin Davies - Commercial Director at Arconic UK

Dr Gerd Gotz - Director General of European Lord Brookman Aluminium

ALFED members discussing Minister Andrew Stephenson delivers key industrial issues on the his speech supporting the aluminium terrace at Westminster industry and its key strategic role

Andrew Stephenson MP, ALFED members, industry leaders, Lords, Minister at BEIS and Ladies, government ministers and politicians Tom Jones CEO of ALFED influencing the UK industrial strategy

16 www.alfed.org.uk WORKING WITH GOVERNMENT

DEPARTMENT FOR BUSINESS, ENERGY & INDUSTRIAL STRATEGY (BEIS) - MASTER CLASS IN ALUMINIUM

The visitors were hosted by Tom Jones, The education continued well into ALFED organised two CEO, Melissa Beasley, Communications the first evening with business days of intensive visits Executive, and Jan Lukaszewski, Technical discussions over dinner hosted by to members’ plants on Manager of ALFED. The visit was a Simon MacVicker and Graham Flukes clear indication of how strongly BEIS is of Bridgnorth Aluminium. Wednesday 3rd and committed to the UK aluminium industry. The second day commenced with a tour Thursday July 4th - a The first “Master Class” introduced of Bridgnorth Aluminium to appreciate the the visitors to Arconic at Kitts Green, intricate metallurgy and technology that “Master Class” in the near Birmingham, to see the melting, underpins the production of the ultimate production of aluminium casting and hot rolling of slab and the high quality and surface finish, cold and the UK aluminium processing and extensive testing of rolled litho plate and sheet. The speed aerospace materials. As an eye opener, of production of the highly automated manufacturing industry the visit demonstrated how seriously the processes captivated the party! with BEIS officials Ryan aluminium industry is committed to health In total contrast was the “tier” 1 press and safety with the party being issued with McLaughlin, Deputy working, fabrication and assembly “Personal Protective Equipment”. operations of Salop Design and Director Rules of Origin In contrast the second visit to Vertik-Al Engineering. The multistage progression and Tariffs and customs, introduced demonstrations of pre- presses and the accompanying machine treatment and impressive vertical line beat held the visitors open eyed! Salop Briony Thompson and powder coating of aluminium. This Design & Engineering, demonstrated the Robyn Street, Senior demonstrated how the vivid colour aluminium industry commitment to the powder coats are applied, the public next generation as they run “In-Comm Policy Advisors. face of all our large cities and the training academy”. The academy provides aesthetic face of aluminium that apprenticeships with bespoke equipment most general public see. creating the chances to learn on industry Our third plant visit was to Hydro standard equipment, and seamlessly fit Cheltenham to see extrusion and into industry positions. anodising. The group were introduced The last “Master Class” visit to the to the production of extrusion processes. European Metal Recycling (EMR) The ability to be freely extruded into in Willenhall was perhaps the most an almost unimaginable multiplicity of important. The EMR demonstrated shapes sets aluminium apart from any how the valuable end of life, scrap other metals. BEIS were captivated at and demolition metal resources are the sight of long length complex sorted and turned into raw material extrusions being extruded. for infinitely recycling.

16 17 www.alfed.org.uk www.alfed.org.uk WORKING WITH GOVERNMENT

GUIDANCE ON EU EXIT FROM THE DEPARTMENT FOR BUSINESS, ENERGY AND INDUSTRIAL STRATEGY (BEIS)

The UK will be leaving the The best way to find information for your Your Employees: business is to go to GOV.UK, where you If the UK leaves the EU without a deal, EU on 31 October 2019. can find everything that you need EU / EEA and Swiss citizens who were There are a number of to prepare: resident in the UK prior to exit must www.gov.uk/business-uk-leaving-eu. apply to the EU Settlement Scheme steps that the Government Here you will find information about a to get settled or pre-settled status is advising businesses to number of areas in which your business by 31 December 2020. take, in the event that we may be affected by EU Exit, including: If you require any assistance to navigate Importing and Exporting: this advice, or to identify the correct are not able to reach a deal person to speak to about a query, the If you are an importer or exporter to Infrastructure and Materials EU Exit with the EU, and instead the EU you should get a UK Economic and Trade Team in BEIS would be leave without a deal in place. Operator Registration and Identification happy to help. You can contact them via: (EORI) number and decide if you want to [email protected]. hire an import-agent or make customs declarations yourself. Chemicals Use (REACH): If you currently purchase a chemical substance directly from an EU / EEA supplier, you must make sure any substances you purchase are covered by a valid UK REACH registration by someone within the supply chain.

18 www.alfed.org.uk WORKING WITH GOVERNMENT

EXPORTING IS GREAT

The campaign, led by the Department for the Exporting is GREAT campaign – 1,300 The Government’s most International Trade (DIT), aligns with the businesses have signed up to advocate ambitious export-focused Government’s Export Strategy which sets on our behalf, but to create an exporting an ambition to grow the UK’s overseas movement across the UK we need your marketing campaign ever – sales as a share of GDP from 30% to 35% help to grow our this community by aims to build a nationwide by: thousands more. These businesses have • encouraging and inspiring businesses featured in thousands of pieces of print, movement of UK companies that can export but don’t or are just digital and social media coverage as selling their products and beginning, we’ve told their stories far and wide. Many • informing businesses; helping them have also joined the private Exporting is services overseas. access the right information, advice GREAT Facebook group and provide and and practical assistance, encouragement advice to novice exporters; • connecting businesses to overseas turning our campaign to a community and buyers, markets and each other, and the community to a national movement. • ensuring no viable export fails for lack of finance or insurance from the What’s in it for ALFED members? private sector. • Become part of Exporting is GREAT, the Government’s most ambitious The Exporting is GREAT campaign and high-profile export focused supports this by focusing its objectives on campaign ever increasing the number of companies that believe they can export, know where to • Be considered for the campaign’s go for export support, take action towards creative and related PR, social media exporting and intend to start (or have and advertising activity started) exporting. • Be considered for DIT’s Export Many thanks for ALFED support so far on Champion initiative which involves the award-winning Exporting is GREAT deeper engagement with the campaign. Just last year, as a direct result department of the campaign: • Join a UK-wide community where • Up-to 130,000 businesses took steps companies come to ask questions, towards exporting get advice on overcoming barriers • 1 in 5 campaign recognisers that and find out where to get support can export but never have (turnover • Get access to a suite of digital assets £500k+) developed concrete plans to use in their communications to start exporting and marketing We have achieved this and much more Members can find out more by contacting by putting real businesses at the heart of the ALFED team on 0330 236 2800.

