Extrusion Design & Innovation (EI)

Abhay Agarwal, Bhoruka Extrusions Private Limited, India

India's rapid urbanization demands infrastructure components that are durable, sustainable, and quick to deploy. While aluminum extrusions effectively replace termite-prone wood, existing market solutions fail to unlock the metal's full potential, often resulting in heavy, expensive and poorly finished assemblies. This research redefines the role of aluminum in public infrastructure by treating the door frame not as a product, but as a value-added system. This is achieved by refining geometry to include integrated architraves, concealed fixings and optimizing weight. The objective is to develop streamlined fabrication and installation guidelines to empower local contractors for the Central Public Works Department, Government of India. By significantly optimizing consumption and improving aesthetics and joinery, this study enhances the economic and logistical viability of metal frames for expansive governmental deployment, creating a scalable model for sustainable public infrastructure. It proves that intelligent extrusion design can deliver superior value to the Indian state and serve as a template for global infrastructure projects.

Sutanay Parida, National Aluminium Products Company S.A.O.G., Oman

Billet unloading from shipping containers is a common but high-risk activity in aluminum extrusion plants. Traditional methods often require personnel to enter containers to install rollers or remove supports, exposing them to confined-space hazards and suspended loads. Although widely practiced, such methods typically carry high-severity risk ratings. At Napco, where multiple billet containers were unloaded daily, a structured risk assessment led to a complete redesign of the unloading process with the objective of eliminating human entry into the container. A simple mechanical lifting fixture was developed to engage the exposed end of a billet bundle, allowing secure extraction of the full bundle directly from outside the container using a 10-ton forklift. The new method fully removes personnel exposure to container-related hazards, reduces manpower requirements, shortens unloading time, and improves operational efficiency. This paper presents risk analysis, design concept, and practical results of implementing a safer billet unloading practice.

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