• Closed-Loop Recycling • Mexican Aluminum Industry • Service Center Metals Ten Years & Growing Al Casting Conidence Built on innovation and reined through experience, Wagstaff billet and ingot casting technologies are a gateway to proitability. Casthouses around the world rely on the history, experience, and service offered by Wagstaff to foster conidence within the casting operation. That conidence is valuable and necessary to safely cast aluminum and to ultimately maximize proits in the marketplace. The leader in Direct Chill Casting Technology › Casting Machines › Automation › Rolling Ingot Casting Systems › Metal Level Control › Billet Casting Systems › Worldwide Service and Support To ind out how your operation can increase casting conidence Call +1 509 922 1404 | www.wagstaff.com Directory of Secondary Aluminum Equipment Mfrs and Suppliers Index Page 71 Categories/Companies Page 72 Alphabetical Listing of Companies Page 76 DEPARTMENTS: Light Metal World ............................................................................ Page 80 New Equipment Spotlight ............................................................... Page 84 Reg. U.S. Trademark Secondary News ............................................................................. Page 87 “The International Magazine of the Light Metal Industry” Extruder News ................................................................................. Page 88 Contracts & Expansions.................................................................. Page 90 July/August 2013 • Volume 71, No. 4 New Products/New Literature ......................................................... Page 91 International Patent Calendar ......................................................... Page 92 ARTICLES: Conference Calendar ...................................................................... Page 96 World Secondary Aluminum Industry Annual Review Classiieds ....................................................................................... Page 97 By Rudolf P. Pawlek .............................................................Page 6 Personalities & Plants ..................................................................... Page 98 Service Center Metals: In a Land of Hope and Dreams By Joseph C. Benedyk .........................................................Page 18 COVER: This large, 6 x 7 inch aluminum extruded rectangular bar is one of Service Center Metals (SCM) 6061 Manifold Thunder Bar products. Aluminium Two Thousand Congress 2013 – Milan The Virginia extruder tailors its soft alloy extrusion products solely for Highlights of Extrusion Presentations service center customers. Premium bar products are designed for supe- By Joseph C. Benedyk .........................................................Page 24 rior machineability with elevated mechanical properties and commercial Second International Aluminum Recycling dimensional tolerances. At their ten year anniversary mark, SCM has Workshop, Trondheim, Norway also begun building a compact remelt plant. See story on page 18. By Anne Kvithyld and John Green .......................................Page 30 Novelis Develops Sustainable Can Stock Copyright © 2013 by Fellom Publishing. All rights reserved. Interview with John Gardner, Novelis ........................................... Page 38 Articles may not be reproduced without written permission of the publisher. Grupo Cuprum: Mexico’s Largest Extrusion Company Publisher .......................ANN MARIE FELLOM By Andrea Svendsen............................................................Page 40 Associate Publisher ..................ERIC WESTLUND IMEDAL Congress Shows Robust Aluminum Industry Editor ..........................Joseph C. Benedyk By Andrea Svendsen............................................................Page 44 Managing Editor .................. Andrea Svendsen Aluminum Recycling in the 21st Century: Circulation Manager ..................Claudia Compian Challenges and Opportunities Contributing Editor ................... Rudolf Pawlek By Marshall Jinlong Wang ....................................................Page 62 th LIGHT METAL AGE (ISSN 0024-3345) is published bi-monthly by Fellom Pub- 75 Anniversary for Gillespie & Powers lishing Co., 170 South Spruce Avenue, Suite 120, South San Francisco, CA Custom Designed Aluminum Melting ......................................Page 66 94080-4519. SUBSCRIPTION RATES 2013, Hard Copy: 1 year U.S.