18 19 www.alfed.org.uk www.alfed.org.uk MARKET REPORT

GLOBAL PRIMARY ALUMINUM PRODUCTION

Global primary production in 2009 was the total; in 2009 it was 20%. Asia, not Thanks to the International 37.7 million tonnes and in 2018 it including China, has been growing Aluminium Institute (IAI) was 64.3 million tonnes, indicative of primary production steadily over the last the rapid increase in the range of end- ten years, as has the Gulf States, now we now have the data on uses of aluminium and the increasing responsible for 8% of global production. global primary aluminium market share for aluminium in each The other areas of the world have seen end-use sector. Work by Alcoa several their primary production reducing year- production for the first years ago showed that as the wealth of on-year. It is interesting to note that with half of 2019. How does any population increased, as measured today’s London Metal Exchange (LME) by GDP per head, then the end use of price for primary aluminium of $1800 it compare with previous aluminium in kilos per head of population per tonne, ten years ago the LME primary increased accordingly. This will certainly aluminium price was more-or less the years, where we have come be true for China and India. same, $1800 per tonne. That may well be to expect that each year’s The global tonnage production for some part of the explanation for where production is higher than January to June 2019 was 31.616 million we are today with primary production. tonnes, indicating that perhaps the 2019 The Gulf States, initially in the 1970s the year before? total will show a reduction on the year in Dubai and Bahrain, but now also before, which is a totally new situation. in several other Gulf States, are an By Dr David Harris This would come as no surprise with aluminum success story worthy of global trade reduced by conflicts, largely study on any MBA course. They set up between USA and China, and reduced primary aluminium production more than economies across the world, particularly 50 years ago as an investment to diversify in China, Europe and USA. from their petroleum products industry During this half year China was and to make maximum use of abundant responsible for 56% of primary aluminium energy resources and the availability of production, which is a typical figure deep-water ports. In more recent years in recent years. In 2008 China was they have been adding value to primary responsible for 37% of total production. aluminium with developments in semi- For both western and eastern Europe fabricated products, much of it being combined, those countries in the half used in their own building programs year collectively produced 12 % of and the rest of it exported.

EDUCATION THE ALUMINIUM FEDERATION DESERT WHEEL CHALLENGE The output of this was the Aluminium reading, curriculum links, rules of Early in 2018 ALFED Desert Wheels Challenge 2019 - competition, sponsor branding) commissioned a practical project aimed at 7 to 11year to support the engineering challenge. BLOODHOUND Education olds; designed to contextualise classroom Over 47,670 engaged in our challenge learning and support teachers by linking it either by entering the competition to develop an exciting and to the National Curriculum at Key Stage 2. or downloading our resource and engaging (STEM) challenge Using the 10 years of research and as a classroom project. development of the Bloodhound Project The challenge was launched in September using the BLOODHOUND we were able to share videos, additional 2018 and registration entries closed on Project as a focus information and teaching resources to 31st March 2019. support the competition brief and use The quality of entries was high with highlighting and raising the real-life forthcoming testing location schools submitting a poster and video of South Africa as a backdrop. awareness of aluminium. recording of their findings. A mark scheme We developed a comprehensive was used against the competition criteria competition framework and relevant and feedback given to schools. documentation (teacher pack, student guides, videos & video links, additional

Competition Winners: 1st Place – St Bede’s College, Manchester Prize: A Rocket Car Workshop

20 www.alfed.org.uk SUSTAINABILITY & RECYCLING

EARTH OVERSHOOT DAY (EOD) 2019: HUMANITY HAS ALREADY USED UP THE PLANET’S ALLOWANCE OF NATURAL RESOURCES FOR THE ENTIRE YEAR!

was able to renew all its resources spent by humanity to reach one-planet compatibility According to international humans every year. before 2050”. sustainability organisation The day marks the point when the amount GFP says opportunities to move the day Global Footprint Network of energy and resources humanity is using can be found in five areas: cities, energy, EOD has moved up two exceeds the amount earth can replace in food, population and the planet. that year. It means that in just seven months, For instance, cutting CO2 emissions from months over the past humans have exhausted the amount of burning fossil fuels by 50% would move 20 years. EOD is an water, soil, clean air and other resources that the day by 93 days. the planet can generate in 2019, meaning Other ways humanity could MoveTheDate annual campaign by the from now until December all the energy we involve looking at the ways we design and Global Footprint Network use is unsustainable in the long-term. manage cities and moving from sprawling, (GFP) designed to draw The extra waste we now produce cannot segregated cities to compact, integrated be absorbed and will cause harm, and we ones. attention to Earth’s limited are using too many other natural resources - Local, plant-based diets are favoured over natural resources. like eating fish, plant-based food and meat - industrial animal-based ones since food too quickly. production currently uses more than half The date of Earth Overshoot Day is of our planet’s bio capability. calculated by comparing the amount of Protecting nature through conservation, Falling on July 29 means humanity is ecological resources the earth can generate reforestation and regenerative farming will currently using nature 1.75 times faster that year, by humanity’s demand for that year. also be key in helping sustainability. The than our planet’s ecosystems can regenerate. According to GPD, overshoot is possible GFP also recommends empowering women It means humans currently consume because we are depleting our natural capital. “leads to smaller, healthier and better 1.75 earths every year. The costs are becoming increasingly evident educated families”. Last year EOD fell on August 1 while in the form of deforestation, soil erosion, Source: Evening Standard the year before that it was on August 3. biodiversity loss, or the build-up of carbon It has been calculated that by 1973, when dioxide in the atmosphere. human consumption began outstripping MoveTheDay is a campaign within a what the planet could produce, EOD fell in campaign - that is, an initiative to push early December. Before the 1970s, the earth back EOD by five days each year “allow

