Golden Aluminum and SMS group commission next-generation strip caster

Golden Aluminum and SMS group have successfully commissioned the new nexcast® aluminum strip caster at the Fort Lupton site in Colorado, USA. The jointly developed technology enables the continuous casting of high-alloy aluminum grades in a compact, energy-efficient production line.

The nexcast® system replaces a 40-year-old casting unit and directly converts molten aluminum into 36-inch-wide hot-rolled coils. Designed and tested in Germany by SMS group, the caster achieved first coil production on July 5, 2025—just four weeks after installation began. It reached full production within its first month, completing casting campaigns of up to 60 hours and handling flexible alloy changeovers, including high-magnesium AA5182.

The new caster is the core of a fully integrated line for cold rolling and coating. It supports the cost-effective processing of aluminum with high scrap content and is designed to meet requirements in the packaging, automotive, and construction sectors.

Key to the system’s flexibility is its moving copper mold, which allows the casting of heat-treatable and high-alloy grades not typically feasible with conventional continuous casters. Smart process controls further enhance material properties through optimized downstream rolling and heat treatment.

Compared to conventional direct chill (DC) casting, nexcast® reduces energy use and carbon emissions by eliminating intermediate steps such as ingot casting. With a layout of under 60 meters from melting to coiling, the line also offers notable space and capital cost advantages.

Golden Aluminum CEO Jeff Frim highlighted the project as a major step forward, citing improved efficiency, sustainability, and expanded capabilities as key benefits of the collaboration with SMS group.

Source and Photo: SMS Group