Production
For our projects, where it is required or recommended by the consultant, ALCON sections are extruded from imported prime quality billets of aluminum alloy AA6063, the internationally recommended alloy for architectural and structural applications.
The billet is imported from certified sources like Dubai and Alba, conforming to ASTM B221 and BS 1474 standards. High-quality imported materials and direct facilitation by international associates, along with proper certifications and permits, enable us to cut shipping, production, assembly, and delivery time in half.
We specialize in various extrusion alloys for architectural applications, conforming to AA6063 & AA6061 alloy designations (ASTM B221-08 standards). We also have the capability to develop aluminum alloy 3003 & 2024 for aerospace applications.
Our foundry follows strict safety standards in melting and workmanship. Each piece is thoroughly examined before proceeding to the next phase. We ensure the use of high-purity primary ingots and PVC rods for the finest quality production.
New Mujahid Alcon Industries (Pvt.) Limited has a state-of-the-art foundry with a 20-ton/day melting capacity. Our systematic raw material inventory is structured to ensure convenience and affordability for all clients.
At ALCON, quality and consistency are never compromised. Each production checkpoint is supervised for quality control. We respond to market needs, offering variety in pricing and quantity, ensuring maximum efficiency and client satisfaction.
Production
For our projects, where it is required or recommended by the consultant, ALCON sections are extruded from imported prime quality billets of aluminum alloy AA6063, the internationally recommended alloy for architectural and structural applications. The billet is imported from certified sources like Dubai and Alba, conforming to ASTM B221 and BS 1474 standards. High-quality imported materials and direct facilitation by international associates, along with proper certifications and permits, enable us to cut shipping, production, assembly, and delivery time in half.
We specialize in various extrusion alloys for architectural applications, conforming to AA6063 & AA6061 alloy designations (ASTM B221-08 standards). We also have the capability to develop aluminum alloy 3003 & 2024 for aerospace applications.
Our foundry follows strict safety standards in melting and workmanship. Each piece is thoroughly examined before proceeding to the next phase. We ensure the use of high-purity primary ingots and PVC rods for the finest quality production. New Mujahid Alcon Industries (Pvt.) Limited has a state-of-the-art foundry with a 20-ton/day melting capacity. Our systematic raw material inventory is structured to ensure convenience and affordability for all clients.
At ALCON, quality and consistency are never compromised. Each production checkpoint is supervised for quality control. We respond to market needs, offering variety in pricing and quantity, ensuring maximum efficiency and client satisfaction.
Imported AA6063 Billets
After age hardening at 175 to 190°C, extrusion profiles are tested according to ASTM B647-10 using the Webster Hardness Gauge to measure indentation hardness. To avoid issues like eutectic melting or sub-surface porosity from hydrogen diffusion, constant monitoring is conducted to maintain the material's tensile properties. Metallographic examination is also carried out for further assurance.
Our extrusion profiles meet the standards of BS1474 and ASTM-B 9450. Throughout the extrusion process, temperature measuring points, including those for billet heating, pre-press charging, and press exit, are continuously monitored and controlled. The extruded profiles are sized, stretched for uniformity, and age hardened in a gas-fired oven per ANSI H-35.1 for Aluminum Alloys 6063-T6 & 60601-T6.
Imported AA6063 Billets
After age hardening at 175 to 190°C, extrusion profiles are tested according to ASTM B647-10 using the Webster Hardness Gauge to measure indentation hardness. To avoid issues like eutectic melting or sub-surface porosity from hydrogen diffusion, constant monitoring is conducted to maintain the material's tensile properties. Metallographic examination is also carried out for further assurance.
Our extrusion profiles meet the standards of BS1474 and ASTM-B 9450. Throughout the extrusion process, temperature measuring points, including those for billet heating, pre-press charging, and press exit, are continuously monitored and controlled. The extruded profiles are sized, stretched for uniformity, and age hardened in a gas-fired oven per ANSI H-35.1 for Aluminum Alloys 6063-T6 & 60601-T6.
Extrusion
At Alcon, we operate multiple extrusion presses, including two main variants: 1600 MT (Germany) and 1000 MT (USA), which can handle diameters from 152 mm to 178 mm and lengths of 520 mm. These presses are ideal for extruding, anodizing, powder coating, and die work. All presses are equipped with inversion apparatus for smooth operation and speed control to achieve the desired finish.
Our production plant features three extrusion lines: 1000 MT, 1600 MT, and 600 MT, using billets of 127 mm, 139 mm, and 152 mm. With proper maintenance, we can produce over 5000 tons of high-grade aluminum profiles annually. These profiles conform to ASTM-B221 and BS-147 standards. We use 5.5", 6", and 7" diameter billets, which are homogenized and 100% ultrasonically inspected. AA6063 aluminum is a standard for architectural and structural applications, making it easy to extrude, anodize, powder coat, and die.
Extrusion
At Alcon, we operate multiple extrusion presses, including two main variants: 1600 MT (Germany) and 1000 MT (USA), which can handle diameters from 152 mm to 178 mm and lengths of 520 mm. These presses are ideal for extruding, anodizing, powder coating, and die work. All presses are equipped with inversion apparatus for smooth operation and speed control to achieve the desired finish.
