EXTRUSION EXPERTISE. INDUSTRIAL EXECUTION.
Turn extrusion knowledge into
measurable performance
XtruAdvance helps aluminum extrusion companies improve productivity, quality, and profitability through practical engineering expertise, automation integration, and data-driven optimization.
25+
years of leadership
30+
plants worldwide
End to end
strategy to shop floor
INTEGRATED CAPABILITY
From the first constraint to sustained improvement.
XtruAdvance combines technical consulting, automation, intelligent optimization, and workforce development because lasting performance takes more than a recommendation.
XtruConsulting
Practical technical and strategic support for extrusion plants, OEMs and investors.
SR&ED tax credit support for Canadian projects
R&E tax credit support for U.S. projects
Technical eligibility assessments for extrusion innovation
Documentation of qualifying R&D activities and evidence
Support through reviews, audits, and specialized tax partnerships
About Tony
“The best process improvement is one the team understands, trusts, and can sustain.”
Engineering depth. Executive perspective. Shop-floor practicality.
Tony Da Silva is a Professional Engineer, MBA, and Six Sigma Black Belt with more than 25 years of leadership experience in aluminum extrusion.
Across North America, he has led plant startups, operational turnarounds, research and development, process improvement, and technology implementation for aerospace, automotive, transportation, industrial, and architectural markets.
Today, as founder of XtruAdvance, Tony helps extrusion companies improve service, quality, productivity, and enterprise value through consulting, training, automation, and intelligent optimization systems.
XtruAutomation
Extrusion process knowledge translated into reliable control logic and equipment integration.
Press productivity and bottleneck analysis
Die performance and metal-flow improvement
Recovery, scrap, and quality improvement
Technology officer and board advisory
Intelligence at the press
Operate closer to the true process limit.
Xtru-IQ combines extrusion science, production data and automation logic to identify the best operating window for each extrusion challenge.
- Reduce dependence on operator intuition
- Improve consistency across shifts
- Understand die and process limitations
- Increase output while protecting quality
XtruUniversity
Structured learning that turns extrusion science into confident shop-floor decisions.
6xxx alloy metallurgy
Operator and supervisor systems
Process optimization and troubleshooting
Die Running Light™ methodology
Extrusion fundamentals
Process understanding, 6xxx alloy metallurgy and the variables that govern stable production.
Optimize performance
Productivity, billet temperature, ram speed, recovery, die running and metal flow.
Solve problems
Structured troubleshooting, root-cause analysis and quality-focused decision making.
Transfer knowledge
Customized workshops, competency systems and durable internal training capability.
R&D Tax Incentives
You are already doing qualifying R&D.
Die trials, metal-flow investigations, process optimization, defect reduction, tooling development, and improvements to extrusion speed, temperature, recovery, and mechanical properties may qualify when they involve technological uncertainty and systematic experimentation.
The challenge is often not a lack of R&D—it is failing to identify and document the work already being performed.
XtruAdvance brings aluminum extrusion engineering expertise to the R&D incentive process. We help identify potentially qualifying experimental development, improve technical documentation, and work alongside specialized tax professionals to support strong, technically grounded claims.
Recognize experimental development already happening inside the plant.
Turn technical work into clear evidence of uncertainty, testing and advancement.
Work alongside specialized tax professionals to support stronger claims.
Selected career results
Credibility measured in outcomes.
Representative achievements from Tony’s operational and executive leadership work. Results vary by operation and engagement.
Expertise across the extrusion system.
Sharing practical extrusion knowledge.
- Blisters and Their Many Causes
- The Extrusion of Two-Piece Billets
- A Practical Approach for Comparing Extrudability: 6061 vs. 6005A
- Evaluating Factors Affecting Profile Extrudability
- Measurement of Process Capability for Anodizing Color
Testimonial
“Working with Tony is a pleasure. He brings deep technical expertise, a practical approach to problem-solving, and a clear focus on measurable results.”
Client name and company to be confirmed before publication.
Start a conversation
What is limiting your extrusion operation?
Bring the press constraint, quality issue, training gap or growth objective. We’ll begin with the problem and define the most useful next step.
- Confidential initial conversation
- Technical and executive perspective
- Practical next-step recommendation