“We are proud to be recognised as the most environmentally-friendly aluminium smelter in North America,” Jean-Pierre Bérubé, Vice President – Asset Management and Maintenance of Aluminerie Alouette

Jean-Pierre Bérubé joined Aluminerie Alouette in 2006 as Director of Maintenance. He subsequently held positions in the continuous improvement department as well as in the casthouse, metal shipping and energy sectors. In 2019, he became Senior Director, Metal and was responsible for the operation and optimisation of the potrooms, the gas treatment centres, and the casthouse. In 2021, he was appointed Vice President responsible for the anode plant, asset management and maintenance, potrooms and casthouse.

Mr Bérubé, originally from Rimouski, Quebec (Canada), holds a Bachelor's degree in Mechanical Engineering from Laval University. He began his career on the North Shore in the pulp and paper industry which led him to settle in the municipality of Port-Cartier in 1997. He then held various roles in industrial maintenance and continued his professional development in operations, process controls as well as in energy production.

In this interview with AL Circle, Mr Bérubé has shared his in-depth insights into the Americas aluminium market and how the company Aluminerie Alouette plans to capitalise on the market.

AL Circle: Can you provide a brief overview of Alouette's history and current position in the aluminium industry, particularly in the Americas?

Jean-Pierre Bérubé: Alouette was founded in 1992, responding to both a critical economic necessity in the region and the need to diversify the local economy. This created a deep-rooted bond with the community right from the start.

In 2005, Alouette took a major step forward by doubling its primary aluminium production capacity in a second phase of expansion. 

Today, after more than three decades in operation, Alouette proudly employs over 900 people and has a production capacity of 630,000 tonnes of primary aluminium. As the largest private employer in Sept-Îles and the largest aluminium smelter in the Americas, Alouette has been a Quebec jewel for over 30 years. Its contribution to Canada is considerable, representing almost 20% of the country’s total aluminium production and generating significant economic spin-offs amounting to 300 million dollars every year in Quebec province.

This remarkable success story would not have been possible without the steadfast commitment of our employees, the ongoing support of the community, the collaboration of our valued partners and suppliers, and the unwavering support of our shareholders. Together, we continue to write the Alouette story, propelling our company into an even brighter future.

AL Circle: Alouette is known for its high-quality aluminium production. Could you share some insights into your production processes and how you maintain the quality standards?

Jean-Pierre Bérubé: From the outset, Aluminerie Alouette has been committed to producing green and responsible aluminium. This vision is at the heart of our mission as a company deeply rooted in the principles of sustainable development. We maintain exceptional health, safety and environmental standards, demonstrating our commitment as a responsible employer and corporate citizen.

Our ability to continually reinvent ourselves is based in large part on our corporate culture of continuous improvement. Innovation is part of our DNA, stimulated by the expertise and commitment of our employees. They are constantly striving to improve our work processes and practices, while integrating the necessary changes. This culture of continuous improvement has enabled Alouette to integrate sustainable development practices for many years now.

At the heart of our operations, the health and safety of our employees remains an unchanging priority. Everything is designed to ensure a safe working environment. 

With this in mind, we meet or exceed the most stringent industry standards. Our certifications and accreditations, including Aluminium Stewardship Initiative (ASI) and ISO standards (9001, 14001, 45001), are tangible proof of this. This quest for excellence continues to guide Alouette towards a sustainable and prosperous future.

AL Circle: What are the key products or alloys that Alouette specializes in, and how do they cater to the unique demands in the American market?

Jean-Pierre Bérubé: As an aluminium smelter specializing in the production of primary aluminium, our mission is to manufacture environmentally friendly quality aluminium for a demanding global customer base. Our vision is to offer a product with a minimal carbon footprint, while maintaining optimum efficiency in all our processes.

We are proud to be recognised as the most environmentally-friendly aluminium smelter in North America. This outstanding performance in green aluminium production is the result of our ongoing process optimisation, aimed at constantly reducing our greenhouse gas emissions. What's more, our cutting-edge technological advances and privileged access to a clean energy source, hydroelectricity, play an essential role in our ability to produce superior-quality, environmentally-friendly aluminium.

AL Circle: Can you discuss recent innovations or technological advancements that have improved Alouette's manufacturing processes?

Jean-Pierre Bérubé: Alouette stands out as a pioneer in Industry 4.0 within its sector of activity. Driven by a culture of innovation, Alouette is committed to the constant optimisation of its processes and working methods, emphasising efficiency, product excellence, and the production of green aluminium. In this spirit of innovation, we started the journey to transform casthouse operations to 4.0 standards. This includes robotisation, casting automation up to remote operation surveillance. Alouette is recognised internationally for its outstanding leadership. Our primary production casthouse is hailed as the most efficient in North America, testifying to our steadfast commitment to research and development.

In reduction area, we have also embarked on a digital transformation, integrating data collection, analysis and artificial intelligence.

We maintain close ties with the community, particularly with academic institutions such as the University of Québec at Chicoutimi and the Cegep of Sept-Îles (College Degree), enabling us to collaborate on innovative projects, new technological advances testing as well as our employees competencies development on this specific aspects.