20 21 www.alfed.org.uk www.alfed.org.uk SUSTAINABILITY & RECYCLING

SUSTAINABILITY

The Aluminium Federation is actively Importantly, we’re focusing on ways Aluminium is ideally involved with government and industry to do this while delivering improved positioned to help – in the UK and worldwide – to promote performance, so we’re in an even UK industry as it aluminium as a solution to greater energy stronger position to promote aluminium efficiency and reduced waste. as a win-win solution to customers. moves towards more From an innovation perspective, we’re We’re seeing success in areas such as sustainable supply chains. supporting members in taking a complete automotive and aerospace, with trends lifecycle approach to sustainability, towards lightweighting offering increasing Here’s how we’re looking at everything from refining to opportunities to integrate aluminium into creating opportunities production to use to recycling. This design. Food production is another area - includes elements such as responsible not only is aluminium endlessly recyclable, for our members. sourcing and energy management. but it offers a total barrier against light and moisture, which helps reduce carbon footprint while extending shelf life. The examples go on, and we will see aluminium play an increasingly important role in a sustainable economy thanks to its many helpful characteristics. From advocacy and standards development through to innovation and training, the Aluminium Federation will continue to champion the industry in this crucial area. For further information please contact Margaret Lane: [email protected].

RECYCLING

We actively promote opportunities to get members, other industries and Aluminium is an affordable, involved in this important area. Aluminium trade bodies worldwide to maximise highly recyclable material is an affordable, highly recyclable material aluminium’s contribution to innovation that supports a global that supports a global circular economy. and policy. We actively promote opportunities to For example, a recent initiative is our circular economy. get involved in this important area. collaboration with European Aluminium Because aluminium can be recycled regarding the EU Circular Economy endlessly while maintaining its quality, Package, which looks at elements such it’s a key part of global drives towards as recognition of multiple recycling, waste reduction and a circular economy. aluminium packaging targets and metal We work closely with government, recovery from incinerator bottom ashes. We’re tying this into innovation-related activity promoting more efficient recycling processes and the use of recycled aluminium in new applications. This includes advanced engineering and packaging among others, and also involves advising on related standards development. Another crucial part of recycling is education, and through both our training courses and outreach campaigns, we promote developments that move our industry forward. For further information please contact Margaret Lane: [email protected].

22 www.alfed.org.uk SUSTAINABILITY & RECYCLING

THE EUROPEAN ALUMINIUM RECYCLING INDUSTRY

By Magdalena Garczyńska, Recycling Director at European Aluminium

Aluminum recycling is a vital part of The Waste Shipment Regulation conditions” in waste legislation for Europe’s wider aluminium value chain. Review exported waste to countries that do not Aluminium recycling in Europe generated apply the same environment, health and The European Commission is currently around €10.0 billion in revenue in 2018. safety (EHS) standards as we have in reviewing the Waste Shipment Regulation, In Europe, there are more than 220 Europe. which lays down rules for waste recycling plant, many of which are small shipments within the EU and between and medium-sized enterprises (SMEs) The loss of valuable scrap the EU and non-EU countries to improve and family-owned businesses. About to third countries environmental protection. A well- 8.0 million tonnes of scrap is recycled in The success of our industry to drive functioning Waste Shipment Regulation Europe each year, which includes process the circular economy depends on the is crucial to enabling Europe’s circular and run-around scrap. sufficient supply of scrap, the raw material economy and ensuring the efficient use that feeds the aluminium recycling We believe the European recycling of raw materials. industry has the potential to grow process. Since 2002, the EU has been a This year the European Commission significantly. Our Vision 2050 report shows net exporter of aluminium scrap. Around is preparing the Regulation’s Impact that in the coming decades, demand for one million tonnes of scrap depart Europe Assessment that will be followed by the aluminium will remain strong in European for other parts of the world every year. legislative proposal in 2020. The European and worldwide. With supportive policies In 2018, the EU exported around 970,000 Commission should take this opportunity for our sector by 2050, recycled aluminium tonnes of aluminium scrap, an increase of to simplify and better define a number and primary aluminium are expected 7 percent compared to 2017. Around 80 of procedures. to answer almost equal shares of total percent of this is exported to Asia. While European demand, which is forecasted Firstly, the shipment of waste across the Chinese ban on imports of waste to reach around 18 million tonnes. the EU needs to be facilitated and and scrap meant EU exports to China simplified by adding new green listed But our industry understands that decreased by around 6.3 percent last year, codes for waste where needed, for increased growth must go hand in hand since 2019 (data until May) we see a revert example for coated or uncoated windows, with decarbonisation. We have long been dynamic as EU scrap exports to China doors, curtain walls, and other framing a catalyst for sustainability and recycling, increased by 72%. profiles which mainly consist of aluminium working to create a circular economy At the same time, more low-grade scrap and plastic. with infinitely recycled aluminium. With is available for recycling in Europe. impressive aluminium recycling rates Secondly, the volume for testing samples Low-grade scrap is more challenging to of over 90% in transport and building for research should be defined differently sort and recycle than high-grade scrap. and more than 60% in packaging, the in order to allow to ship waste for testing However, refusing low-grade scrap and European aluminium industry is already without lengthy notification preparation exporting it to third countries where making a significant contribution to the procedure. The current limit of a ‘waste’ the scrap might be recycled under European circular economy. To achieve sample is 25kg, which is insufficient for any questionable EHS conditions, is not full circularity, however, we must maximise pilot test in customer plants, according the answer. We hope that traders and the collection of valuable resources from to our members. technology developers of the European the end of life of products so we can Thirdly, to ease the administrative burden recycling value chain see the increased use the resources again to create new on companies and avoid shipment delays, availability of low-grade scrap as a signal products. EU legislation will have a large we also ask the Commission to simplify to up investments in effective sorting role to play, but we also require a greater the complex notification procedure technologies which can maximise understanding of how our metal is being companies must undergo to inform this valuable resource. Sorting should used by downstream customers and relevant authorities of the dispatch, preferably be done by specific product society at large and what role we can transit, and destination of waste. and by alloy family to provide the best play in ensuring that our precious material Finally, the EU should use the ongoing conditions for reuse and recycling and can be recycled again and again for assessment of the Waste Shipment Review to satisfy future demand. further use. to clarify what it means by “equivalent

