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September 1, 2009
Alcoa and Sergomel launch lighter aluminum body for transporting chopped sugar cane that uses less fuel
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Aluminum equipment, on show on Sergomel’s stand at Fenasucro & Agrocana 2009 is, among other of its qualities, stronger and capable of carrying bigger loads.
During Fenasucro & Agrocana 2009 Alcoa and Sergomel, a Brazilian manufacturer of bodies and trailers used in sugar plantations, are launching a body for carrying chopped sugar cane (road-train) for mechanized harvesting. This has the support of the CTC (Sugar-cane Technology Center), the sector’s R & D body.
The equipment has aluminum boxes and wheels and offers a series of advantages for the sugar and alcohol sector: it is lighter, stronger, capable of carrying a bigger load and reducing fuel consumption and tire wear, in addition to being recyclable. All these features allow the aluminum body to adjust easily to the Weighbridge Law, issued by Conatran (National Road-Traffic Council), in December 2007, which determines the weight tolerance levels of transport vehicles.
The XVII Fenasucro and VII Agrocana – International Sugar and Alcohol Trade Fair, 2009 takes place between September 1 and 4 in the Zanini Events’ Center in Sertãozinho (SP).
Various advantages
Bu using aluminum in the bodies the gross weight of the overall vehicle reduces by 35 %, as from 5 tons onwards, and can reach as much as 9 tons. The weight of the boxes and wheels is 50% lighter than steel equipment with the same configuration from other manufacturers. This results in a gain in the volume that can be carried, taking into account the maximum weight allowed by law.
In addition to the weight reduction there is a 7% reduction in fuel consumption, with the consequent reduction in emissions. Energy output is greater and the working life of the tires increases. The number of times the gears have to be changed reduces with the equipment’s greater autonomy. It is also easier to wash. These indicators were obtained from field tests.
Alcoa is the only aluminum manufacturer that is developing this solution, which is exclusively used by the sugar cane segment, where it can be used in several types of body composition (bi-train, multiple trailer, road-train, half-trailer), where the sugar and alcohol production mills use mechanized harvesting.
“We produced the first equipment almost 10 years ago and it’s all still being used. This long learning curve allowed us to develop suitable equipment, with improvements in structural points and in assembly concepts”, explains Reginaldo Otsu, Marketing analyst from Alcoa’s Extruded Products Division. The executive also says that there are three pilot projects of this product that are being used by two of the country’s major sugar and alcohol production groups.
According to Adriano Terra, product engineer from Sergomel, the great advantage of using aluminum is the gain in the manufacturing process, since the extruded profiles come ready for use in the load box assembly process, thereby making handling easier and eliminating processes like cutting and bending, for example.
The size, length and geometric shape of the profiles also provide a construction alternative for the project, eliminating some welding points and increasing the strength of the profile joints, making production of the equipment easier.
“With the change in the market and the competition it’s important we look for partnerships with major companies, like Alcoa, so that we can have support in our constant search for solutions for the sugar and alcohol market”, states Adriano.
The whole concept and development of this bodywork was carried out by engineering teams from the CTC (Sugar Cane Technology Center) and by a team of specialists from Alcoa, comprising Brazilians and Americans.
Forged aluminum wheels - Alcoa is the world’s leading manufacturer of forged aluminum wheels, the only ones that can overcome the major challenges presented by the commercial transport of loads and passengers. With these wheels the Company started offering fleet operators worldwide the real advantage of transporting bigger loads, meaning fewer trips, savings in both fuel and time and helping protect the environment.
The road-train is equipped with 24 wheels, which leads to a reduction of approximately half a ton in the weight of the equipment. Alcoa’s forged aluminum wheels are much lighter and stronger that traditional ones, in addition to running at an average temperature that is much lower than others that exist in the market, thereby increasing the working life of other components, because of one of aluminum’s important characteristics: heat dissipation. In addition to being approved in the conventional tests demanded by vehicle assemblers Alcoa’s wheels also pass the rigorous JWL-T (impact) and LBF (simulated running under severe road conditions) tests.
About Alcoa
Alcoa is the world leader in the production and management of primary aluminum, fabricated aluminum and alumina combined, through its active and growing participation in all major aspects of the industry. Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa's businesses to customers. In addition to aluminum products and components including flat-rolled products, hard alloy extrusions, and forgings, Alcoa also markets Alcoa® wheels, fastening systems, precision and investment castings, and building systems. The Company has been named one of the top most sustainable corporations in the world at the World Economic Forum in Davos, Switzerland and has been a member of the Dow Jones Sustainability Index for seven consecutive years. More information can be found at www.alcoa.com
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