«Realit» Group

Production of aluminium profiles

Telephones: +7 (499) 500-57-53, +7 (484) 399-61-91

Company history

Realit was founded in 2002 and is currently one of the leading manufacturers of extruded aluminium profiles in Russia.

Year 2002

Configuration of the plant equipment was identified, and tenders for its supply were conducted among a dozen and a half companies on different positions of the equipment. Simultaneously, a large construction project was commenced within the integrated house-building factory in the city of Obninsk.

Year 2003

Realit was put into operation. Casting line equipped with gas tilting melting furnace manufactured by the Italian company Cometal Engineering S.p.A., completed with a hydraulic actuator for alloy discharge was put into operation. Press No. 1 with capacity of 1,800 ton-force by the firm Presezzi Extrusion S.R.L. (Italy) and finishing line by the company Cometal Engineering S.p.A was also put into operation. Horizontal powder coating line manufactured by the firm K.F.P. (Italy) was launched.

Year 2006

Disk powder coating vertical line (by the Italian firm Trasmetal S.p.A) was commissioned, which is environmentally friendly owing to chromate-free profile processing technology.

Also in 2006, Press No. 2 with capacity of 1,250 ton-force, manufactured by the proven by then as reputable company Presezzi Extrusion S.R.L. was launched.

This new equipment launched in 2006 allowed our company to increase capacities in pressure moulding by 1.5 times, and triple the production of painted profiles in 2007.

Year 2007

New packaging machine by the Italian company AUTEL was launched, which enabled us to pack each profile individually, i.e. wrap them in plastic film.

Year 2008

Press No.3 was launched with capacity of 2,800 ton-force by the Italian company Presezzi Extrusion S.R.L. The launch of this new press enabled us to double pressure moulding capacities.

Year 2009

Together with All-Russia Institute of Light Alloys the technology for high-temperature homogenization of billets and profile ageing was changed. This work was commenced in 2008 and was aimed at production costs reduction, productivity increase, and product quality improvement.
Application of high temperature homogenization has enabled us to achieve the following results:

- hot billets plasticity increase;

- extrusion ratio growth;

- profile surface quality improvement;

- enhancing of mechanical properties and microstructure uniformity of pressed products;

- reduction of billet thermal treatment cycle time, which increased the productivity of the homogenization furnace.

The switch to this new mode reduced the cycle time of homogenization by 30-40 %, which resulted in the increase of productivity of the homogenization furnace by 1.5 times, and also led to up-levelling of mechanical properties of the resulting pressed articles.

Also in 2009, the Realit became a member of the Russian Union of Metal and Steel Suppliers.

Year 2010

In the beginning of 2010 the scheduled repair of the forging and pressing equipment, as well as horizontal and vertical painting lines was conducted. The replacement of the furnace lining was conducted on the melting and casting complex with the use of modern imported materials and application of advanced methods for heat-resistant concrete pouring. Also the melt refining line was reconstructed, enabling the production of high degree purity metal.

In November 2010 the first ever in the Realit plant’s history joint certification audit of the quality management system was conducted by VNIIS (Russian Research Institute for Certification) JSC and TÜV International RUS LLC. This audit confirmed that the quality management system of Realit meets ISO 9001:2008 in respect to design, development, manufacture and supply of aluminium structures for construction purposes, whereof the appropriate certificate was issued.

Year 2012

In March 2012, the plant introduced a new system of shipments, which addressed the main problems that affected the speed of shipment. The new system brought the benefit of significant reduction of vehicle loading time, enabling us to increase the volume of daily shipped products by more than 40%.

Then, in May 2012, our process engineers put a lot of effort into improving the quality of aluminium billets produced at the plant. As a result of this work the surface of in-house made billets has significantly improved. This progress was made owing to optimization of technological processes and application of unique lubricants for billet-forming equipment developed by our plant. The new lubricant not only ensures smooth surface for new billets, but also secures absence of any foreign graphite inclusions on their surface.

Year 2013

Large-scale modernization of horizontal and vertical lines for aluminium profiles painting was performed. The second automatic packaging machine and the second line for protective film application to profiles were put into operation.

Year 2014

New melting and casting complex with production capacity of 48,000 tons of billets per annum was commissioned.