- Aluminum is the third most abundant element in the nature and extrusion is valuable due to commercial fenestration and manufacturing products. Aluminum profiles are causing severe damage during the fabrication and installation process. Sawing, drilling, and tapping are the most common mechanical damages cause in aluminum profiles when subjected to the organic coating. Aluminum is interacting with the Alkali Hydroxides (Ca(OH)2, NaOH, KOH, RbOH, and CsOH) during the cement-based installation process [1]. There are several companies that involving to the manufacturing of aluminum profiles in Sri Lanka. In Sri Lanka, the film applying process of aluminum profiles is carried out by human hand. Due to this problem, companies are looking for solutions to minimize time consumption and cost. The aim of this study is to find a possible solution and design a machine to protect the surface of the aluminum profiles. The objective is to minimize the time consuming and cost-effective method for the film application process. The system was tested with different profile shapes and results were analyzed with the existing manual method. We observed that the designed machine was 87.04% more efficient than the manual existing method in Sri Lanka.

Keywords : Motor control, Alkali hydroxide, PLC, Organic coating, Aluminum fabrication, Motor drives, Microcontroller.