Finally, Alouette's aluminium smelter has a test plant with 18 dedicated pots. This provides us with a unique testing ground for new techniques and operating procedures, furthering our quest for excellence.

AL Circle: Sustainability is a growing concern in the industry. How does Alouette approach environmental responsibility in its operations, from sourcing raw materials to production processes? Are there specific sustainability initiatives or goals that Alouette has set for the coming years to reduce its environmental footprint?

Jean-Pierre Bérubé: A commitment to excellence and sustainable development is at the very heart of Aluminerie Alouette's culture. Since its inception, our aluminium smelter has made significant progress, notably reducing its specific greenhouse gas emissions per tonne of aluminium by over 40% through process optimisation. We are also proud to point out that over 80% of our residues are recycled as part of our internal operations fostering an internal circular economy.

What's more, our privileged strategic position enables us to transport most of our aluminium to our customers by vessels via the St. Lawrence Seaway, commonly known as the "blue highway".

However, our ambition goes far beyond these achievements. Alouette's goal is to be carbon neutral by 2050, and we are putting in place the necessary means to achieve this ambitious objective. Over the past two years, we have intensified our ESG (Environmental, Social, Corporate Governance) commitment by integrating globally recognised metrics. In addition, we have put in place a structure to ensure rapid progress, particularly in the areas of energy efficiency, research projects and carbon neutrality.

AL Circle: What are the current market trends and challenges that Alouette is navigating in the Americas, and how is the company adapting to them?

Jean-Pierre Bérubé: The overriding challenge facing Alouette is to reconcile the increase of its production capacity with its ongoing quest to reduce its carbon footprint. This demanding duality reflects the major trends shaping the aluminium industry.

In a context where demand for aluminium is constantly evolving, Alouette must be agile to meet the changing needs of its customers while maintaining its commitment to environmental sustainability. This dynamic highlights the imperative need to innovate and adopt best practices to meet these challenges while remaining competitive.

The aluminium industry is at a critical juncture, with growth and sustainability at its core. Alouette is determined to seize these opportunities while overcoming the obstacles, thus affirming its position as a leader in this ever-changing environment.

AL Circle: Which manufacturing sector do you anticipate will be the key demand driver for aluminium in 2024?

Jean-Pierre Bérubé: The shift from fossil fuels to alternative energy is rapidly accelerating, marking an unprecedented and pivotal turning point in our energy landscape. To ensure a prosperous energy transition, two key sectors emerge as critical in terms of demand: the electrification of transportation and the growth of the battery industry.

As a producer of primary aluminium, we are positioning ourselves as a key player in meeting the growing demand for aluminium content linked to the new technologies deployed in electric vehicles. Our role is to anticipate and meet this growing demand. This strategic direction embodies our commitment to innovation and sustainability, positioning Alouette as an essential partner in the global energy transition.

AL Circle: How does Alouette plan to capitalise on the increasing demand for sustainable and lightweight aluminium in the automotive, construction, and aerospace sectors?

Jean-Pierre Bérubé: As one of the world's most environmentally-friendly aluminium smelters, Alouette has been committed to the production of green, responsible aluminium for many years. This strategic position makes us a key player in meeting the growing demand from the transportation sector.

We are determined not only to preserve this leadership position, but also to strengthen it even further to remain at the forefront of our sector. Our commitment to innovation and continuous improvement are the fundamental pillars that will guide us towards this goal. We see this quest for excellence as an unwavering commitment to a greener, more sustainable future, and we are determined to maintain our leadership in responsible aluminium production.

AL Circle: Looking ahead, what are Alouette's strategic plans for the future, especially in terms of expansion, product development, and regional growth in the Americas?

Jean-Pierre Bérubé: Our growth strategy aims to increase our production capacity, while significantly reducing our greenhouse gas emissions. This ambitious plan is based on optimising our existing assets.

Implementing this growth requires substantial investments to ensure the sustainability and modernisation of our operations. Our aim is to produce increasingly environmentally-friendly aluminium, while strengthening our position as an industry leader.
AL Circle: Alouette is recognised as a leader in the aluminium industry. How does the company maintain its leadership position, and what sets it apart from regional competitors?

Jean-Pierre Bérubé: Alouette is not just a company, it's a whole community that is supported and encouraged to grow.

This synergy is underpinned by the unwavering commitment of our employees, who play a vital role in the progress of our organisation. In an environment marked by scarcity of manpower, the remarkable involvement of our employees represents an invaluable asset for our company. We can also count on long-standing partners who share our vision of excellence, strengthening our community and contributing to our shared success.

Furthermore, our agile organisational framework, anchored by a management committee in Sept-Îles, empowers us to operate with flexibility and efficiency. This adaptability serves as a crucial resource, nurturing innovation and efficient decision-making, both integral components of our strategy to sustain leadership and drive continual progress. Our Alouette community, comprising our workforce, partners and our dynamic structure, remains the driving force behind our accomplishments and our capacity to remain at the industry's forefront.