ABOUT EUROPEAN ALUMINIUM properties that is part of the solution to achieving sustainable goals, European Aluminium, founded in 1981 and based in Brussels, is the while maintaining and improving the image of the industry, of the material voice of the aluminium industry in Europe. We actively engage with and of its applications among their stakeholders. Our 80+ members decision makers and the wider stakeholder community to promote include primary aluminium producers; downstream manufacturers of the outstanding properties of aluminium, secure growth and optimise extruded, rolled and cast aluminium; producers of recycled aluminium the contribution our metal can make to meeting Europe’s sustainability and national aluminium associations are representing more than 600 challenges. Through environmental and technical expertise, economic plants in 30 European countries. Aluminium products are used in a and statistical analysis, scientific research, education and sharing of wide range of markets, including automotive, transport, high-tech best practices, public affairs and communication activities, European engineering, building, construction and packaging. Aluminium promotes the use of aluminium as a material with permanent Follow us on Twitter @EU_Aluminium.

22 23 www.alfed.org.uk www.alfed.org.uk ENERGY

STREAMLINED ENERGY & CARBON REPORTING – An overview for the Aluminium Industry

The legislation requires all large UK- and Industrial Strategy (BEIS) to align with As of April 2019, registered companies to report on their best practice in the UK and internationally, the UK Government’s energy consumption, carbon emissions, and is intended to complement new Streamlined Energy and energy efficiency measures in their recommendations from the G20 Financial annual director’s report. Stability Board’s Taskforce on Climate- and Carbon Reporting The new reporting requirements are related Financial Disclosures (TCFD). (SECR) framework has accompanied by a steep increase in The recommendations aim to improve energy taxation, now contained within transparency and investor information come into effect. the Climate Change Levy (CCL). to underpin the transition to a global low-carbon economy. Using the most efficiency modern smelters, the aluminium industry Who needs to comply with SECR? consumes approximately 14 kilowatt- BEIS estimates that 11,900 companies hours (kWh) of electricity to produce a across the UK will need to comply with the single kilogramme of primary aluminium. new regulation. As a result, energy costs are deeply Businesses that need to comply will be important for the sustainability and classified as ‘large’ under the Companies profitability of the industry in the UK. Act 2006 and have at least two of the What is SECR? following: This regulation was created in order to - At least 250 employees replace the mandatory greenhouse gas - Annual turnover greater By Lord Redesdale, emissions reporting requirements for than £36 million* CEO of the quoted companies and will come into - Annual balance sheet greater Energy Managers Association effect immediately after the closure of than £18 million* the CRC Energy Efficiency Scheme for *Please note that the definition of ‘large’ large UK energy users. It will operate companies is different from that of ESOS. in parallel with the Energy Savings Low energy users (using less than Opportunity Scheme (ESOS) which also 40,000kWh per year) will be exempt from applies to large UK companies and will reporting, however such an organisation continue after the introduction of SECR. is required to state, in its relevant report, The reporting itself has been developed that its energy and carbon information is by the Department for Business, Energy, not disclosed for that reason.

24 www.alfed.org.uk ENERGY

Furthermore, UK subsidiaries will not Quoted companies have been required When will companies need to report? have to report if covered by the parent since 2013, under mandatory greenhouse Reporting is aligned with companies’ company report. However, UK-based gas reporting requirements, to disclose financial year. Therefore, companies falling subsidiaries that are not covered by their global scope 1 and 2 GHG emissions within the scope of SECR will need to parent report will need to comply with and intensity metric in their annual report beginning on the first full financial SECR if eligibility requirements are met. reports. year that falls after the April 2019 start- Therefore, reporting under SECR will add: What needs to be reported? date. The new SECR reporting requirement • Global energy use (electricity, gas, and transport); Tax Implications mandates that large non-quoted With the closing of the CRC Energy companies and LLPs in the UK must: • Report on all principal energy efficiency actions taken within Efficiency Scheme for large UK companies, • Report on their UK energy use the financial year. the government will base revenue (electricity, gas, and transport); collected on an expanded Climate • Report on their associated GHG How is the information reported? Change Levy (CCL). emissions (scope 1 and 2 mandatory, The above information required by SECR CCL is charged by the government on scope 3 optional); will be reported by companies and LLPs electricity, gas, and solid fuels and are • Include a carbon intensity ratio in in their annual director’s report submitted listed on energy bills. The rates going the report. The EMA is compiling to Companies House. The report must forward are set out in the table below. a list of metrics that are most be approved by the board of directors By leveraging the opportunity created by commonly used by different sectors (company) or a named partner (LLPs). and will make recommendations SECR to demonstrate energy efficiency As the information is to be included in the after consultation on which ratios for year-on-year progress, businesses annual report, it must also be included in should be used as best practice will be able to improve profitability, the audited financial statements and be by different sectors. comparability, and transparency within the approved by the auditor. Auditors must • State the methodology used industry. approve SECR information: to report. For more information about SECR • Report on all of their principal energy • For consistency with financial compliance and training, please contact efficiency actions taken within the statements; Alex Ross at the EMA: financial year. • Consistency with knowledge acquired [email protected] Principal energy efficiency actions have by the auditor in the course of or 0203 176 2834. a wide definition and this will be an area performing the audit; of considerable debate. The EMA SECR • Any need to further qualify the report. methodology gives clear guidance on how to define principal measures, best practice to follow, and lists the main areas and processes that should be recorded in the report.

TAXABLE COMMODITY RATE RATE CHANGE FROM 1 APRIL 2018 FROM 1 APRIL 2019

Electricity 0.00583 0.00847 45.28% (£ per kilowatt hour (KWh))

Natural gas 0.00203 0.00339 67.00% (£ per KWh)

LPG 0.01304 0.02175 66.79% (£ per kilogram (kg))

Any other taxable commodity 0.01591 0.02653 66.75% (£ per kg)

(HMRC 2018)

24 25 www.alfed.org.uk www.alfed.org.uk ALUMINIUM PROCESSING

‘THRU-PROCESS’ TEMPERATURE MONITORING DRIVES EFFICIENCY IN ALUMINIUM PROCESSING

With high growth in Proving thermal processing of aluminium parts is done to specification, efficiently global aluminium and economically is critical. Helping demand processors with this need PhoenixTM offers a range of temperature profiling solutions of aluminium are designed specifically for applications rapidly looking to in the aluminium manufacturing market. In many situations PhoenixTM improve the efficiency has worked directly with key industry players to develop bespoke solutions for of operations. is achieved. The data logger is protected applications such as reheating aluminium by a water tank design thermal barrier slabs or log homogenization, solution as it travels, with the slab, through treatment (T6) of aluminium automotive the furnace. From live monitoring parts, CAB brazing radiators or powder significant reductions in soak time coating aluminium extrusions. have been achieved.