Our production plant features three extrusion lines: 1000 MT, 1600 MT, and 600 MT, using billets of 127 mm, 139 mm, and 152 mm. With proper maintenance, we can produce over 5000 tons of high-grade aluminum profiles annually. These profiles conform to ASTM-B221 and BS-147 standards. We use 5.5", 6", and 7" diameter billets, which are homogenized and 100% ultrasonically inspected. AA6063 aluminum is a standard for architectural and structural applications, making it easy to extrude, anodize, powder coat, and die.
Anodizing
Alcon uses a multiple overhead crane system to safely transfer each aluminum profile through various chemical baths. The chemical composition, including pH levels, conductivity, dielectric properties, sealing effectiveness, color matching, and stability, is closely monitored. The aluminum profile is buffed using a buffing machine to refine the surface before undergoing degreasing, etching, rinsing, and anodizing. Deionized water is used throughout the anodizing process to prevent contamination.
Our anodizing unit is equipped with six 6000A DC capacity PLC-controlled systems, backed by chillers to regulate bath temperatures. Anodizing is an electrolytic process that coats metallic surfaces with a protective or decorative oxide layer. This anodic coating, made of hydrated aluminum oxide, is resistant to corrosion and abrasion. Our process follows the British Standard BS3987 and meets environmental and safety directives set by the FDA, USDA, ELV, WEEE, and RoHS.
Anodizing
Alcon uses a multiple overhead crane system to safely transfer each aluminum profile through various chemical baths. The chemical composition, including pH levels, conductivity, dielectric properties, sealing effectiveness, color matching, and stability, is closely monitored. The aluminum profile is buffed using a buffing machine to refine the surface before undergoing degreasing, etching, rinsing, and anodizing. Deionized water is used throughout the anodizing process to prevent contamination.
Our anodizing unit is equipped with six 6000A DC capacity PLC-controlled systems, backed by chillers to regulate bath temperatures. Anodizing is an electrolytic process that coats metallic surfaces with a protective or decorative oxide layer. This anodic coating, made of hydrated aluminum oxide, is resistant to corrosion and abrasion. Our process follows the British Standard BS3987 and meets environmental and safety directives set by the FDA, USDA, ELV, WEEE, and RoHS.
Powder Coating
New Mujahid Alcon Industries (Pvt.) Ltd has also installed an advanced powder coating facility for aluminum sections. We offer polyester, durable polyester, and super-durable polyester powders. Our facility ensures high-quality powder-coated products with excellent aesthetics, a wide range of colors, and UV and humidity resistance up to 90 microns. Thermosetting formulations meet architectural requirements for durability and appearance.
We use 'Jotun' as our primary color range and have recently introduced Kynar500 resin-based architectural (PVDF) coatings. At Alcon, we can produce coating thickness layers between 12 to 25 microns in dull, champagne, light champagne, brown, and black finishes, ensuring high-quality and long-lasting results.
Powder Coating
New Mujahid Alcon Industries (Pvt.) Ltd has also installed an advanced powder coating facility for aluminum sections. We offer polyester, durable polyester, and super-durable polyester powders. Our facility ensures high-quality powder-coated products with excellent aesthetics, a wide range of colors, and UV and humidity resistance up to 90 microns. Thermosetting formulations meet architectural requirements for durability and appearance.
We use 'Jotun' as our primary color range and have recently introduced Kynar500 resin-based architectural (PVDF) coatings. At Alcon, we can produce coating thickness layers between 12 to 25 microns in dull, champagne, light champagne, brown, and black finishes, ensuring high-quality and long-lasting results.
Die Workshop
Die cutting is perhaps the most significant element in the production of high-quality products and requires great skill and technologically advanced die design and cutting-edge machinery. At Alcon, we are well-equipped in all aspects—skill and technology—to meet these requirements. We place great emphasis on developing a die shop of modern standards.
Tempering is carried out at 510°C, followed by case hardening in a nitrating furnace to achieve a hardened surface for maximum billet production and finish. Tooling is carried out by CNC milling, followed by surface grinding, polishing, blasting, and indenting for precise tracking and record-keeping.
Power Generation
At Alcon, we are capable of generating 3 MegaWatts of power, thanks to our brand-new power plant installation, ensuring seamless operations and sustainability.
Die Workshop
Die cutting is perhaps the most significant element in the production of high-quality products and requires great skill and technologically advanced die design and cutting-edge machinery. At Alcon, we are well-equipped in all aspects—skill and technology—to meet these requirements. We place great emphasis on developing a die shop of modern standards.
Tempering is carried out at 510°C, followed by case hardening in a nitrating furnace to achieve a hardened surface for maximum billet production and finish. Tooling is carried out by CNC milling, followed by surface grinding, polishing, blasting, and indenting for precise tracking and record-keeping.
Power Generation
At Alcon, we are capable of generating 3 MegaWatts of power, thanks to our brand-new power plant installation, ensuring seamless operations and sustainability.
