A RICHARDS CONSULTING LTD (ARC) SUCCESSFUL COLLABORATION WITH HULAMIN TO COMMISSION THE WIDENED S5 ALUMINIUM COLD MILL IN SOUTH AFRICA

Alan Richards • October 8, 2025

Ongoing collaboration results in successful, on-time start-up of S5 mill

  •  Increased maximum strip width capability of the mill to 1875 mm
  • Higher material temperature capability enabling faster and back-to-back rolling
  •  Improved strip quality including:

o  New flatness sensor incorporating load cells

o  New strip scanner heads

o  New spray system

o  New enhanced ARC strip dryness system

o  An upgraded optical centre guide system

o  New snubber roll

  • A new, ARC designed compact 3-roll entry bridle with colouring roll
  • A new oil-air lubrication system for the mill
  • Upgraded spool handling to cater for dual spool lengths
  • Manufactured, installed & commissioned on schedule


In September 2023, HULAMIN awarded the contract for the widening of their S5 aluminium cold rolling mill to A Richards Consulting Ltd (ARC). This was followed by Phase 2 which was successfully designed, manufactured, installed and commissioned by mid 2025, as per the original deadline.


Wider Strip Processing

Increasing the maximum strip width opens new markets to HULAMIN and allows the S5 mill to focus on processing wider, 14-out high quality can stock material. In addition, this will enable better distribution of product across all areas of the plant thereby increasing the overall plant utilisation. The main component of this upgrade being a new entry bridle with colouring roll designed and supplied by ARC, which not only allows the wider material to be processed but also includes features to ensure accurate roll positioning, stable tension control and ease of maintenance. The bridle facilitates the mounting of new wider coolant spray bars and the existing coil feed unit.

 

Also included are new, longer work rolls and back up rolls with new bearing arrangements and the associated chock modifications to accommodate the increased width and higher operating temperatures.

 

The ARC design caters for increased strip temperatures and speeds but also meets the challenges of accommodating the new surface inspection cameras, strip scanners, strip dryness equipment, load cells and flatness measurement system in an already congested area of the mill.

 

Feedback from HULAMIN after the successful start up included;

 

“The mill upgrades were completed as per the project plan with little or no issues related to the work executed by ARC. All the equipment and modifications fitted as planned and have been operating well”

 

Mill Upgrades

Upgrading a rolling mill is often necessary when introducing a new product and provides an alternative to investing in completely new equipment. Upgrading is also a cost effective solution to updating old or obsolete technology and can also minimize the loss of production associated with replacing equipment with new. However, this is a very specific area of expertise and one which requires the highest level of know-how.

 

Working closely with HULAMIN over the past 2 years or so, ARC has been able to provide insight into the process aspects of this upgrade, analysis and evaluation of different solutions. ARC also provided CAPEX estimates for the design, supply and implementation and the full design, supply and supervision of installation & commissioning of the new upgraded S5 cold mill.

 

“I once again would like to acknowledge the great work done by the ARC team and the Hulamin team. This project showed that great things can be achieved when we form great partnerships and a shared vision.”

Marlon Reddy – Engineering Executive, HULAMIN

 

Aluminium Supplier to Africa and the World

HULAMIN is not only the largest aluminium rolling operation in Sub-Saharan Africa, but is one of the largest exporters, which represents more than 60% of sales. Aluminium semi-fabrication in the form of plate, sheet & foil is supplied to customers across South Africa, Africa and the world focusing on specific product and end-use markets such as automotive, packaging, transportation, building and electrical applications.

 

A Richards Consulting Ltd (ARC) is a specialist consulting and engineering group with it’s registered office in London. ARC operates from Dorset with a highly experienced team of experts dedicated to the rolling mill industry. This experience is based on many years gained working with companies such as Davy McKee, VAI, SMS Parkegate, FATA Hunter, HATCH etc.

Specialising in upgrades and modernisations, the ARC team understands the critical and complex nature of this business and is ideally placed for providing an efficient, flexible and proactive service to support clients. ARC services range from feasibility studies, due diligence and asset integrity reports, through to full engineering design, project management and supply services. www.arichards.co.uk


A RICHARDS CONSULTING LTD (ARC) AWARDED CONTRACT BY HULAMIN TO UPGRADE THE S4 ALUMINIUM COLD MILL IN SOUTH AFRICA

By Alan Richards • October 8, 2025
Continued cooperation between ARC and HULAMIN

ARC opens new office

By Alan Richards • June 25, 2024
We are thrilled to have moved into our new office in Wimborne, Dorset.

