Novelis produces first coil at Alabama's $5bn aluminum rolling and recycling plant
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Novelis Inc. has produced the first coil on the cold mill at its $5 billion Greenfield aluminum recycling and rolling plant in Bay Minette, Alabama, marking a major commissioning milestone for one of the largest new US aluminum manufacturing investments in decades.
The first-coil production moves the facility closer to customer qualification and commercial shipments, which Novelis said remain on track to begin in the second quarter of 2027. All assets required to commence commercial shipments are currently in the commissioning process.
Novelis moves toward commercial production
The Bay Minette facility is the first fully integrated aluminum recycling and rolling plant built in the United States in more than 40 years. Once fully operational, it will add 600 kilotonnes of annual rolled aluminum capacity, serving the beverage packaging, automotive, and specialty product markets.
Novelis President and CEO Steve Fisher said the first coil from the cold mill represents an important step in commissioning the facility and increasing the supply of rolled aluminum in the US.
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“With the North American market being capacity constrained, this investment will help Novelis meet long-term market demand, strengthen our U.S. manufacturing footprint and increase the use of recycled content in our products,” Fisher said.
The project is designed to strengthen Novelis’ manufacturing footprint at a time when the company sees capacity constraints across the North American market.
Integrated recycling capacity
Alongside the rolling operation, Bay Minette includes a recycling center capable of processing more than 15 billion used beverage cans annually.
The integrated setup is intended to increase the use of recycled aluminum in Novelis’ products while supporting its rolling capacity across key end-use markets.
Once fully operational, the advanced facility is expected to create up to 1,000 new jobs.
With first coil production now achieved, Novelis is progressing through commissioning and customer qualification ahead of the planned start of commercial shipments in Q2 2027.
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