Keep Your Extrusion Line Running Efficiently Expert troubleshooting, repair, and optimization.
With over 25 years of experience in the aluminum extrusion industry, we specialize in extrusion press troubleshooting, repair, and performance tuning. Our services restore your press to peak operating condition while ensuring long-term reliability and modern integration with modern control systems.
Why Prioritize Aluminum Extrusion Performance?
Dialing in your extrusion process ensures stable profiles, fewer defects, and longer equipment life. Minor variances in temperature, tooling, or material flow can quickly escalate — proactive optimization keeps throughput high and scrap rates low.
We take a hands-on approach to improving your extrusion performance. With in-depth knowledge of system design and operation, we offer practical solutions that solve problems fast and strengthen your long-term efficiency.
- Complete assessment of electrical, hydraulic, mechanical, and control systems
– Pre-visit preparation:
• Review schematics, drawings, and OEM manuals
• Collect maintenance history and fault logs
• Confirm parts availability
• Prepare test instruments and diagnostic tools
- We use structured fault-finding to quickly identify and resolve the root cause of failures or performance issues.
– Remote PLC/alarm log review (when available)
– Collaboration with your maintenance and controls team
– Development of a customized fault-tree checklist to minimize downtime on-site
We provide complete electrical, hydraulic, and mechanical repair and modernization services to restore performance and reliability. Our work includes wiring and PLC repairs, pump and valve service, alignment and lubrication adjustments, and precise calibration of pressure, temperature, and flow controls. We specialize in PID speed tuning, furnace and press optimization, and PLC modernization — including migration from legacy systems, integration with HMI/SCADA, and safety-rated upgrades. Real-time SCADA and ERP connections ensure accurate data, improved efficiency, and long-term system reliability.
Restoring Performance Through Precision Repairs and Upgrades
Corrective Repairs & Upgrades
Our team delivers fast, reliable repair and upgrade solutions to restore your extrusion line’s performance and efficiency. From electrical and hydraulic systems to PLC modernization, we keep your equipment running at its best.
We provide comprehensive electrical, hydraulic, and mechanical repair services to restore extrusion performance and reliability. This includes wiring, sensors, control panels, PLCs, switches, and motors; pumps, valves, hoses, seals, cylinders, and pressure adjustments; as well as drives, bearings, lubrication systems, alignment, and other wear components.
Our calibration and tuning services ensure precise control throughout the extrusion process. We fine-tune pump controls, hydraulic pressure, billet heating, load cells, flow meters, valves, and encoder systems. Closed-loop speed control with PID tuning, furnace tuning, and press tuning all work together to maintain stable pressure, consistent ram speed, and superior product quality.
We modernize outdated control systems by migrating legacy PLC platforms (Siemens S5, Allen-Bradley SLC, Omron, and others) to current, supported hardware. Our upgrades include structured PLC programming, integration with HMI/SCADA systems, Ethernet/IP or Profinet networking, redundancy for reliability, safety-rated PLCs, and seamless connection to plant-wide data systems.
We connect extrusion operations to the digital plant environment with real-time SCADA and ERP integration. This allows for live production monitoring, OEE tracking, performance analysis, and smarter decision-making — giving your team complete visibility and control over every stage of the process.
-Design and fabrication of tailored handling systems for extrusion lines
– Solutions for billet loaders, log loaders, billet conveyors, profile stackers, destackers, automated basket handling, and basket warehousing systems
– Built to integrate seamlessly with new or existing presses
– Focus on reducing downtime, improving workflow, and increasing overall line efficiency
– Engineered for safety, reliability, and long-term durability
– Integration of safety PLCs and certified hardware
– Installation of light curtains, interlocked gates, and laser scanners
– Development of functional safety layouts and zone definitions
– Safety requirements specification, including safety matrices
– Compliance with ISO, OSHA, and industry safety regulations
– Risk reduction analysis and corrective actions
– Operator training on safe extrusion press operation
-Design and fabrication of tailored handling systems for extrusion lines
– Solutions for billet loaders, log loaders, billet conveyors, profile stackers, destackers, automated basket handling, and basket warehousing systems
– Built to integrate seamlessly with new or existing presses
– Focus on reducing downtime, improving workflow, and increasing overall line efficiency
– Engineered for safety, reliability, and long-term durability
– Preventive and predictive maintenance program development
– Integration of SCADA/ERP for production visibility and decision support
– Safety audits and compliance strategies
– Guidance on modernization paths: PLC migration, Industry 4.0, and digital transformation initiatives
Operational Consulting (Productivity & Quality Focused)
– Dead cycle optimization – reducing non-productive press time between billets to maximize throughput
– Butt-end scrap reduction – implementing procedures and equipment adjustments that maximize billet yield and improve die cleanliness
– Puller and stretcher synchronization – fine-tuning settings to reduce bowing, twisting, and dimensional variation in profiles
– Hydraulic and cooling system balancing – eliminating flow/pressure inconsistencies that cause slowdowns, chatter, or uneven extrusion speed
– Log oven and billet temperature control – ensuring thermal consistency for improved metallurgical properties and extrusion quality
– Press alignment and vibration control – addressing wear, backlash, and misalignment issues that shorten die/tool life and impact product stability
What To Expect When working with Gateway Industrial Automation
When you choose us, you receive:
Detailed Findings and Recommendations
Each service begins with a thorough inspection and data analysis, providing clear, actionable insights into equipment condition, root causes of issues, and steps needed to restore optimal performance.Joint Repair Execution with Your Maintenance Team
We work directly alongside your in-house maintenance personnel when needed, ensuring seamless coordination, efficient repairs, and hands-on knowledge transfer for future upkeep.Full Operational Testing After Service
Once repairs or adjustments are completed, we perform comprehensive operational tests to confirm that all systems are functioning properly, safely, and at peak performance before returning the line to production.Comprehensive Service Report and Performance Benchmarks
After each service, you’ll receive a detailed report outlining the work performed, preventive maintenance recommendations, and key performance metrics — including extrusion speed, dead cycle time, scrap rate, and energy efficiency — to help track ongoing improvements.
Why Choose Us
What Sets Us Apart
With decades of proven experience in Aluminum Extrusion, our team delivers the knowledge and reliability needed to keep your extrusion operation performing at its best.
25+ Years of Industry Expertise: Extensive hands-on experience with all major extrusion press designs and manufacturers.
Electrical, hydraulic, mechanical, controls, safety, and remote service capabilities under one roof.
PLC upgrades, SCADA and ERP integration, and full safety compliance for future-ready operations.
Serving automotive, aerospace, and architectural markets with both on-site and remote service options.
We'd Love To Hear From You
contact us
Find us Here
-
152 Main Street
Milladore, WI 54454
Open Hours
- Monday-Sunday
- 24 Hours
Ready to improve performance? Let’s get started...
With over 40 years of combined experience, Gateway Industrial Automation partners with manufacturers across the U.S. to design, integrate, and support smarter, more reliable automation systems. Reach out today and let’s start your next project.
Contact Info
- 152, Main Street Milladore WI 54454
- Mon - Sun 24 Hours
- info@gatewayautomation.tech
- 715-716-0055 (Shaun)
- 715-610-1565 (Tim)