HC4000 Extruder

The Holton Crest HC4000 Rotary Extrusion machine is specifically designed around the CRE process, with the latest dual axis machine including the very latest technology and digital control systems, enabling precision control measures at all times.

With a maximum production rate of 4,000 kg per hour (for copper processing) and the capacity to manage feed material from 19 to 28mm diameter, the HC4000 is a high output, high precision machine, designed around the individual requirements of our customers.

Holton Crest HC4000 Extruder

The Holton Crest rotary extruders are uncompromising in design and build, constructed to be superior in quality, performance and reliability; essential requirements within the hot, dusty and dirty CRE process. Our powerful and adaptable extruders have been designed using decades of experience and advanced 3D CAD software, with a comprehensive programme of research and development to continually improve the technology and process to deliver optimum production levels and the highest quality extruded products.

Our depth of knowledge and single-minded focus on the extrusion process, combined with the use of new technology ensures precise tooling control of our HC4000 dual axis machine, providing the best possible conditions for the extrusion process throughout the life of the tooling and a superior extruded product every time. In fact, our HC4000 machine for aluminium recently installed in Europe is the largest single machine CRE contract to date, which really demonstrates our ability to deliver at the highest level, with many different applications and configurations.

Machine Description

The HC4000 is our flagship machine with high output of high precision products where extreme load carrying capacity is matched with high production rates.

Detailed information on each of the main component parts can be found below:

Machine Base and Head Frame

The extruder base consists of fabricated and precision machined steel structures with mountings for the machine head, main drive, cartridge change table and supporting systems.

The machine head frame consists of a bolted and dowelled substantial steel structure secured to the base assembly.  The head is through-bored to accept the main shaft assembly.  This critical component has been extensively stress tested using industry leading FEA to ensure maximum longevity and trouble-free service.

Main Shaft Assembly

The extrusion wheel is supported by a flange on either side and held in place by the front and rear bearing hubs. These components are clamped together by means of a large central tie-bolt screwed into the front bearing hub and pre-stressed by a hydraulically loaded nut. This feature gives essential compressive support to the extrusion wheel together with providing a means for dismantling of the main shaft assembly for rapid extrusion wheel replacement. Drive to the extrusion wheel is transmitted through the rear hub and flange using a combination of friction and dowels.

The main shaft bearings are high capacity spherical roller bearings mounted on the front and rear bearing hubs. The bearings and shaft assembly are mounted directly into the main head side plates and retained with sealed housings. The bearings are supplied with continuously filtered and temperature controlled lubrication oil.

Main Drive

The Main Drive consists of a variable speed DC electric motor coupled to a multi-stage bevel-helical reduction gearbox with a right-angle output shaft. This configuration results in the motor and gearbox being parallel to the extrusion line, thus saving space. Input and output shaft connections to the main drive gearbox are by grease-filled double engagement gear couplings.


The central cartridge assembly contains the groove sealing segments and the extrusion die. It consists of a faceted steel block with cut-outs to suit the various die combination pieces. The cartridge, with its tooling in place can be quickly removed from the machine for die maintenance.

The cartridge holder assembly & shear provides support for the cartridge and contains temperature control systems to improved process consistency whilst managing the excess heat generated by the process. A hydraulically controlled shear blade cuts the extruded product once the production run has been completed.


Clamp Assemblies

The cartridge within its holder is clamped from behind, below and above. The clamping pressures are dynamically adjusted to precisely balance the opposing process forces and keep the cartridge in the optimum working position. The upper and lower clamps are integrated into the head-frame and the rear clamp is held in position by two hydraulically actuated latch pins. In order to change the cartridge the latch pins are retracted and the rear clamp and cartridge holder are driven back. The cartridge may then be pulled out of the holder and onto an adjacent table ready for maintenance or exchange.

Hydraulic System

The hydraulic system consists of two hydraulic power packs. One provides medium and high pressure supply to the precision critical components while the other one supplies low and medium pressure to the rest of the extruder for general operation.

