From scrap to billets: ClearFlow plans major secondary aluminum investment in Kentucky

ClearFlow Metalworks plans to invest $28 million in a new aluminum manufacturing facility in Russellville, Kentucky, marking an expansion of secondary aluminum production in the United States. The project is expected to create 50 full-time jobs, with its first phase designed to deliver an estimated annual production capacity of approximately 100,000 tons.

The company, which focuses on sustainable aluminum recycling and production, will develop the facility in phases. Phase I will feature a secondary aluminum billet casting operation, processing recycled aluminum materials into billets for extrusion and other downstream manufacturing applications.

The project will establish ClearFlow's manufacturing presence in the U.S. and support domestic demand for aluminum products while expanding recycling and secondary metal production. The company plans to invest in a newly constructed speculative building at Shelton Lane Industrial Park in Russellville.

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Kentucky backs $28 million aluminum manufacturing project

The Kentucky Economic Development Finance Authority has preliminarily approved a 15-year performance-based incentive agreement that could provide ClearFlow with up to $1,000,500 in tax incentives. The incentives are contingent on the company meeting specified investment, employment, and wage targets.

Kentucky workforce service providers may also assist the company through recruitment and job-placement services, customized training, and job-training incentives.

"We are excited to partner with Logan County and the city of Russellville as we establish our operations in Kentucky," said John Dusanenko, CEO of ClearFlow Metalworks, in an October press release. "We are truly grateful for the support and collaboration we have received throughout this process."

Local officials also welcomed the investment, highlighting its potential contribution to employment and manufacturing activity in the region.

"We're proud to welcome ClearFlow Metalworks to Logan County and to the commonwealth of Kentucky," said Phil Baker, Logan County judge and executive. "We're excited to have them join our community, and we're ready to support their success as they put down roots here."

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Secondary aluminum production supports domestic manufacturing

The planned facility will focus on converting recycled aluminum into billets for downstream applications, including extrusion. Secondary aluminum production uses recovered metal as a feedstock, supporting the reuse of existing aluminum resources in manufacturing.

With an estimated annual production capacity of approximately 100,000 tons in its first phase, the Russellville project will add to the country's domestic aluminum manufacturing infrastructure. Its phased development approach will allow ClearFlow to establish its operations while supporting demand from U.S. manufacturers.

The investment also adds to a series of manufacturing projects announced in Kentucky across different industrial sectors. Recent developments include investments in beverage production, chemical distribution, piping manufacturing, and automotive supply operations.

For ClearFlow, the $28 million project represents a move into the U.S. manufacturing market, with secondary aluminum billet production forming the foundation of its planned operations.

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