From Scrap to Billet, Our World-Class Foundry Delivers Sustainable, High-Quality Aluminum at Scale.
Foundry & Billet Casting
Vertically Integrated. Sustainability Drive. Quality Assured.
ABC Aluminum Solutions operates one of North America’s most advanced aluminum foundry and billet casting facilities.
Our vertically integrated process transforms recycled aluminum scrap into high-performance billets—delivering unmatched consistency, precision, and sustainability.
Recycled-Content Remelt Plant
Our advanced remelt facility prioritizes recycled content, significantly reducing environmental impact while delivering exceptional-quality aluminum billets tailored for high-performance extrusions.
At ABC Aluminum Solutions, sustainability is central to our operation
- Industry-Leading Capacity & Capability: Over 60,000 metric tons, reinforcing supply security and flexibility for our customers.
- State-of-the-Art Technology: Advanced melting systems optimize energy efficiency, reducing natural gas consumption by over 40% compared to traditional furnaces.
- CO₂ Emissions Reduction: We save approximately 95% of energy compared to primary aluminum production, cutting annual CO2 emissions equal to removing 23,000+ Cars from the Road
Advanced Recycling & Scrap Processing
Our dedicated scrap processing line integrates the latest technologies for sorting, shredding, and purifying aluminum scrap.
Scrap Processing Line
Advanced shredding and alloy sorting for pure, ready-to-process aluminum material.
Automated Scrap Handling
Semi-automated machinery efficiently processes up to 5 tons/hour, enhancing throughput and energy efficiency.
Efficient Waste Recovery
Rotary furnaces with advanced cooling systems maximize metal recovery, minimizing waste.
Superior Aluminum Begins at the Source
From scrap to precision billets in 8 Steps
Scrap Selection & Preparation
Carefully sorted high-grade aluminum scrap, precisely combined with virgin aluminum (12–15%), ensures alloy consistency.
Melting & Precise Alloying
Dual-chamber furnaces melt aluminum uniformly; precise alloying ensures exact chemical specifications.
Precision Impurity Removal
Automated slagging systems efficiently eliminate impurities, ensuring premium billet purity.
Testing & Quality Monitoring
Continuous inline testing verifies that each billet batch meets rigorous quality standards.
Advanced Metal Treatment
Grain refinement, degassing, and filtration optimize billet strength and extrusion performance.
Horizontal Direct Chill Casting
Cutting-edge horizontal casting technology produces consistently uniform, high-grade billets.
Precision Cutting & Traceability
Laser-marked, precision-cut billets ensure complete traceability from casting through extrusion.
Billet Homogenization
Controlled heating and cooling cycles optimize billet microstructure, enhancing mechanical properties and extrudability.
Advanced Billet Casting Facility
Engineered for peak performance and efficiency, our billet cast house utilizes continuous horizontal casting (HPI technology), streamlining billet dimensions, reducing scrap, and improving productivity.
- Integrated Quality Assurance: Real-time filtration, degassing, and chemical management systems guarantee billet purity.
- Horizontal Casting Technology: Eliminates traditional casting pits, maximizing quality and minimizing waste.
- Homogenization for Superior Extrudability: Advanced heat-treatment ensures optimal billet microstructure and extrudability.
Commitment to Sustainability & Safety
Setting benchmarks in aluminum recycling and safety, our facility prioritizes environmental stewardship and workplace excellence.
At ABC Aluminum, we close the loop — recovering and recycling aluminum scrap locally to lower emissions, and promote a greener future.
- Advanced Emission Control
- Innovative fume treatment systems maintain emissions below stringent global standards.
- High Internal Scrap Recycling Rate:
- Recycling over 90% of internal scrap drastically reduces energy usage and carbon footprint.
- Safety & Efficiency Automation:
- Fully automated systems enhance operator safety, operational efficiency, and consistent reliability.
Self-Sufficient Billet Supply
With an annual casting capacity of 25,000 metric tons, we produce industry-standard billet diameters (6", 7", 8", 10", 12”) across key alloys including 6061, 6063, and 6005—ready for direct-to-production extrusion.
Wtih a Dedicated, Expert Foundry Team
Located adjacent to our extrusion facility, our advanced 75,000 sq ft foundry optimizes transportation and inventory management, minimizing environmental impact.
Our highly skilled foundry professionals embody ABC’s core values of continuous improvement, quality assurance, and stringent safety practices, consistently delivering exceptional productivity and unmatched reliability.
