The new indirect extrusion press replaces two old presses and is part of Hydro’s ongoing efforts to increase efficiency and modernize its operations. The recycling expansion increases the facility’s capacity to more than 270,000 tons per year, the largest in Hydro. After the expansion, the recycling facility will be able to process 64,000 tons of post-consumer scrap annually, an increase of 30,000 tons.

“With these investments, we continue the development of the Cressona plant as a key part of Hydro Extrusions in North America. The increased efficiency and the ability to deliver recycled aluminum with a lower carbon footprint to our North American customers caters to the growing demand for more sustainable products,” says Jeff Lehman, Business Unit President, Extrusion North America.

Hydro’s facility in Cressona was built in 1942 by the U.S. government and is the largest aluminum extrusion site in North America with 15 hectares (149,000 square meters) under roof. The site has 1,100 employees and boasts 11 extrusion presses, three extrusion ingot casting units, extensive fabrication capabilities and a distribution warehouse.

Added benefits of indirect extrusion

The 3,000 ton, 12-inch indirect extrusion press has state-of-the-art technology, and is equipped with advanced automation and monitoring systems, which helps Extrusion North America to better serve key markets such as the transportation, distribution, and industrial sectors.

Indirect extrusion presses are less common than direct extrusion presses and Hydro’s only indirect extrusion presses are in North America. The benefits of the indirect extrusion process include more consistent dimensions, grain structure and mechanical properties compared to the direct extrusion process.

Closed-loop recycling system

The enhanced recycling capacity and capabilities support the shift toward a closed-loop system, allowing aluminum scrap to be reprocessed into new products, further advancing Hydro’s sustainability efforts.

The ability to process post-consumer aluminum scrap, aluminum that has lived a life in a product and comes back to be recycled, is important to create a more circular society where all materials are recycled. When using post-consumer aluminum scrap to make new products, the embedded carbon footprint in the material is significantly lower than average.

These dual investments come at a time when the demand for sustainable, low-carbon aluminum is rising across numerous industries, including automotive, building and construction, and distribution. With these expanded capabilities, Hydro is well-positioned to meet the growing expectations of North American customers who increasingly prioritize sustainability in their supply chains.