FACTORY

Aluminij's Cast House produces aluminium billets, rolling ingots, and primary foundry alloys to international standards, with chemical compositions tailored to the specifications of our long-standing customers. Quality is ensured throughout the production process by a comprehensive suite of auxiliary equipment, including spectrum analysers, online hydrogen degassing systems, hydrogen detectors, ultrasonic billet testers, and homogenisation furnaces. All incoming materials are tested in our laboratory before entering the production process, ensuring that only materials meeting our quality standards are used.

Billets are produced by semi-continuous vertical casting using Wagstaff AirSlip technology, which delivers the highest quality billets characterised by a smooth surface finish, minimal shell zone, and uniform grain structure. The system accommodates diameters from 152 to 254 mm and strand counts from 36 to 78 billets per drop, providing significant flexibility across alloy grades and customer requirements.

Aluminij has invested continuously in its production technology and workforce to maintain and improve product quality, operational efficiency, and environmental performance. A comprehensive modernisation of the Aluminij facility was completed in 2002 at a cost of 250 million euros, introducing new production technologies that increased output, efficiency, and quality while significantly reducing noise levels and dust emissions. In 2008, the Green Anode Plant was modernised with the installation of a vacuum vibrocompactor from Outotec, and the existing fume treatment plant was replaced with a new system by Innovatherm, based on adsorption of anode furnace exhaust gases on an alumina surface.

Subsequent investment has focused on digitalisation, advanced quality control systems, and environmental protection technologies, ensuring that Aluminij's production methodology remains aligned with modern industrial standards.

Aluminij's laboratory provides continuous quality oversight at every stage of the production process. Each casting is subject to an in-depth chemical spectrum analysis and alloy composition spark test, ensuring that the chemical composition of every batch conforms to international standards and customer specifications. The laboratory's testing processes are continuously refined to maintain the highest levels of accuracy and reliability.

Aluminij employs fully automated ultrasonic testing as a standard component of quality inspection for aluminium extrusion billets and forging stock. Depending on the application, fully automatic linear or helical testing stations are integrated directly into the production flow or installed as standalone units. This approach moves beyond the random spot checks associated with portable hand-held equipment, providing reliable examination of all billet material — a requirement for highly stressed components used in the automotive and aerospace industries, where consistent quality is non-negotiable.

For billet surface quality control, Hertwich ultrasound surface inspection technology is used to detect even the smallest surface defects caused by the casting process. Any defects identified are removed automatically, ensuring that only flawless material proceeds through the production line.

Protecting the health and safety of all employees, business partners, and visitors is a fundamental responsibility at Aluminij. Security systems are installed throughout the facility to monitor and enforce safety protocols, and daily training and awareness programmes are provided for employees and contractors to maintain the highest standards of safety at all times.

All operations and activities are designed with the safety of people and the environment as a core principle. Work areas are continuously assessed for compliance with health and safety regulations, and Aluminij has invested significantly in ergonomics and employee wellbeing programmes. The company holds ISO 45001 certification for occupational health and safety management, independently accredited by Bureau Veritas, reflecting its commitment to maintaining a safe and healthy workplace across all operations.