ALUMINIUM SLAB MONITORING PhoenixTM LTD THE BENEFITS! www.phoenixtm.com Prior to hot rolling aluminium slabs are preheated. The time at temperature (Soak) is essential to ensure that the material can be further processed efficiently and avoid excessive roller wear. Employing the PhoenixTM RF Telemetry system, the soak process can be monitored in real time to verify that the correct rolling temperature (slab core)

THE VOICE OF THE UK ALUMINIUM INDUSTRY

ALFED quarterly magazine offers you a great opportunity to promote your products and services to key decision makers and influencers within the aluminium industry in the UK.

SCHEDULE: Issue 3 – 5 December 2019 Issue 4 – 27 March 2020 Issue 5 – 29 May 2020 Issue 6 – 23 September 2020

For more information please contact: Kirsi Lintula, Editor e: [email protected] m: 07768 566 437

26 www.alfed.org.uk INNOVATION

FRONIUS FOURTH OPEN HOUSE

Fronius are global technology leaders The day was complemented with topical The Aluminium Federation in welding, photovoltaics and battery seminars from both Fronius and many actively participated in charging. They are never daunted by new external industry experts and gurus, the fourth Fronius “Open challenges succeeding where others fail in providing visitors an informative day of achieving what seems to be impossible. product, process and industry knowledge. Day” on Wednesday Fronius are a highly active member of Subjects ranged from industry related 15th May, an informative ALFED supporting events with insights in products and associations right through to using social media to enhance your day, brimming with fun. new technologies, continually interacting with members and providing their own business’ performance and EV topics. Over 400 delegates, training seminars, both for specific Balancing the entire day health and safety including 18 ALFED ALFED members and wider industry. issues were at the top of the seminar The ALFED stand attracted 32 delegates agendas, with briefings on the Health members, attended an who were seeking help and technical and Safety Executive enforced control inspiring day in the Fronius support in transitioning into aluminium, measures for welding operation in the several are pursuing membership. UK. Demonstrations covered areas such world class Innovation as the fume extraction torch including The “Open Day” covered the latest the external fume extraction attachment, Centre in Milton Keynes. cutting-edge welding technologies and both the Respiratory Protective processes, including the highly flexible Equipment (RPE) and the Fronius Vizor TPS/i welding system integrated with the Air/3, a powered air purifying respirator legendary Cold Metal Transfer (CMT), complete with a comfortable and fully process for manual and robotic welding automatic welding visor certified with applications, the newest, faster TIG the highest filter quality. welding process, Arctic, which requires no prep on materials up to 10mm, Wire Fronius are also active in the fields of Arc Additive Manufacturing (WAAM), battery charging and solar energy so and the new generation of lightweight, attendees had plenty to feast their portable and cordless welding systems. eyes over as this event catered for all Data analysis capabilities using the three divisions. Fronius Weld Cube were also An enjoyable fun-filled day packed with demonstrated. Not an average open interesting seminars and demonstrations, house, guests were encouraged hands featuring the very latest state-of-the-art on practical training in all the forms of systems. welding with many completing a full lap of the demonstration booths. Most tested their speed, accuracy and motor skills in various challenges throughout the day.

26 27 www.alfed.org.uk www.alfed.org.uk

TECHNOLOGY

HOT FORM QUENCH SETS ALUMINIUM LIGHTWEIGHTING STANDARD Impression Technologies launches new white paper on its HFQ® Technology

The drive to reduce emissions and a high cycle rate and the ability to form Impression Technologies, improve efficiency through lightweighting deep-drawn and complex shapes from the global leader in constantly requires manufacturers to find high and ultra-high strength aluminium. aluminium lightweighting, new solutions. The white paper, titled It is an ideal process for reducing mass and ‘Hot Form Quench (HFQ®) Technology: improving efficiency across all automotive has released a new white The new international standard for cost- applications, from body in white (BIW) paper introducing the effective automotive lightweighting using and chassis to EV battery enclosures. aluminium’, outlines how manufacturers benefits of its ground- can easily and cost-effectively replace steel “The technology also allows for integration of aluminium parts, with fewer operations breaking new technology: or low-gauge aluminium components using HFQ. The process cycle time for HFQ is at required to achieve equivalent designs. It hot form quench (HFQ). least as rapid as alternatives such as boron removes the requirement for reinforcement The innovative hot forming steel processing, enabling the low-cost, panels and improved dimension control high-volume manufacturing demanded in eliminates the need for springback process was developed automotive applications. compensation in tool and part design, easing downstream part assembly to offer a step change in The white paper describes the benefits and operations. HFQ conveniently combines aluminium forming across process of HFQ in detail. It also includes heat treatment and pressing, combining examples and case studies that illustrate solution heat treatment, forming, in-die multiple industries, including how the technology can be applied and quenching and age hardening. It is easy automotive and aerospace. what can be achieved: a measurably to adopt as it can use existing press and stronger final component, alongside major tooling technologies and combines with savings in weight and cost when compared a single draw operation, HFQ enables a with other common alternative processes. reduced investment entry point. “The automotive industry is on a constant “This new white paper describes how the mission to improve structural strength, technology works and provides essential integrity, consistency, durability and information about participating in the safety, all while reducing weight and HFQ Technology revolution. Impression cost,” explained Jonathan Watkins, Technologies is seeking to simplify vehicle CEO of Impression Technologies. design and boost production efficiency, “This is a very challenging set of goals while also raising standards and driving that requires constant evolution and quick the technological development of the uptake of new technologies and processes. lightweight vehicles of tomorrow.” “HFQ is a unique, patented process that To download the white paper, please visit enables low-cost production of high- http://bit.ly/2Yht73V. strength aluminium parts. The benefits of aluminium in automotive applications For more information on Impression are widely known, but there have been Technologies, visit impression- concerns around cost, strength and technologies.com. More details on HFQ production rate. HFQ addresses these with can be found at www.hfqtechnology.com

