Accessible raw materials, state-of-the-art technology, professional engineers, technical know-how, qualified management and a strong market demand…
all the ingredients necessary for success…quite many to rationalize the establishment of the Modern Aluminum Industries Co. (MODAL).

However, another ingredient was needed to sustain the momentum and ensure that a competitive product is continuously being produced. The answer came…simple, yet very crucial; a complete adherence to Quality.

MODAL incorporates an effective system integrating the quality-development, quality-maintenance and quality-improvement efforts…enabling engineering, production, services and marketing to perform at their most efficient levels.

MODAL production system comprises an Extrusion Line, an Anodizing Line, a Powder Coating Line, a Polishing Line…and finally Wrapping and Storage. Throughout these stages of production, rigorous tests are carried out to ensure that quality is continuously monitored.

Press
The surface of the aluminum alloy is checked to make sure it is clean
and clear of any deformities. Dies are
tested and corrected to high precision. Here, the alloys are extruded to
aluminum profiles of various shapes and cross sections, depending on the dies used.

To obtain hardness and maintain the asymmetric nature, emerging profiles
are then cooled naturally by air.

Aluminum profiles are never touched by bare hands.

Stretching & Run-Out Tables

The profiles are straightened prior to cutting by stretching.

Anodizing
Anodizing is a process to produce
a film of aluminum oxide on the
profile’s surface, so as to protect
it form natural oxidizing or what we
call “rusting”, thus increases its
hardness and durability against
weather conditions.
Anodizing is carried out by passing a direct current at a sufficient voltage through a suitable acid electrolyte.

To prepare aluminum for this treatments, profiles are first de-greased to remove oils and greases, etched and further treated to remove any remaining impurities. During the anodizing process the profile surface starts to gradually change into a porous dielectric aluminum oxide.

Then profiles are introduced to the electro-coloring process, so as to deposit tin sulphate into the aluminum pores. The obtainable colors range from light, medium and dark bronze to start black, depending on the treatment time.

To ensure conformity of the anodized layer, a layer thickness test is carried out at not less than five measuring points, with 3-5 readings each. The porous surface is then sealed to insure sustaining the highest quality.

Powder Coating
Powder coating is a process to coat
the aluminum profiles with a synthetic powder of a wide range of colors.
The surface of the aluminum profile
is first degreased to remove oils and greases. Any present oxide layer is etched by dipping the profiles in an acid activation tank. Profiles are then rinsed with deionized water to remove any remaining chemicals. Now the profiles are ready to undergo the chemical
conversion coating (CHROME-FREE SYSTEM).

The coating resulting from this bath has excellent paint bonding properties. To ensure stability before spraying, the profiles are passed through a hot air dryer.

Inside this special cabinet, a chosen color is sprayed uniformly until the profiles reach the thickness required.

Finally, the profiles are treated in an infrared oven and are passed through a hot air atmosphere to create a strong chemical bond between the powder and the profiles.

To ensure uniformity of coating a layer thickness test is carried out, at not less than five measuring points with 3-5 readings each. To test the quality of the powder adhesion to the profile surface. Further tests are carried out, such as; an adhesion test, a cupping test, a bending test and an impact test.

Additional tests are also carried out to test other aspects, such as; a corrosion test, a solvent test, a gloss test, a weathering test and a resistance to boiling water and pressure test.

Polishing

To gain and achieve the polished aspect of the profiles, a polishing machine is used where cotton buffs passes over the profiles at a certain rotating speed, at a very high pressure and with paste sprayed over the profiles.



Wrapping
The wrapping unit receives profiles
from both anodizing line and the
powder coating line. Before profiles
are wrapped, they are inspected for
the last time by a quality control unit. After final inspection is completed, profiles are wrapped
automatically with a special
non woven material or crepe
paper and stored, ready for delivery.