Hindalco Industries Limited – Mouda – is the a journey of transformation from a standalone entity established with best-in-class facilities of rolling Flat Rolled Products to a world- class foil manufacturing hub on its way to achieve excellence in processes and products.
The unit’s vision is to ‘Achieve excellence in processes and products to establish leadership position in quality and cost in bare foil and paper laminate segment’.
We produce bare foil for pharmaceutical and food applications. Our product basket includes cigarette laminate, semi-rigid containers and house foil. Freshwrapp, Superwrap, and Freshpakk are some of our well-known brands.
Our production is centred on continuous casting route from cold metal, enhanced by the sourcing of hot rolled coils from sister units. The Ajanta Project, which was conceptualised under the guidance of Novelis Foil & Technical Products division, utilises continuously cast coils to produce ultra-light gauge foil i.e. foil with thickness below 7 microns.
Our processes are superior to conventional processes as we use energy efficient continuous casting process which produces metal with superior quality of hygiene through an inline degassing unit, deep bed filtration system, and high levels of temperature control. We have a 60-tonne capacity twin chamber melting furnace for recycling foil scrap and supplying molten metal to jumbo 3C continuous casters supplied by Pechiney, France.
The unit has one of the most sophisticated cold rolling mills from Achenbach, Germany, which specialises in thin-gauge tight tolerance products, and is equipped with state-of-the-art automatic thickness and flatness control systems.
The unit has the best quality foil mill assets transferred from Novelis, Bridgnorth, UK. The foil mills, of Achenbach, Germany, and SMS, Germany, are equipped with the latest thickness and flatness control systems, and are capable of rolling foils from 6 to 50 microns thickness.
The unit has ‘solvent-free’ paper from Kroenert, Germany, and foil lamination machine using water-based glue and inks.
Our equipment is designed for maximum productivity with 6kg per mm coil density, 1600mm product width and foil rolling speeds of 1200-1500 meters per minute.
Plant highlights:
- Production based on continuous cast route
- On-line deep bed filtration for superior metal – average width: 1550mm
- Average speed: 1090 mpm
- AFC on mills
- AGC on mills
- Focused product range – ultra-light gauge and paper foil laminate
- In-house vacuum distillation unit for reclamation of rolling oil
- Scrap is consumed in-house
- Eco-friendly converting process – water-based glue, slip coats and inks
- Focus on bare foil & laminate segment
- Erstwhile facilities of Novelis, Bridgnorth shifted and upgraded
The unit also has a state-of-art paper laminator which has:
- Solvent-less glue lamination using water-based glue and inks
- Propane-fired direct heating in lamination.
In order to cater to growing customer demands, the unit is installing a new foil rolling mill, which will be commissioned in the first quarter of FY20.
The unit is certified with ISO9001 & ISO14001, guided by the Business Excellence framework of the Aditya Birla Group & Hindalco Management Framework.