29 www.alfed.org.uk TECHNOLOGY

DISSIMILAR LASER WELDING OF ALUMINIUM AND COPPER ALLOYS

An increasing number of enquiries The Welding Institute (TWI) over the past two years from members worked for its members asking for support in this area led to the successful development of a high-speed to solve the technical laser-technology-based solution. problems of joining An increase in manufacturing demand aluminium to copper using in the automotive industry, for example, for products with high capacity battery laser welding technology. cells is leading to interest in the technical solutions. High capacity battery cells use aluminium and copper, as the anode and cathode terminals respectively, to improve electric current flow and boost a vehicle’s performance. Existing electrical keyhole instability and brittle intermetallic connection joining technologies, such formation are common issues found when as ultrasonic welding and the use of laser welding these metals. direct conductive adhesives, are deemed too slow for the high demand in a manufacturing situation. Laser welding is considered an attractive process to industry due to its high processing speed and highly repeatable, fully automated, process. However, laser welding of copper to aluminium presents several challenges. Because of the high surface reflectivity and thermal conductivity of copper, and the poor miscibility of aluminium and copper,

HEALTH, SAFETY & ENVIRONMENT HEALTH & SAFETY SERVICES

At the Aluminium Federation We have put together a package of Management of health and safety in resources and training to help you fulfil the workplace we understand that you your legal requirements, keep your team A practical ½ day workshop for managers have a business to run safe and resources to help you manage to highlight your requirements. Showcase health and safety in your workplace with the templates, check lists, training and wish to support you in assurance and confidence. available and how this works to support being compliant with HSE Whether you are new to it and need full your business. support from our experienced team or just Health & safety co-ordinators training legislation with the minimum need assurance that you have everything disruption to your business. in place, we have the ‘one stop’ solution A half day training session to support for you and your business. those who have practical health & safety responsibilities on the shop Our H&S consultant, Rob Bennett (left), floor. Giving them the ‘tools’ and has a diverse industry and education confidence to ensure your workplace experience over the past 30 years from complies with HSE legislation. delivering workshops for Boots, Halfords, ARCO and The BLOODHOUND SSC land Other services speed record project to running his own We provide Fire Risk Assessment and H&S training and consultancy business Noise Risk Assessment service in addition will enable us to support our members to a half day training courses, such in new and practical ways. as Fire Marshal, Manual Handling, Working at Height, Abrasive Wheel Site safety audit and Risk Assessing. Rob will come to you for the day to give you a health and safety assessment of We also offer a consultancy service for your business followed by a report with those who don’t have the manpower to recommendations. This may simply be allocate staff to complete the necessary a way of giving you a 3rd party assurance tasks such as risk assessing. These services or help to set an action plan for the will be bespoke to support your business essential things ALFED can support needs and requirements. you with H&S compliance. For further information please contact our training team on 0121 281 2281.

30 www.alfed.org.uk HEALTH, SAFETY & ENVIRONMENT

ALFED HEALTH, SAFETY & ENVIRONMENT COMMITTEE Open to all members and drawn from across the whole industry

The aims of the group are to share best the support of an environmental consultant The ALFED HSE Group practice and experiences with a view to who updates on topical issues, changes meet quarterly, made up the improvement of HSE within the UK and enforcements. of a cross section of Aluminium Industry. Whilst many of us Some of the shared experiences that the are competitors, for the purposes of HSE, group have benefitted from include the people, HSE professionals, our values and beliefs are simple, we Hydro HSE apprentice scheme; which are one team and our collective efforts everyone in the group found, thought HR managers and MDs will have a positive benefit for us all. Our provoking and wished to replicate. amongst others, who meetings are normally held in the ALFED We witnessed Kieran Vale of Hydro offices; however, we have held meetings in being awarded with the Neil Birt represent various member member group sites and always welcome (Past HSE Group Chair) HSE Memorial companies within the the opportunity to attend different venues. Award was most inspirational for the team. Our group meetings are attended by an On a practical level, the presentation that ALFED membership HSE Inspector, which is appreciated by the DipHex (Chemical Safety) provided at along-with, core support group who benefit from both updates and the HSE conference, resulted in several lessons learnt and the pro-active approach groups installing this at their facilities. from ALFED. New members and direction to relevant and appropriate We later discovered, as a result of using are always welcome and it case studies, journals and UK legislation. this product, two companies had been able There have been recent UK legislative to use it as part of their First Aid treatment is free of charge to attend. changes and it has been most beneficial and therefore, prevented serious eye injury to have HSE support and to work with the or indeed loss. There are many others regulator and to understand the HSE approach. but these are a few examples of the many By Helen Williams, Every two years, the HSE group host a 2 benefits of the HSE group. ALFED H&S group chair day conference where we aim to attract not We are always looking at ways to improve just HSE team members but engineering and to achieve the maximum benefits from managers, operations directors and our group activities. If you would like to anyone else for whom HSE items are often attend our group meeting as a taster, or “necessary evil” and perhaps non added would like any further information, please value. Our most recent conference in contact myself or Margaret Lane at ALFED. March 2019, saw representatives from Alternatively, if you have any ideas as to many member companies; talks from how we make improvements, these are various bodies including the HSE, safety always very welcome. suppliers and several motivational speakers Our next meeting is on Thursday 26th who were keen to impart their experiences, September 2019 at the ALFED Offices particularly those who have suffered or in Halesowen at 10.30am. Thank you to witnessed industrial accidents and wished the group members for your attendance to share the far- reaching effects and and much valued participation over the repercussions in doing activities which last year and last but by no means least, were unsafe ensuring that safety is always thank you to the Members’ companies kept in focus. who actively encourage and allow their Environmental issues are particularly attendance at group meetings. complex and the group also benefit from

