VERTICAL INTEGRATION
THE WHOLE ALUMINIUM JOURNEY,
IN ONE FACTORY
At the 5th km of the P.E.O. Larisis – Athinon, in 40,000 m² of covered space, EXALCO controls every stage of production: from recycling and alloy casting to extrusion, coating and thermal break, through to storage and distribution across Greece.
Explore the factory floor plan and see each department, its equipment and capacity.
INTERACTIVE FLOOR PLAN
THE FACTORY DEPARTMENTS
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FACTORY FLOOR PLAN · LARISSA
01 FACTORY DEPARTMENT
PAINT SHOP ENTRANCE
Paint shop side entrance
- 24/7 OPERATION
- 2 LOADING RAMPS
- 100% MATERIAL WEIGHING
The side entrance of the paint shop feeds the powder-coating lines with profiles from extrusion, separately from the factory’s main traffic.
- EQUIPMENT
- Supply gate & weighbridge
- CAPACITY
- Inbound materials for coating
- LOCATION / AREA
- North side
02 FACTORY DEPARTMENT
POWDER-COATING PLANT A
Powder-coating plant entrance
- 200+ COLOURS
- QUALICOAT CERTIFICATION
- 5.200 m² SURFACE
The first powder-coating line, with pre-treatment, curing ovens and automatic coating-thickness control, in line with the European QUALICOAT standards.
- EQUIPMENT
- Vertical coating line, QUALICOAT certified
- CAPACITY
- 200+ RAL, wood-effect & anodised finishes
- LOCATION / AREA
- Coating wing
03 FACTORY DEPARTMENT
POWDER-COATING PLANT B
Powder-coating plant entrance
- 2 COATING LINES
- 60+ SPECIAL FINISHES
- 100% THICKNESS CONTROL
A second coating line dedicated to special finishes, wood effects and custom colours made to order.
- EQUIPMENT
- Second coating line & sublimation
- CAPACITY
- Wood effects and special finishes
- LOCATION / AREA
- Coating wing
04 FACTORY DEPARTMENT
ROBOTIC RACK WAREHOUSE
Automated rack warehouse
- 100% AUTOMATION
- 3.000+ RACK LOCATIONS
- -40% RETRIEVAL TIME
A fully automated warehouse where robotic systems store and retrieve profile racks, cutting handling times and damage.
- EQUIPMENT
- Robotic rack retrieval system
- CAPACITY
- Automated management of thousands of locations
- LOCATION / AREA
- Central wing
05 FACTORY DEPARTMENT
THERMAL BREAK
Thermal break department
- 12,000 t PROFILES / YEAR
- 3.000 m² SURFACE
- EN SHEAR TESTS
In the thermal break department, profiles are joined with polyamide strips and tested for shear strength, producing the ALBIO thermally insulated systems.
- EQUIPMENT
- Polyamide strip insertion & rolling lines
- CAPACITY
- 12,000 t of thermal-break profiles / year
- LOCATION / AREA
- 3.000 m²
06 FACTORY DEPARTMENT
AUTOMATED PACKING
Automated packing department
- 3 PACKING LINES
- 100% BARCODE LABELLING
- 48h READY FOR LOADING
Finished profiles are automatically packed with protective film, barcode-labelled and sent on to the loading warehouses.
- EQUIPMENT
- Automated packing & labelling lines
- CAPACITY
- Pallets ready for loading
- LOCATION / AREA
- Central wing
07 FACTORY DEPARTMENT
EXPORT WAREHOUSES
Export loading warehouses
- 5 EXPORT CONTINENTS
- 4 STORAGE AREAS
- 12.000 m² SURFACE
The export loading warehouses consolidate orders by country and container, with dedicated loading ramps.
- EQUIPMENT
- 4 loading bays
- CAPACITY
- Exports to 5 continents
- LOCATION / AREA
- West wing
08 FACTORY DEPARTMENT
SPARE PARTS
Spare parts & storage
- 5.000+ PART NUMBERS
- 24h AVAILABILITY
- 100% ERP TRACKING
A central spare-parts store for presses, ovens and production lines, so that maintenance can be carried out without delay.
- EQUIPMENT
- Organised spare-parts store
- CAPACITY
- Immediate maintenance cover
- LOCATION / AREA
- West wing
09 FACTORY DEPARTMENT
ANODISING
Surface treatment department
- EN CERTIFIED ANODISING
- 20 µm OXIDE THICKNESS
- C5 CORROSION RESISTANCE
The anodising department, where aluminium gains a durable oxide layer, ideal for coastal and demanding environments.
- EQUIPMENT
- Anodising & electrolytic colouring baths
- CAPACITY
- Anodising certified to EN standards
- LOCATION / AREA
- West wing
10 FACTORY DEPARTMENT
EXTRUSION PRESSES
Presses 1600 · 1750 · 2200 · 2300 · 2840
- 5 PRESSES
- 27,000 t PROFILES / YEAR
- 8.000 m² SURFACE
The heart of the factory: five extrusion presses of different capacities, covering everything from slim sections to large and custom-designed profiles.
- EQUIPMENT
- 5 extrusion presses, 1,600 – 2,840 t
- CAPACITY
- 27,000 t of profiles / year
- LOCATION / AREA
- 8.000 m²
11 FACTORY DEPARTMENT
PRESS 1100
1100 press facility
- 1,100 t PRESS FORCE
- Ø 5'' BILLET DIAMETER
- 24/7 OPERATION
A stand-alone unit with a 1,100 t press, dedicated to small sections, trial runs and special orders.
- EQUIPMENT
- 1,100 t extrusion press
- CAPACITY
- Small & special sections
- LOCATION / AREA
- Separate building
12 FACTORY DEPARTMENT
DOMESTIC TRADE WAREHOUSES
Domestic trade loading warehouses
- 48h NATIONWIDE DELIVERY
- 5 WAREHOUSES
- 400+ PARTNERS
The domestic trade warehouses supply the nationwide partner network, with orders routed by region.
- EQUIPMENT
- 5 loading bays
- CAPACITY
- 48-hour delivery across Greece
- LOCATION / AREA
- South wing
13 FACTORY DEPARTMENT
DIES
Die manufacturing & repair department
- in-house DESIGN
- CNC MACHINING
- -50% LEAD TIME
The die shop designs, manufactures and repairs the extrusion dies, enabling fast production of custom profiles for industrial customers.
- EQUIPMENT
- CNC machining, hardening, inspection
- CAPACITY
- Custom sections designed in-house
- LOCATION / AREA
- South wing
14 FACTORY DEPARTMENT
CHANGING ROOMS & CANTEEN
Men’s / women’s changing rooms, canteen
- 400+ EMPLOYEES
- 2 CHANGING ROOMS
- 1 MEDICAL ROOM
Staff facilities include men’s and women’s changing rooms, a canteen and a medical room, ensuring safe and comfortable working conditions.
- EQUIPMENT
- Changing rooms, medical room, canteen
- CAPACITY
- 400+ employees across the group
- LOCATION / AREA
- Central staff zone
15 FACTORY DEPARTMENT
STAFF PARKING
Staff car park
- 120+ PARKING SPACES
- 3 SHIFTS
- SW ENTER
The staff car park is next to the factory entrance, with access kept separate from lorry traffic.
- EQUIPMENT
- Organised car park
- CAPACITY
- Serving all shifts
- LOCATION / AREA
- South-west entrance
GALLERY
