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Novelis building $2.5 billion Alabama aluminum mill in milestone project

A $2.5 billion aluminum mill being built by Atlanta-based Novelis in the South Alabama Mega Site in Baldwin County is the first facility of its kind to be constructed in the U.S. for 40 years.

Novelis said the Alabama mill will leverage the company’s long-term relationships with leading beverage, packaging and automotive brands seeking sustainable aluminum solutions.

Commissioning of the facility, which will employ 1,000 people at full production, is scheduled for mid-2025.

“Through this investment, we want to demonstrate the strength of our growing customer partnerships, the commitment we have to sustainably grow our business, and the innovative, forward-thinking approach we are taking to modern manufacturing,” said Steve Fisher, president and CEO of Novelis.

Novelis said the new plant will be the most sophisticated and sustainable of its kind and will have a strong focus on employee safety.

The magnitude of this project makes it a game-changing development for Alabama’s industrial sector and a jobs engine for the region. The facility will be powered with renewable energy, use recycled water and be a zero-waste facility.

In addition, the Baldwin County plant will make use of advanced automation and digital technologies, including artificial intelligence, augmented reality and robotics.

The facility will have an initial 600 kilotonnes of finished aluminum goods capacity per year focused on the beverage container market, with flexibility for automotive production.

The project also adds a new recycling center for beverage cans, increasing the company’s recycling capacity by 15 billion cans per year when fully operational.

“Novelis’ decision to locate the nation’s most technologically advanced aluminum mill in Baldwin County is a powerful testament to both the state’s attractive business climate and to the capabilities of our talented manufacturing workforce,” said Greg Canfield, Secretary of the Alabama Department of Commerce.

“The magnitude of this project makes it a game-changing development for Alabama’s industrial sector and a jobs engine for the region.”

At a ground-breaking ceremony for its project to build a $2.5 billion aluminum mill in Baldwin County, Novelis arranged boxes of Cokes and Sprites to spell out ‘Made in Alabama.’ (Image: Governor’s Office/Hal Yeager)

AIDT, the state’s primary workforce development agency and part of the Alabama Department of Commerce, is assisting Novelis in assembling and training of its workforce.

The project was first announced in May 2022.

By the time a ground-breaking ceremony was held for the project in October 2022, Novelis was already moving full steam ahead on the project.

The company had already selected its core leadership team for the facility and had begun actively recruiting for open roles in engineering, maintenance, finance, human resources and IT.

“With this massive investment and large-scale hiring plans, Novelis will launch a high-tech aluminum mill that will generate significant economic impacts throughout the region for generations,” Governor Kay Ivey said.

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