30 31 www.alfed.org.uk www.alfed.org.uk MEMBER NEWS

ALUMINIUM EXTRUSIONS, A CHANGE OF EMPHASIS

“Industry research claims that over the shapes to full suites and has increased Nick Whitehouse, next ten years, the global aluminium capability with a full range of processing National Product Manager - extrusions market revenue is anticipated services to match customer need. This Aluminium Extrusions to grow at a CAGR of 4.5%, according capability includes cutting, finishing, to the report of Future Market Insights packaging, prefabrication and thermal with Aalco, reports that (FMI). Curtain walling and door & window breaking - all with the aim of adding value though challenging, profiles will remain the highest selling to the extrusions the company offers product category meaning that the and reducing the investment in time and the market for aluminium building & construction sector is likely equipment that would otherwise have to extrusions in the UK to remain the top consumer by tonnage”. be borne by customers. remains ‘buoyant’. “Whilst the report focuses on the Global Whitehouse continues: “Many customers market, Europe is anticipated to witness are realising major benefits in sourcing excellent growth in the aluminium from Aalco rather than direct from a mill – extrusions market size, by around 26% benefits that include reduced timescales, over the next 10 years”. lower cost, flexibility, the opportunity to “Aalco is a major supplier to the building make changes in scheduled quantities and & construction sector but has identified the ability to keep abreast with technology that the greatest downward pressure on changes without having to make the margins is exerted on what are, largely, financial investment themselves”. commodity products. So, whilst continuing He concludes: “In short, Aalco can to support customers in this sector, Aalco concentrate on what it does best – is working to identify additional markets the sourcing and supply of high-quality, that provide opportunities for value- industry-leading materials, whilst its added activities”. customers can focus on developing Aalco has developed a healthy business and manufacturing the very best in bespoke extrusions, from single products that they can”.

For further details and to book your stand contact Kirsi Lintula: +44 (0)7768 566 437 | [email protected] www.advancedengineeringuk.com

32 www.alfed.org.uk MEMBER NEWS

PRESTIGIOUS GOLD MEDAL MARKS THE DISTINGUISHED CAREER OF PROF. GEOFF SCAMANS

Innoval Technology is research spans several decades and every properties and structural integrity that element of the materials cycle. While he can be fabricated using 100% recycled delighted to announce that is perhaps best known for his pivotal work content. its Chief Scientific Officer, on surface engineering and corrosion Everyone within Innoval Technology mechanisms in aluminium alloys, work that would like to extend their warmest Prof. Geoff Scamans, has remains the leading reference material congratulations to Prof. Scamans. on the subject to this day, he has also been awarded the Gold A full list of award winners can be found campaigned tirelessly for sustainable at www.iom3.org/iom3-awards-2019 Medal by The Institute of manufacturing and efficient use of Materials, Minerals and materials. Mining (IOM3) in their Through his work at Innoval Technology, Geoff has Annual Awards. been responsible for over 20 successful collaborative IOM3’s Gold Medal is a premier award research projects over the presented to a company, team or past decade. These projects individual who has made a significant span applications from contribution to the industrial application transportation to construction, of materials. The awards were presented packaging, energy and at a gala dinner in London on 11th July defence. They have delivered to mark IOM3’s 150th anniversary. major technological advances, Geoff is a very worthy winner of the including the development Gold Medal. His remarkable record of of high-performance alloys internationally acclaimed, multidisciplinary with excellent mechanical

TWI AND ALFED UNITE TO PROMOTE ALUMINIUM FOR INDUSTRY

Aluminium use has seen growth in If managed correctly, aluminium can be Having already signed the automotive industry as well as in recycled carbon neutrally as it takes just a Memorandum of architecture, while the rail industry is also 5% of the energy required to produce new Understanding, TWI set to follow with increased use of the aluminium to recycle existing materials. material too. Meanwhile, the aerospace However, there is a need for expertise and ALFED are continuing industry continues to embrace aluminium in how joining may impact this to work closely together to for properties including corrosion recyclability, which TWI and ALFED resistance, recyclability and its strength- plan to provide through our partnership. promote aluminium to-weight ratio. Aside from research and development, for industry. However, there remain some challenges ALFED and TWI are planning to that TWI and ALFED hope to address, provide training to realise the benefits including retaining the material strength of aluminium for industry, while TWI of aluminium after joining. Members are now welcome to attend Plus, with the Automotive Council ALFED member events. Roadmap requiring high tensile In addition, TWI and ALFED are to hold aluminium, there is a need for support joint events, with the first of which having from joining and materials experts to taken place at TWI’s headquarters in assist with fabrication. Cambridge on 27th March, 2019. There are also considerations around Find out more: https://bit.ly/2Sj3I8A the environmental impact of aluminium production and use, and it is in the area of recycling that this material can be seen to offer real benefits.

32 33 www.alfed.org.uk www.alfed.org.uk

CAREER ZONE

THE IMPORTANCE OF PRODUCTIVITY

Improving productivity is one of the hot business topics of 2019.