Coining Roll

The feedstock is guided under a hydraulically adjustable, compacting roller which compresses the rod into the wheel groove. The compressed rod is then carried round by the wheel to the extrusion zone. The coining wheel is carried in substantial roller bearings, mounted in a hydraulically adjustable frame, enabling the penetration of the wheel in the groove to be adjusted. The hydraulic power is provided by connecting to the machine hydraulic system. The compacting wheel of the coining roll assembly is a separate piece which can be replaced in the event of damage, wear, or change of groove size.

The Wheel Scraper and Inlet Rod Shear are situated on the inlet side of the wheel. The scraper removes any leakage material from the wheel in order to keep it clean and to avoid the build-up of material on the outside of the cartridge. A shear is provided to cut the feedstock and stop the process to enable die or coil changes.

Cooling System

A cooling water system is provided to cool the main shaft hubs, cartridge holder and coining roll shaft . Additional supply and drain points are provided for standard accessories. The cooling water is recirculated via a pump and water-to-water heat exchanger.

In addition, a gas tube and cooling trough are situated directly after the extruder to provide immediate cooling and conditioning of the product. The temperature controlled and filtered water is held in a reservoir and uses adjustable flood and spray nozzles to supply directly to the product. This is followed by an air drying unit.

Digital Control System

The electrical control system is based around a PLC system which controls all aspects of the line with control voltages of 115V AC and 24V DC.  A touch screen desk is provided for monitoring and control of all the machine functions. All systems are interlocked to prevent incorrect status on the line.  Faults displayed are, for example, motor overloads, over-temperature, flow loss etc.  An audible alarm is supplied for machine running faults. Local push buttons are located on the machine for functions executed within their vicinity, for example feedstock shear or cartridge table up/down.


All Holton Crest machines now come with our new digital control software with full PLC and near real-time control, enabling adaptive control for a stable process with precise control measures.

HC4000 Performance

All Holton Crest machines are specifically designed around the Continuous Rotary Extrusion process to deliver high performance and optimum production output with a superior quality extruded product at all times.

The following table highlights the performance data of the HC4000 extruder. All figures are genuine and proven performance statistics and highlight the high performance nature of our equipment.

We are specialists in Continuous Rotary Extrusion, ensuring that our machines are specifically designed around optimising the process for the best possible production output.

Coilers and Supporting Equipment

The core scope of supply from Holton Crest includes a machine, control system, hydraulics and product cooling, all exclusively designed and built to individual customer requirements. We also provide a coiler and/or payoff for our machines, which are specifically designed around our own processes, and can come with auto changeover at full speed. Different payoffs can be supplied, dependant upon specific customer needs – from rotary, to automatic, vertical and more.


More information on our range of ancillary products can be found below:


Our range of coilers and take up units are used to wind extruded products onto drums. For single product take up, the TU26 Traversing Take Up Unit is an ideal solution, with the unit traversing to allow neat layers of wound product.

The frame allows for varying drum sizes and the drive is carefully controlled to ensure coil quality is maintained.

Auto Change Coilers

Holton Crest has designed and manufactured an automatic changeover twin coiler that is designed to continuously wind wire produced on a Holton Crest machine into open coils without any interruption in production speed.

The unit consists of two horizontally mounted expanding mandrels. When the required coil size has been wound, the wire is sheared from that coil and automatically hooked onto the other mandrel to start producing the next coil.

Cut to Length



Holton Crest machines can accept a wide range of different feedstocks, from cast bar to rod and granular particle feed. We provide a range of different payoff methods to ensure a smooth, fast payoff whilst supporting your individual requirements, including:

Rotary Payoff - Includes a payoff turntable for accommodating continuously cast copper or aluminium rod feedstock.

Automatic Vertical Payoff - Allows for single or dual input configurations, with twin coils being automatically unwound vertically and straightened before entering the extruder, enabling precise control over feedstock preparation.

Particle Feed - Includes a particle hopper mounted on top of the extruder to allow for continuous feed of granular feedstock and controlled production.

Product Cooling

Product cooling is a key part of the continuous rotary extrusion process, minimising oxidisation and ensuring the high quality of the extruded product. The Holton Crest cooling unit consists of a free standing tank and cooling trough.