Muscle Shoals aluminium plant, USA
Constellium's plant at Muscle Shoals is an aluminium manufacturing plant based in Alabama (USA) with over 1,200 employees. With its widest strip mill in the USA and a world-class recycling center, the site represents one of the largest sites within Constellium.
About Constellium's plant at Muscle Shoals
Muscle Shoals’ main product is aluminium can sheet for the packaging industry, particularly for beverage containers. It manufactures sheet used in all three components of an aluminum can, namely body stock, coated end stock and tab stock.
Additionally, Muscle Shoals’ rolls and finishes aluminum sheet wider than any other mill in North America.
To develop the site’s Body-in-White capabilities, Constellium plans to invest massively in the plant.
Constellium's plant at Muscle Shoals at a glance
Wise Alloys LLC
4805 Second Street
Muscle Shoals, AL 35661
Tel: +1 (256) 386 6000
Muscle Shoals plant's manufacturing capabilities
Constellium’s Element 13 facility is one of the world’s largest recyclers of used beverage containers in the world. Element 13 is a self-sufficient DC Casting Complex that is responsible for nearly half of Muscle Shoals Cast House input.
Constellium uses state-of-the-art electromagnetic casting in a Greenfield Casting Facility built within the alloys plant. Electromagnetic casting uses an electromagnetic field to levitate and contain molten aluminum prior to solidification, rather than the solid mold used in standard direct chill casting. This process creates a smoother ingot, or long piece of aluminum, that does not require scalping to remove rough edges, thus saving time and cost in the manufacturing process.
The hot rolling mill consists of a series of three mills that compress the 30,000+ pound slabs of aluminum. The process begins on a reversing mill, one of the largest in the industry, which reduces the slab, or ingot to four inches thick. The breakdown mill has automatic computer controls to ensure the flatness and surface quality requested by the customer.
The cold rolling area consists of several mills including a two stand, a three stand and a five-stand mill. The three-stand tandem cold mill is used for finished body stock for aluminum cans. This mill is equipped with hydraulic automatic gauge control, a shape meter, and the most modern controls available. Finished products vary in thickness from .0100 inches to above .0140 inches, and are conditioned by the cold working of the mill for formability and strength as per customer specifications.
End stock and similar packaging products go to an additional high-speed, state-of-the-art 66-inch line that trims, levels, pre-treats, rinses, applies and cures an organic coating on both sides of the aluminum sheet. These coatings can be clear base coats or a variety of colors and protective finishes, depending on end use.
Our Sheet Finishing department consists of multiple slitting operations to trim according to customer needs. We recycle 100% of all trim scrap, the trim is collected through a quick draft system and sent to a baler where we compress the scrap and collect it in a roll-off box that is picked up and returned to the Cast House.