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Aluminum Insights Breaks Ground on New Extrusion Facility

Aluminum Insights
Aluminum Insights founders at the groundbreaking ceremony (L-R): Steve Brenneman, business development; Niles Graber Alvarez, chief financial officer; and Jeff Miller, chief executive officer. (Source: Aluminum Insights.)

Aluminum Insights broke ground on its new, $17.5 million, state-of-the art aluminum extrusion facility in Syracuse, Indiana. Founded in 2020, Aluminum Insights is a start up company that aims to serve a select group of customers in the Upper Midwest to support their extrusion needs, integrate seamlessly into their supply chain, and partner in innovation.

The new extrusion facility will be housed in a 76,000-square-foot building, which features 500 kilowatts of rooftop solar and eight acres of native grassland and trees surrounding the plant.

The extrusion press the company has chosen is made by Italy-based Presezzi Extrusion Group, which is a world-class, 2,920-ton, 8-inch press line that includes the latest in automation and mechanical technology and advanced safety features. Besides the high-efficiency 26 MN indirect extrusion press, the site will include a CNC fabrication area, which will include routing, cutting, and machining of extrusions.

The new 26 MN indirect extrusion press, supplied by Presezzi Extrusion Group, will process 8-inch billets between 600 and 1800 mm in length. It includes the PE.E.S.S. energy-saving system, which features a variable frequency drive (VFD) that minimizes energy consumption and reduces dead cycle time, which  consequently increases productivity.

The human-machine interface (HMI) for the press includes a dedicated control pulpit designed with integrated diagnostics, energy management, and Industry 4.0 machinery feedback, including maintenance and remote service support.

In addition to the extrusion press, Presezzi will also supply the COIM log oven and handling area and the complete handling system, including a HECS® air/water quenching system, a single-puller with flying saw, a cooling table, a 50-ton stretcher, a finishing saw, an automated stacker, and basket handling conveyors, as well as the aging oven.

“Bringing equipment of this caliber to a new facility designed specifically for this purpose will enable us to operate at a very high level from inception,” said Jeff Miller, CEO of Aluminum Insights. “For those in our surrounding communities interested in learning something new, this business creates unique opportunities to be part of a world-class team and world-class extrusion operation.”

Based on Aluminum Insights’ job creation plan, the Indiana Economic Development Corporation (IEDC) committed $825,000 in incentive-based tax credits. These tax credits are performance-based, meaning the company is eligible to claim incentives once local Indiana professionals are hired and investments are made.

Site construction of the new extrusion facility is underway, led by Ancon Construction. Installation of the extrusion equipment will begin in early January and is expected to be fully operational in April 2022.

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