— $52.00; 2 TMS Annual Meeting and Exhibition .......................................Page 68 years— $66.00; 3 years— $80.00. Surface mail rates, 1 Year— $92.00; 2 years— $136.00; 3 years— $180.00. Airmail rates, 1 Year — $122.00; 2 years— $206.00; 3 Extrusion Industry News & Technology years— $290.00. Digital: 1 year— $35.00. Back issues $12.00 each plus postage. Special single copy prices for large directory issues— $15.00 plus postage. In- Flying Cut Puller Systems ....................................................Page 52 dex— $2.00 per year. Periodicals Postage Paid at South San Francisco, CA, and at The Beneits of Wet Blasting for Extrusion Die Shops ........Page 54 additional mailing ofices. New Partnership Creates Tecalex USA ...............................Page 56 POSTMASTER: Send address changes to LIGHT METAL AGE, 170 South th Spruce Avenue, Suite 120, South San Francisco, CA 94080-4519. Brightline Celebrates 60 .....................................................Page 58 Phone: (650) 588-8832 • FAX: (650) 588-0901 Turla Delivers Handling System for Automotive Line ...........Page 60 email: [email protected] • www.lightmetalage.com 4 LIGHT METAL AGE, AUGUST 2013 The Novelis Yeongju recycling and casting center that opened in October 2012 is the largest aluminum beverage can recycling facility in Asia. (Photo courtesy of Novelis Inc.) World Secondary Aluminum Industry Annual Review By Rudolf P. Pawlek, Contributing Editor Editor’s Note: Companies covered in this review are those whose content is achieved, then one point is awarded.) Certain primary business is secondary aluminum production. However, limitations continue to prevent the aluminum industry this review is also comprised of companies with remelt facilities, from going to 100% recycled content including the avail- companies that process scrap from semifabricating processes (such ability and quality of recycled content sources, as well as as extrusion scrap, etc.), and companies that remelt aluminum the ability to maintain consistent inishes on products products (such as UBCs, automotive parts, etc.). with varying degrees of recycled materials versus those materials produced with higher concentrations of pri- This overview covers the period of June 2012 to June mary materials. 2013. In light of increasing energy and raw material pric- The demand for recycled aluminum for the automo- es for primary aluminum production, scrap is displac- tive market is also increasing, as auto manufacturers aim ing primary metal as feed for casthouses and foundries to not only decrease the weight in their vehicles, but also because it can cost 10-20% less. This has resulted in ris- to improve their carbon footprint across the entire value ing scrap prices and tight supply, which has caused some chain. smaller secondary smelters and recycling companies to close. Companies are looking more and more to increase Africa the worldwide amount of available scrap aluminum. Nigeria Novelis, Alcoa, and other organizations are investing in programs to increase the recycling rate of UBCs and In January 2013, the Federal Airports Authority of other scrap. Several companies are also starting to cre- Nigeria (FAAN) set up a special task force focused on ate closed-loop programs with their customers in order the disposal of abandoned aircraft in airports across the to ensure all scrap aluminum created during the manu- country. The aircraft, including models ranging from facturing process is sent back to the aluminum producer Fokker 28 and Embraer 100 to Boeing 727 and 737, will for recycling. be taken away, dismantled, and used as scrap aluminum Some companies have been making major capital in- for recycling and conversion into corrugated aluminum vestments to expand their recycling capacities. Novelis, rooing sheet, sliding doors, windows, and other small- in particular, is in the process of doubling its worldwide scale industrial use. capacity through expansions at its facilities in Germany, Italy, South Korea, and Brazil. Both Alcoa and Aleris Re- South Africa cycling have invested in recycling expansions, as well, in the U.S. and Germany. In November 2012, Hulamin Limited entered into an Architects and the construction industry in general agreement with Bevcan, a division of Nampak Limited, continue to move towards a higher recycled content to supply aluminum sheet for the manufacture of alumi- product. Recycled content in aluminum-based products num bodied beverage cans. Deliveries to Bevcan are ex- is a valuable asset as it relates to LEED Certiication in pected to increase to 14,000 tons by 2015, in addition to buildings. The industry still operates under the LEED the can end and tab stock Hulamin already supplies. In 2009 edition, where recycled content materials can con- conjunction with this announcement, the company also tribute up to two points to a building’s total LEED points. reported that it is considering an appropriate investment (To achieve the two points the project must have at least in recycling infrastructure to reprocess UBCs back into 20% recycled content, based on cost