Hydro held a ground breaking ceremony on October 27, marking the start of construction of a new 5,900 tonne indirect extrusion press line at Cressona, Pennsylvania. The US$53.5 million investment will modernize production capabilities of the plant, as well as strengthening Hydro’s North American manufacturing footprint.
“We are extremely proud of this new equipment and the additional capabilities it brings to Hydro Cressona,” said Mike Hammer, vice president and general manager of Hydro Extrusion North America’s Industrial and Distribution Region. “This project will improve efficiency, enhance product quality and expand our indirect extrusion capacity to serve the growing needs of our key customers.”
Hydro has a robust presence in the United States, with nearly 6,000 employees and 19 production sites across 14 states. With plans to invest more than US$800 million over the next five years, the company has raised concerns about the impact of U.S. tariff policy on the competitiveness of domestic manufacturing. Extrusion presses and other specialized equipment produced only in Europe are currently subject to elevated and frequently changing tariffs that increase costs and drive uncertainty.
The new investment in its Cressona facility is the the latest step in Hydro’s strategic modernization efforts in North America. Originally built in 1942 by the U.S. government, Hydro’s facility in Cressona is one of the largest aluminum extrusion plants in the western hemisphere, with 15.8 hectares (148,000 sq m) under roof. The site has more than 1,200 employees, nine extrusion presses, three extrusion ingot casting units, extensive fabrication capabilities, and a distribution warehouse.
The Cressona investment plan will replace equipment dating from the 1950’s with state of the art indirect extrusion press. Rather than moving the billet toward a stationary die (as in direct extrusion), the indirect extrusion process moves the die toward the billet, reducing friction between the billet and the container. This can can provide more consistent dimensions, grain structure, and mechanical properties, making it well suited to demanding applications where consistency and product performance are important. The new indirect press will also bring Industry 4.0 technology, advanced automation, increased energy efficiency, and deliver best in class safety performance.
At Hydro Cressona, demand for indirect extrusions is growing in markets including commercial transportation, automotive, and electrical, where customers increasingly require high performance profiles with consistent dimensions, superior grain structure, and consistent mechanical properties. Indirect extrusion is a specialized process that will support Cressona’s efforts to serve these markets.
“This investment is about much more than a new piece of equipment. It is about Cressona, our employees, our customers and the future of manufacturing in North America,” said Jeff Lehman, business unit president, Hydro Extrusion North America. “Cressona continues to serve as the keystone of our North American operations, and we’ve invested more than USD 150 million in the site over the past three years. We remain fiercely committed to investing in our U.S. operations, but the aluminum industry needs more nuanced trade policies that do not increase the cost of capital equipment and hinder industrial growth.”
Hydro expects to commence operations of its new indirect press in the first quarter of 2028.