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Spectro Alloys Completes Phase One of Billet Casting Expansion in Minnesota

An industrial building in the snow© by Spectro Alloys

Spectro Alloys Corp., a Midwest secondary foundry alloy producer, completed the first phase of construction on the expansion of its Rosemount campus in Minnesota. The expansion allows for the production of aluminum billet and improves recycling rates in Minnesota while meeting growing demand for recycled aluminum.

“This increase in capacity and capabilities means Spectro will have a greater impact on recycling rates in Minnesota, on meeting the needs of sustainable manufacturers, and on advancing the increasingly vital circular economy,” said Luke Palen, president of Spectro Alloys.

Aluminum is infinitely recyclable, and recycling requires 95% less electricity than producing new metal and generates a fraction of the greenhouse gas emissions. Aluminum billet is used as raw material by extruders to manufacture profiles for products like railings, window and door trim, and structural components for cars, boats, airplanes, trailers, docks, and more. Sheet ingot is a high purity slab of aluminum weighing up to 60,000 pounds that serves as feedstock for rolling mills.

Founded in 1973, Spectro Alloys operates one of the highest efficiency aluminum recycling plants in the U.S. The company provides high-quality recycled aluminum alloys to regional die casters and foundries, where it is made into new products for the automotive, power sports, and other industries. Recycling at Spectro Alloys involves shredding, sorting, and processing aluminum with the most advanced technology used in the industry today. In 2024, Emirates Global Aluminium purchased a majority share of Spectro.

Phase one of the expansion project includes a 90,000 sq ft addition that enables Spectro Alloys to expand its product offering into billet produced from post-consumer scrap aluminum. New equipment will be assembled and calibrated in the facility over the next several months. This facility will create an estimated 50 new jobs and add nearly 120 million lbs per year of additional recycling capacity to Spectro.

Opus was the design-builder and architect of record on the project. “We applaud Opus for their partnership on this project. Their depth of expertise, the quality of their work, and their ability to meet our compressed timeline were second-to-none and set us up to make a much more significant impact on our environmental performance and the economy,” said Palen.

“We are thrilled that Spectro Alloys found value in our design-build model and trusted us to deliver their facility on time and on budget, both of which we did,” said John Williams, vice president of construction with Opus. “It’s always rewarding to partner with clients who are doing good work, and, in the case of Spectro, to partner on a project that will have tangible, meaningful benefits today and well into the future.”

First production at the expanded operation is expected to begin in the second half of 2025. Full production ramp-up is expected in the first quarter of 2026.

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