Novelis relies on Danieli for its new, 1-Mtpy greenfield complex for aluminium strip

Leading flat-rolled aluminium producer Novelis –recognized as one of the world’s largest recyclers of aluminium– is relying on Danieli technology for its new plant to be built in Bay Minette, Alabama, USA.

Through this investment, the American producer will add annual production capacity for one million tons of the most advanced aluminium alloys, specifically for can stock and the automotive industry applications.

The new complex –consisting of a 1+4 hot-strip mill, a continuous coating line, and a high-speed trimming line starring sturdy and modern equipment controlled by advanced automation– is expected to become a benchmark for the most advanced aluminium strip production.

The hot mill facility will set a new standard with cutting-edge features, including high-capacity bending systems, fast and accurate Hydraulic Gap Control cylinders for dynamic thickness regulation, fine passline adjustment system and Danieli's patented Optimized Shaped Roll –OSR.

A high-speed continuous coating line, including patented roll-coater design for high-speed paint applications, as well as new semi-shells design for an air-floatation oven with improved air-fluid dynamics, will perform efficiently and in full respect of the strictest environmental regulations.

Coil finishing will be operated by a high-speed trimming line, including the widely recognized Danieli CNC trimmer technology for automatic knife positioning to achieve impeccable slitting quality and width tolerances. Surface inspection, inline coil preparation and oil coating by Danieli Coulombopt electrostatic oiling technology with integrated online oil-film measurement will complete the line for highest quality and maximum productivity.

The commissioning is expected to begin in the second half of calendar year 2026.