Following publication of the Government’s Small Businesses and Productivity Report and its Industrial Strategy, business intermediaries and Government departments have been talking about the importance of increasing productivity. Evidence suggests that UK productivity has not grown as expected over the last 10 years and, as a result, the productivity gap between the UK and the other G7 countries has widened, putting the UK at a competitive disadvantage to its rivals¹. The causes of the UK’s lower productivity levels are complex and subject to research from a policy, academic and industrial perspective. Small businesses, the engine of the UK economy, do not a framework in which they can develop Does the University of actively measuring their productivity the skills needed to improve productivity Wolverhampton offer any other so they have a limited understanding whilst still contributing to the day- business support programmes? to-day operations of their employer. of the level at which they operate, the Alongside apprenticeships, the University There is funding to offset the costs of impact that those levels have on their also offers funded innovation projects apprenticeships of up to 95% for non- profitability and how their productivity such as Knowledge Transfer Partnerships levy payers and apprentices’ learning could be improved. Many businesses (KTP). These are bespoke programmes is contextualised to the needs of their are focused on securing short-term that provide the resources and expertise employer, making apprenticeship a profitability, often at the expense of needed to deliver strategic projects. cost-effective improvement solution. longer-term productivity, by buying in Part-funded by the Government, the resources to deal with performance issues Universities such as the University of partnerships enable businesses to create rather than developing in-house and Wolverhampton, one of ALFED’s dynamic collaborations with the University, sustainable solutions. Other organisations preferred partners, have developed a and a recent graduate, to complete a are not maximising Government growth range of programmes that specifically business improvement project that they incentives and initiatives either because address many of the performance would not be able to deliver in isolation. they are not aware of the support that issues affecting small businesses. Their The projects can focus on any aspect exists or because the initiatives appear leadership programmes, for example, of a business that owners believe will time consuming to apply for, too complex combine the latest management have a positive impact on income levels or difficult. thinking with the practical application and will support sustainable increases in of skills to ensure apprentices develop profitability. The projects are designed So what’s the answer? the management knowledge needed Industry and sector leaders argue that to enhance organisational capability and to improve efficiency, profitability deliver transformative change as well as they need cost-effective productivity and productivity. The University of solutions that recognise the resource accelerate innovation and create new Wolverhampton’s programmes have knowledge. The projects are funded via constraints of small businesses. They been designed to meet the resource seek initiatives that improve performance competitive bidding which the University needs of small businesses by providing supports using a specialist resource. without significantly increasing costs; that the majority of learning via a bespoke For more information about how are easy to access and that are cognisant platform so that employees can study the University of Wolverhampton’s of the context in which they operate. at their desks rather than a University productivity support programmes can One programme that satisfies these premises. They are also taught by benefit your organisation, please contact: requirements and gives businesses experienced practitioners who have Karen Shaw on 01902 321675 or 07973 the ability to improve productivity previously worked in industry, in senior 151808, email: [email protected] is apprenticeships. Supported by management and director level roles, so Government funding, apprenticeships understand the commercial requirements ¹Small businesses and productivity (https:// publications.parliament.uk/pa/cm201719/cmselect/ are no longer reserved for school leavers of small businesses. cmbeis/807/807.pdf, November 2018 or those working in junior positions. The newly introduced higher and degree level apprenticeships give individuals

35 www.alfed.org.uk PARTNER NEWS

YOUR QUESTIONS ANSWERED

employee’s first 2 years of employment Q: My employee was due to go Your work in the aluminium it is important to ensure there is a clause on holiday on Friday however has trade is vital. And while within the contract to state that you have now handed in a 2 week sick note, the right to vary procedures for employees your speciality may not should that time be considered as with less than 2 years’ service. Failure to be HR, matters relating holiday or sickness? do this could result in a breach of contract to running your workforce A: Employees who are sick before claim if the procedures are contractual. or during a period of annual leave are It is recommended that you include a and business can undeniably entitled to request the holiday to be probationary period within your contract take up considerable time. taken at a different time, this however of employment. This would allow you does need to be requested by the to dismiss an employee within the Croner, the trusted HR employee and is not automatic. If the probationary period (typically three partner of ALFED, provide employee falls sick during a period of to six months) if the employee did not annual leave they would need to follow meet the required standard. some anonymous questions the same absence reporting procedure received by the member as they usually would for a period of Q: We have received a grievance incapacity for work. If there is not from an employee and they support helpline, and their enough time left within the leave year have asked to see notes from expert answers. for the annual leave to be rescheduled this would need to be allowed to be all meetings and any file notes As an ALFED member, carried into the next annual leave year. from other employees involved, you have access to free, can I give this to them? specialist advice on any Q: Should a full capability process A: The information in the files will be be followed if an employee has less covered under the Data Protection Act of these areas – as well than 2 years’ service? 1998. This means that the information as wider HR, employment, cannot be accessed by anyone unless A: Employees only gain full employment there is good reason to do so. In this safety and tax matters – rights once they have 2 years’ service with situation it would be better to seek a company. Although this is the case it is by calling 0844 561 8133. agreement from the employees for their still advised to follow ACAS best practice notes to be released as the employee is when going through a capability or not entitled to see the other employee’s disciplinary process. If you want to be personal information. able to vary procedures during the

36 www.alfed.org.uk KEEPING THE UK AT THE FOREFRONT OF TESTING TECHNOLOGY NEW MATERIALS TESTING HUB FOR THE BLACK COUNTRY

Rubery Owen is delighted to announce that it is developing a state-of-the art testing facility called The Rubery Owen Testing and Research Centre, in the heart of the Black Country, for three of its businesses in the materials testing sectors, Phoenix Materials Testing, Rotech Laboratories and Merlin Powder Characterisation. Whilst maintaining their existing premises, they will enjoy the collaboration of expertise and innovation at a new combined testing facility and laboratory. The Rubery Owen Testing and Research Centre will combine the latest in high temperature, humidity and pressure testing capabilities along with current fatigue and thermomechanical fatigue (TMF) testing. It will also house the Merlin Powder Characterisation test facility, in which the physical properties and compressibility of powders are determined by use of an hydraulic compaction simulator. This unique, cutting-edge facility will help to keep the UK at the forefront of testing technology.

PLEASE JOIN US FOR THE OPEN DAY AND ENJOY A FULL GUIDED TOUR

WEDNESDAY 13TH NOVEMBER 2019

The Rubery Owen Testing and Research Centre 7am – 10am: welcome breakfast D1, The Wallows Industrial Estate 11am – 2pm: working style lunch Fens Pool Avenue 4pm – 6pm: afternoon canapés Brierley Hill If you have any food allergies, please let us know. West Midlands DY5 1QA RSVP [email protected] Please state your preferred arrival time

Find out more about Rubery Owen, Phoenix, Rotech and Merlin by visiting:

www.ruberyowen.com l www.phoenix-mt.co.uk l www.rotechlabs.co.uk l www.merlin-pc.com ALUMINIUM NEWS THE VOICE OF THE UK ALUMINIUM INDUSTRY ISSUE 2 SEPTEMBER 2019

WELCOME ADDITIVE GUIDANCE THE EUROPEAN ALFED TO OUR MANUFACTURING ON EU EXIT ALUMINIUM HEALTH, SAFETY NEW MEMBERS RECYCLING & ENVIRONMENT Developments From the INDUSTRY COMMITTEE Coventry University in Net Additive Department for ISC Wales Manufacturing and Business, Energy Aluminum recycling - Sharing best 3M Advanced Alloys and Industrial a vital part of Europe’s practice and Ash & Lacy Finishes Strategy (BEIS) wider aluminium experiences value chain 10 15 18 23 31