Hydro invests $53.5m in 5,900Mt aluminum extrusion press in Pennsylvania

Hydro has begun construction of a new 5,900 metric ton indirect aluminum extrusion press line at its Cressona facility in Pennsylvania, backed by a $53.5 million investment aimed at modernizing production, expanding specialist extrusion capacity, and strengthening the company’s North American manufacturing operations.

The groundbreaking took place on October 27, with operations expected to commence in the first quarter of 2028. The new press will replace equipment dating from the 1950s and introduce Industry 4.0 technology, advanced automation, improved energy efficiency, and enhanced safety performance.

New press targets growing demand for specialist extrusions

The investment comes as demand for indirect aluminum extrusions continues to grow across commercial transportation, automotive, and electrical markets. Customers in these sectors increasingly require profiles with consistent dimensions, improved grain structure, and reliable mechanical properties.

Hydro expects the new equipment to improve production efficiency and product quality while expanding its capacity to serve these applications.

“We are extremely proud of this new equipment and the additional capabilities it brings to Hydro Cressona. This project will improve efficiency, enhance product quality, and expand our indirect extrusion capacity to serve the growing needs of our key customers,” said Mike Hammer, vice president and general manager of Hydro Extrusion North America’s Industrial and Distribution Region.

Unlike conventional direct extrusion, in which a billet moves towards a stationary die, indirect extrusion involves the die moving into the billet. This reduces friction between the billet and the container and can support more consistent dimensions, grain structure, and mechanical properties.

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Cressona remains central to Hydro’s US manufacturing strategy

Hydro’s Cressona facility is the largest aluminum extrusion site in the Western Hemisphere, according to the company. Originally built in 1942 by the US government, the site covers approximately 148,000 square meters under a roof and employs more than 1,200 people.

Its existing operations include nine extrusion presses, three extrusion ingot casting units, fabrication capabilities, and a distribution warehouse. Hydro said it has invested more than $150 million in the site over the past three years.

Across the United States, the company employs nearly 6,000 people and operates 19 production sites in 14 states. Hydro also plans to invest more than $800 million in its US operations over the next five years.

Hydro raises concerns over equipment tariffs

Alongside its investment plans, Hydro has raised concerns about US tariff policies affecting specialized manufacturing equipment produced in Europe. The company said elevated and frequently changing tariffs increase capital costs and create uncertainty for domestic manufacturers.

“This investment is about much more than a new piece of equipment. It is about Cressona, our employees, our customers, and the future of manufacturing in North America. Cressona continues to serve as the keystone of our North American operations, and we’ve invested more than $150 million in the site over the past three years. We remain fiercely committed to investing in our U.S. operations, but the aluminum industry needs more nuanced trade policies that do not increase the cost of capital equipment and hinder industrial growth,” said Jeff Lehman, business unit president of Extrusion North America.

The Cressona press project represents the latest step in Hydro’s efforts to modernize its North American extrusion operations while responding to demand for higher-performance aluminum profiles. Its planned commissioning in early 2028 will mark the next stage of the facility’s production upgrade.

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