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is a company specialized in aluminium products, starting from its early days as a supplier of reflector components for local Italian companies to its present position as a supplier to all the world’s major lighting system producers. This specialisation has led the Group to become one of the world's biggest producers of components for the lighting technology, solar energy industries and decorative market.

The IRP process
Tooling
Deep Drawing
Brightening and anodizing

The IRP process

Integrated Reflector Program

The Integrated Reflector Program is a process designed to offer total assistance to the producer of lighting equipment:
from planning and design to the completion of the reflector.
It ensures greater efficiency, reduces design risks and limits development investment in the project.

Almeco's technical staff analyze client demands, define the geometric characteristics of the reflector and develop a virtual model, followed by a prototype tool.

In a matter of weeks, the client receives four prototype reflectors in standard finishes: Superbrite, Brite, Softlite and Matt-lite.

Thanks to the Almeco IRP program flexibility, it is also possible to test also not-standard materials (for example Vega 95 and Vega 98), according to the customer's requests.

Tooling

Almeco manufactures its own reflector tooling which then becomes the exclusive property of the customer.

Starting with the reflector design or with an optical model, a CAD model of the reflector tool is generated by the Technical Office and sent to the tooling department, where the deep-drawing and cutting punches and dies and the spinning mandrels or forms reflectors, are produced.

Deep Drawing

When the tools are ready, we proceed to mass production of the reflectors.
The principal forming operations are carried out using the processes of deep-drawing, spin forming and cutting and folding.

Almeco’s deep-drawing operation is a highly technical forming process used to mass produce hollow shapes with the aid of carefully designed long life punches and dies operating under hydraulic pressures with loads up to 250 tonnes.

In the spin forming process, computerised spinning lathes are used to shape symmetrical reflectors around a rotating mandrel or “form” at high speed.

The deep drawn and spun parts are treated afterwards in the piece part anodizing plant. Reflectors manufactured by die cutting and folding are usually manufactured from pre-anodized aluminium or Vega high reflectance products.

Brightening and anodizing

Once the mechanical shaping of the component is complete, it can pass to the surface finishing plant.

The processes used include cleaning, to remove metal working soils, electro-chemical brightening and anodizing.
To achieve these processes the reflectors are mounted on electrically conductive mountings, known as “jigs” and passed through the process stages in a plc controlled process sequence adapted to each particular reflector type.

The IRP process

Integrated Reflector Program

Read more about the ALP Almeco Led Program

Tooling

Deep Drawing

Brightening and anodizing