Gemini Group expanded capacity and scale of the press tooling capabilities at its Consolidated Tool facility in Muscle Shoals, AL. The new equipment allows the operation to offer full-scope services to extruders of aluminum. copper, and brass, ranging from design and engineering to machining, validation, and refurbishment of large containers and press tooling components. This expansion allows the group’s aluminum extrusion tooling company to handle oversized and high-tonnage tooling, reduce lead times, and improve logistics for customers across the southern U.S.
Gemini Group made the decision to expand the Consolidated Tool facility in direct response to evolving needs within the extrusion industry, based on historical data from customers and the experience of Thumb Tool & Engineering, a member of the Gemini Group. “Extrusion presses being installed in the U.S. are increasingly larger in diameter, which requires significantly larger press tooling components, such as containers and related equipment,” said Jeff Weitenberner (Figure 1), vice president of Manufacturing – Tooling Segment, Gemini Group. “By expanding the Muscle Shoals facility, we were able to pivot the operation to focus on the manufacturing of large extrusion tooling components, allowing us to better support customers with shorter lead times and increased domestic capacity.”
Company Profile
Gemini Group is a diversified manufacturing organization with multiple operations strategically located across the U.S., serving several industrial markets. “Within the tooling segment, our companies specialize in the design, manufacturing, and refurbishment of extrusion dies, containers, and press tooling used in aluminum and other non-ferrous extrusion operations,” said Weitenberner. “Across our facilities, we offer a full range of services including extrusion die design and manufacturing, container manufacturing and refurbishment, press tooling components, technical consulting and troubleshooting, on-site die repair and training, and die shop management support and best-practice development. This integrated approach allows us to serve as a comprehensive tooling and technical partner for extrusion companies, rather than simply a tooling supplier.”
Gemini’s tooling segment includes four plants serving the aluminum extrusion sector, including Thumb Tool & Engineering in Bad Axe, MI (added to the group in 1996), MidSouth Central Extrusion Die in Muscle Shoals, AL (added in 2013), Tri-R Dies based in Youngstown, OH (added in 2021), and now Consolidated Tool in Muscle Shoals.
Over the last decade, Gemini Group has continued to invest heavily in expanding capabilities across these tooling operations to better support the evolving needs of the extrusion industry. This includes investments in software, tooling development, and technical services that support customers beyond just supplying tooling.
At Thumb Tool & Engineering (originally founded by Jack Rochefort in 1972), both mill capacity and 5-axis machining capabilities were expanded, allowing the plant to handle more complex tooling designs and increase overall production capacity. At MidSouth Central Extrusion Die, the group installed new equipment and capabilities, allowing the site to manufacture tooling up to 42 inches in diameter.
Following the acquisition of Tri-R Dies, an automated mill line was implemented at the site, which significantly increased throughput and consistency. “From a geographic standpoint, the Youngstown location helps us better serve customers throughout the Midwest and Eastern U.S., improving logistics and delivery times,” noted Weitenberner. “Operationally, Tri-R has been a strong addition to our tooling segment. With the implementation of automation and an automated mill line, the facility now offers industry-leading turnaround times for dies and tooling under 16 inches in diameter.”
Expanded Operations
The Consolidated Tool facility in Muscle Shoals has a long history within the Gemini Group, originally becoming part of the organization through the acquisition of Cockburn Enterprises in 2013, which also included MidSouth Central Extrusion Die. The 38,000 sq ft facility, which is primarily focused on die cast tooling manufacturing, continues to play an important role in the group’s tooling operations. Its central geographic location in Alabama providing logistical advantages, which reduces freight times and costs for many customers across the country.
With the completion of the group’s recent expansion project, the Consolidated Tool facility is now capable of manufacturing and refurbishing extrusion tooling. The planning and engineering for the expansion project were primarily handled by Gemini Group’s internal engineering team. “Many of the machining capabilities required for die cast tooling are similar to those needed for extrusion press tooling, which allowed us to leverage much of the existing equipment and machining expertise already present in the facility,” explained Weitenberner. “To support the new direction, we supplemented the existing equipment with specialized machinery designed specifically for large extrusion tooling components.”
To support the manufacturing of large tooling components up to 96 inches in diameter, 96 inches in length, and 110,000 lbs (55 tons), several key pieces of equipment were installed, including a turntable added to an existing boring mill, a custom honing machine and hone table (Figure 2), a long-bed CNC lathe (Figure 3), and a custom oven and drop-station press. Like many manufacturing projects over the past several years, equipment lead times were longer than originally anticipated. In part, this was due to the fact that much of the equipment required for this expansion was custom-engineered and purpose-built, which naturally contributed to their manufacturing time. As a result, some of the project timelines were pushed back, but the project has now been successfully completed and commissioned.
“For equipment installation, we worked closely with both the equipment manufacturers and our in-house maintenance teams to install and commission the new machinery and supporting systems,” said Weitenberner. “This collaborative approach allowed us to ensure the equipment was properly integrated into the facility and optimized for the new production capabilities.”
Training for the new processes at the Consolidated Tool site was supported by Gemini’s team at Thumb Tool & Engineering, which has been manufacturing and refurbishing containers since 2008. The Thumb Tool team worked closely with team members at the Muscle Shoals facility, providing hands-on training and cross-facility collaboration, thus ensuring the knowledge transfer necessary to successfully operate the new equipment.
“Our team members in Muscle Shoals have fully embraced the transition and expansion of the facility. They have invested significant time in training and developing the skills necessary to support the extrusion industry,” said Weitenberner. “We are confident that the Alabama team will deliver the same level of quality and service that our customers have come to expect from our other tooling locations.”
Conclusion
As extrusion presses continue to increase in size and capacity, the demand for larger press tooling components has grown significantly. The expansion of the Consolidated Tool facility in Muscle Shoals, which will primarily support extrusion press operations in the aluminum, copper, and brass industries, allows Gemini Group to support these larger presses and the companies operating them.
“One of the most exciting aspects of the expansion is the ability to offer customers a true one-stop solution for extruders,” noted Weitenberner. “With the capabilities across our facilities, we can now support extruders operating presses ranging from 3-inch billets up to 30-inch billets, manufacturing virtually all of their extrusion tooling components. In addition, the increased capacity allows us to shorten lead times and respond more quickly to customer needs, which is critical in extrusion operations.”
Editor’s Note: This article first appeared in the April 2026 issue of Light Metal Age. To receive the current issue, please subscribe.