ARC awarded contract to widen the S5 aluminium cold rolling mill at HULAMIN in South Africa

By Alan Richards • February 8, 2024
In September 2023, HULAMIN awarded the contract for the widening of their S5 aluminium cold rolling mill to A Richards Consulting Ltd (ARC). This followed one of several engineering studies carried out by ARC and resulted in the S5 widening project being awarded against a tight deadline to complete Phase 1 by December 2023 ready for board approval. This was immediately followed by Phase 2 which will see the widening project designed, manufactured and implemented by the second quarter of 2025. Project key features: Increase maximum strip width capability of the mill to 1875 mm Higher material temperature capability from faster, back-to-back rolling Improved strip quality including: New flatness sensor incorporating load cells New strip scanner heads New spray system New enhanced ARC strip dryness system An upgraded optical centre guide system A new, ARC designed compact 3-roll entry bridle with colouring roll A new oil-air lubrication system for the mill Upgraded spool handling to cater for dual spool lengths Wider Strip Processing Increasing the maximum strip width will open new markets to HULAMIN and allow the S5 mill to focus on processing wider, 14-out high quality can stock material. In addition, this will enable better distribution of product across all areas of the plant thereby increasing the overall plant utilisation. The main component of this upgrade being a new entry bridle with colouring roll designed and supplied by ARC, which not only allows the wider material to be processed but also includes features to ensure accurate roll positioning, stable tension control and ease of maintenance. Also included are new, longer work rolls and back up rolls with new bearing arrangements and the associated chock modifications to accommodate the increased width and higher operating temperatures. The ARC design caters for increased strip temperatures and speeds but also meets the challenges of accommodating the new surface inspection cameras, strip scanners, strip dryness equipment and flatness measurement system in an already congested area of the mill. Mill Upgrades Upgrading a rolling mill is often necessary when introducing a new product and provides an alternative to investing in completely new equipment. Upgrading is also a cost effective solution to updating old or obsolete technology and can also minimize the loss of production associated with replacing equipment with new. However, this is a very specific area of expertise and one which requires the highest level of know-how. Such is the case with the HULAMIN upgrade, where ARC has designed the new and upgraded equipment and planned the implementation to minimize the loss of production and disruption to the plant. The ARC team has many years of experience in modernisations and upgrades of rolling mills and processing equipment for the steel, aluminium and other non-ferrous industries. Working closely with HULAMIN over the past year or so, ARC has been able to provide insight into the process aspects of this upgrade and the analysis and evaluation of different solutions. ARC also provided CAPEX estimates for the design, supply and implementation and now the full design, supply and supervision of installation & commissioning of the new upgraded S5 cold mill. Aluminium Supplier to Africa and the World HULAMIN is not only the largest aluminium rolling operation in Sub-Saharan Africa, but is one of the largest exporters, which represents more than 60% of sales. Aluminium semi-fabrication in the form of plate, sheet & foil is supplied to customers across South Africa, Africa and the world focusing on specific product and end-use markets such as automotive, packaging, transportation, building and electrical applications. www.hulamin.com A Richards Consulting Ltd (ARC) is a specialist consulting and engineering group with it’s registered office in London. ARC operates from Dorset with a highly experienced team of experts dedicated to the rolling mill industry. This experience is based on many years gained working with companies such as Davy McKee, VAI, SMS Parkegate, FATA Hunter, HATCH etc. Specialising in upgrades and modernisations, the ARC team understands the critical and complex nature of this business and is ideally placed for providing an efficient, flexible and proactive service to support clients. ARC services range from feasibility studies, due diligence and asset integrity reports, through to full engineering design, project management and supply services.

We are proud to be supporting Bridgnorth Aluminium Ltd

By Alan Richards • May 19, 2020
A Richards Consulting Ltd is proud to be supporting Bridgnorth Aluminium with design and detail engineering for technology upgrades. Having manufactured aluminium strip since 1933, Bridgnorth Aluminium Ltd has firmly established itself as a trusted supplier of rolled aluminium products with knowledge and experience spanning many decades, evident in the work they do today. A Richards Consulting Ltd (ARC) includes a team of engineers with many years' experience in the aluminium and steel industries, providing engineering services, general technical consulting, due diligence services, asset integrity reports, process optimisation, capacity plaing and general business advice, particularly in the metals, industrial and manufacturing sectors.

A step into the (almost) unknown...

By Alan Richards • August 31, 2019
Having spent 30 or so years (yes, hard to believe I know), working mainly in the corporate world for large capital equipment and plant builders in the metals and mining industry, and also having been made redundant 3 times in the last 4 years, twice just 12 months apart and once threatened with legal action just for trying to find a job for myself and a dozen colleagues, I decided enough was enough. Yes, I've enjoyed my time in the corporate world I suppose, especially during the periods where I've been lucky enough to live and work overseas and meet the most wonderful people along the way, but in my 'late fifties' it's time to rethink my objectives and redirect my energy into something slightly more varied and rewarding! Maybe it's just a symptom of growing older, maybe it's just me, but it doesn't get any easier does it? Having said that, I always need a challenge or a project and I'm certainly not one to shy away from hard work and putting in the hours, but it is really important for me to love what I do and get that sense of satisfaction whilst achieving tangible results, which is what I've been lacking in recent years. I understand there's not the job security there was in decades past, and also the competition has increased, but 'taking back control' is the way to go apparently! Anyway, spurred on by the annual redundancy and the dread of having to rely on the unpredictable world of metals engineering, I decided to join ibd Business Advice Group as a self employed but accredited business consultant, pick up some new skills through their extensive training courses, and put my energy into helping others starting out on their long road to retirement. Hopefully I can use the diverse and extensive knowledge and leadership, sales, management, manufacturing and project development experience I've gained living and working in countries such as India, South Africa, France, Italy, Russia, Korea and China and of course the UK. I will keep you updated on my progress through what I expect (and hope) to be a challenging but rewarding existence, at least in job satisfaction and work-life balance!