AI and IoT-enabled innovations enhance Sri Lanka’s export capability, operational efficiency and sustainable aluminium production

As global markets raise their expectations for manufacturing quality, traceability and operational efficiency, Alumex PLC, Sri Lanka’s leading aluminium manufacturer and a member of the Hayleys Group, has deployed four key AI and IoT-enabled digital innovations that directly strengthen its capacity to compete internationally and supply large-scale infrastructure projects vital to the country’s economy.

The deployments mark a significant step in Hayleys’ broader strategy to embed digital and AI transformation across its industrial portfolio, moving from isolated technology pilots to Group-wide capability that raises standards across sectors. The initiatives were delivered in collaboration with the Hayleys Group Digital Transformation Unit and technology partners UTECH and Dialog H One.

With approximately half of its revenue generated through exports to 17 countries across five continents including the UK, USA, Canada, Australia, New Zealand, Switzerland, Italy and Singapore, Alumex operates in an environment where quality consistency, production efficiency and sustainability credentials are the baseline requirements of global & local markets.

“Alumex competes in demanding international markets, and these initiatives are investments in our ability to meet the standards our customers expect, protect and grow our export business, and build a more capable and resilient organization,” said Pramuk Dediwela, Managing Director, Alumex PLC.

“These initiatives, developed in collaboration with the Hayleys Group Digital Transformation Unit to address these imperatives, reflect a philosophy that distinguishes Hayleys’ approach: digital transformation that empowers people, not just systems. By combining advanced technologies with the expertise of our teams, we are building smarter manufacturing capabilities that strengthen our competitiveness today while preparing the business for the future.”

At the centre of this transformation is a new AI and IoT-enabled aluminium extrusion line, replacing an older production system and introducing advanced digital capabilities to improve manufacturing precision, productivity and resource efficiency.

The new system strengthens production capacity while enabling greater process control, supporting consistent product quality for both international customers and Sri Lanka’s growing infrastructure sector. The technology is also expected to deliver significant energy efficiencies compared to traditional extrusion systems, contributing to Alumex’s sustainability objectives.

Complementing this investment is the AI-driven Golden Batch for Extrusion Digitisation, which enhances visibility across extrusion operations to support consistent manufacturing performance, continuous improvement and greater operational excellence. The capability strengthens Alumex’s ability to deliver high-quality products while creating a strong foundation for future digital manufacturing initiatives.

The company has also introduced an AI-powered Scrap Optimisation Tool that strengthens material planning, optimises alloy utilisation and supports more efficient resource management. The solution enhances manufacturing performance while advancing Alumex’s commitment to sustainable production and responsible resource utilisation.

Further strengthening digital accessibility across the organisation, the Alumex AI Knowledge Hub provides employees with instant access to operational knowledge, enabling faster decision-making and improving consistency in processes. By making critical information readily available, the platform empowers employees at every level to make better-informed decisions and supports a more connected, agile workforce.

In addition, an IoT-based Energy Monitoring System implemented across its Ekala, Sapugaskanda and Lindel manufacturing facilities, provides real-time visibility into energy consumption patterns. By enabling the company to identify inefficiencies and optimise energy use across its operations, the platform supports Alumex’s drive to improve energy efficiency and reduce its carbon footprint, while supporting informed decision-making, improved operational performance and enhanced sustainability reporting capabilities, which are increasingly important as global markets place greater emphasis on responsible manufacturing.

Together, these initiatives represent a significant step in Alumex’s evolution towards Industry 4.0 manufacturing, reinforcing its ability to compete in demanding export markets while demonstrating how digital innovation creates long-term value through smarter manufacturing, greater sustainability and empowered people.

Representatives from Alumex PLC, the Hayleys Group Digital Transformation Unit, and technology partner UTECH at the launch, marking a key milestone in Alumex’s digital and AI transformation

Image Caption  - Mr. Pramuk Dediwela, Managing Director of Alumex PLC, addresses the gathering at the unveiling of the company’s latest AI and IoT-enabled manufacturing innovations