Production of aluminium light alloy wheels for the European aftermarket – from casting to packaging
ALCAR Leichtmetallräder Produktion GmbH
NeuenradeNew on Amplifa
About ALCAR Produktion
ALCAR Leichtmetallräder Produktion GmbH manufactures aluminium light alloy wheels at its Neuenrade site in the Sauerland region for the automotive aftermarket. The plant produces primarily for the in-house brands AEZ, DOTZ and DEZENT of the Austrian corporate group belonging to the ALCAR Group and supplies national and international wholesale. With an annual capacity of up to 900,000 wheels, production runs in three shifts from Monday to Friday; the weekend is used mainly for maintenance and cleaning work. The value chain covers the entire process: from melting the aluminium through permanent mould casting of the raw form, X-ray quality inspection, deburring and fully automatic machining by turning and drilling to powder coating and painting in a fully automatic painting line. Optionally, the rims are diamond-turned before further inspections and automatic packaging take place. More than 200 employees work at the site; the company trains foundry mechanics, industrial mechanics and IT specialists, among others.
- Site
- Neuenrade
- Processes
- Permanent mould casting (casting of the aluminium metal into the permanent mould), X-ray inspection (top quality inspection), Deburring, Turning (fully automatic), Drilling (fully automatic, mechanical machining), Powder coating, Painting (in various colours), Diamond turning
- Materials
- Aluminium (aluminium metal for light alloy wheels), Aluminium, Permanent mould casting, X-ray inspection, Fully automatic machining, Powder coating & painting
- Certificates
- X-ray inspection of every raw casting, Further final inspections before packaging
- Employees
- over 200
- Industries
- Automotive aftermarket, Tyre and wheel wholesale, Automotive supply / Aftermarket (Automotive aftermarket)
- 01
Melting of the aluminium metal
- 02
Permanent mould casting (raw form)
- 03
X-ray quality inspection
- 04
Deburring
- 05
Fully automatic turning and drilling
- 06
Powder coating and painting
- 07
Diamond turning (optional)
- 08
Further inspections
- 09
Automatic packaging
Materials & Processes
Aluminium
Material for the light alloy wheels, melted and processed into the raw wheel form by permanent mould casting.
Permanent mould casting
Casting process in which the molten aluminium is cast into a permanent mould to form the raw wheel.
X-ray inspection
Quality inspection of the raw casting to ensure top quality.
Fully automatic machining
Turning, drilling and diamond turning for the mechanical machining of the raw wheels.
Powder coating & painting
Surface finishing in the fully automatic painting line in various colours.
Locations
Neuenrade
DEProduction site
- Materials
- Aluminium
- Permanent mould casting systems (foundry)
- X-ray systems (quality inspection)
- Diamond turning systems
- Fully automatic painting line
- Automatic packaging system
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Permanent mould casting (casting of the aluminium metal into the permanent mould)Casting | – | – | – | – | Aluminium |
| X-ray inspection (top quality inspection)Testing | – | – | – | – | Aluminium |
| DeburringMachining | – | – | – | – | Aluminium |
| Turning (fully automatic)Machining | – | – | – | – | Aluminium |
| Drilling (fully automatic, mechanical machining)Machining | – | – | – | – | Aluminium |
| Powder coatingSurface | – | – | – | – | Aluminium |
| Painting (in various colours)Surface | – | – | – | – | Aluminium |
| Diamond turningMachining | – | – | – | – | Aluminium |
| Packaging (automatic packaging system)Assembly | – | – | – | – | Aluminium |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| X-ray systems (quality inspection) | – | – | – | – | Neuenrade |
| Fully automatic painting line | – | – | – | – | Neuenrade |
| Automatic packaging system | – | – | – | – | Neuenrade |
| Diamond turning shop (diamond turning systems) | – | – | – | – | Neuenrade |
| Permanent mould casting systems (foundry) | – | – | – | – | Neuenrade |
Additional services
Quality
Every aluminium raw casting undergoes a top-quality inspection in X-ray systems; after machining and coating, further inspections are carried out before packaging.
| Evidence | Neuenrade |
|---|---|
| X-ray inspection of every raw casting | |
| Further final inspections before packaging |