Manufacturing
Alcon has built a strong reputation for excellence in manufacturing and installation, earning trust and recognition from architects, project consultants, and clients alike. This reputation has naturally led to a growing demand for Alcon’s services in delivering innovative architectural solutions.
To meet this demand, Alcon established specialized divisions focused on aluminum curtain walls, coatings, architectural glass, and stainless steel. Each division operates independently while synergizing seamlessly with others to ensure project success.
Through consistent advancements in scale, technology, and design, Alcon has steadily grown to become a major player in the architectural envelope and glazing industry. Today, Alcon stands as a trusted partner for façade solutions across diverse markets, supported by a dedicated workforce committed to delivering excellence worldwide.
Manufacturing
Alcon has built a strong reputation for excellence in manufacturing and installation, earning trust and recognition from architects, project consultants, and clients alike. This reputation has naturally led to a growing demand for Alcon’s services in delivering innovative architectural solutions. To meet this demand, Alcon established specialized divisions focused on aluminum curtain walls, coatings, architectural glass, and stainless steel. Each division operates independently while synergizing seamlessly with others to ensure project success.
Through consistent advancements in scale, technology, and design, Alcon has steadily grown to become a major player in the architectural envelope and glazing industry. Today, Alcon stands as a trusted partner for façade solutions across diverse markets, supported by a dedicated workforce committed to delivering excellence worldwide.
Aluminium Curtain-Wall Manufacturing Facility
Automated Precision Manufacturing
Alcon stands out as a trusted name in the industry, providing a complete end-to-end solution. We design, engineer, manufacture, and install our products, ensuring our clients enjoy unparalleled security and a single point of warranty coverage.
Our automated manufacturing facilities are equipped to handle intricate processes with ease, while maintaining the flexibility to produce a wide variety of product variants. This allows us to meet the specific needs of our clients, regardless of complexity or scale.
“We have invested heavily in the most advanced manufacturing systems supplied by leading brands such as Elumatec, Siemens, AXYZ, Dubus, and Dadong.”
Aluminium Curtain-Wall Manufacturing Facility
Automated Precision Manufacturing
Alcon stands out as a trusted name in the industry, providing a complete end-to-end solution. We design, engineer, manufacture, and install our products, ensuring our clients enjoy unparalleled security and a single point of warranty coverage. Our automated manufacturing facilities are equipped to handle intricate processes with ease, while maintaining the flexibility to produce a wide variety of product variants. This allows us to meet the specific needs of our clients, regardless of complexity or scale.
“We have invested heavily in the most advanced manufacturing systems supplied by leading brands such as Elumatec, Siemens, AXYZ, Dubus, and Dadong.”
Sustainable Construction
Alcon leverages state-of-the-art design tools and manufacturing processes to transform architectural concepts into reality while prioritizing sustainability.
We are dedicated to reducing the CO2 footprint of our projects through responsible manufacturing practices and energy-efficient selections of glass products.
Our expertise also extends to supporting accreditation for sustainable building standards such as BREEAM and LEED, ensuring our projects meet the highest benchmarks for eco-friendly construction.
Sustainable Construction
Alcon leverages state-of-the-art design tools and manufacturing processes to transform architectural concepts into reality while prioritizing sustainability.
We are dedicated to reducing the CO2 footprint of our projects through responsible manufacturing practices and energy-efficient selections of glass products.
Our expertise also extends to supporting accreditation for sustainable building standards such as BREEAM and LEED, ensuring our projects meet the highest benchmarks for eco-friendly construction.
Architectural Glass Processing Facility
Alcon's Architectural Glass Processing Facility meets the needs of interactive building design and modern construction. Our state-of-the-art equipment enables us to transform architectural concepts into reality with precision and quality.
Operating under a strict quality regime, our facility holds certifications from international insulating and safety councils, along with accreditations for specialized processing.
"We support the accreditation of sustainable building codes such as BREEAM and LEED."
Architectural Glass Processing Facility
Alcon's Architectural Glass Processing Facility meets the needs of interactive building design and modern construction. Our state-of-the-art equipment enables us to transform architectural concepts into reality with precision and quality.
Operating under a strict quality regime, our facility holds certifications from international insulating and safety councils, along with accreditations for specialized processing.
"We support the accreditation of sustainable building codes such as BREEAM and LEED."
Steel & Stainless-Steel Processing Facility
Alcon offers customized steel fabrication solutions to meet any project requirements. With extensive experience, we deliver high-quality, coordinated steelwork on time and within budget. Our expertise supports curtain wall glass systems, façades, canopies, and skylight support structures.
"We maintain our position at the forefront of steel fabrication by adopting cutting-edge technologies."
Steel & Stainless-Steel Processing Facility
Alcon offers customized steel fabrication solutions to meet any project requirements. With extensive experience, we deliver high-quality, coordinated steelwork on time and within budget. Our expertise supports curtain wall glass systems, façades, canopies, and skylight support structures.
"We maintain our position at the forefront of steel fabrication by adopting cutting-edge technologies."