Editor's Pick: Aluminium, the quiet alchemist transforming our everyday life from packaging to construction

The world of aluminium has always left me astonished. Every day, this "green metal" pushes the boundaries of possibility, silently weaving its way into every aspect of our lives. Like a quiet alchemist, aluminium strengthens and supports the modern world, blending into the fabric of our daily routines yet playing an indispensable role. It holds up our bridges and buildings, transforming the visions of architects and engineers into durable, sustainable realities. On the roads, aluminium lightens vehicles, boosting fuel efficiency, and in the skies, it shapes the wings of aircraft, making travel faster and greener. Our electronics also rely on it—aluminium is the "invisible guardian" within our phones and laptops, cooling and protecting them. Even in our homes, it wraps leftovers and frames windows, unobtrusively enhancing our daily lives.

But the list doesn't end there. Remember Tony Stark's high-tech Iron Man suit from the Marvel Universe? Aluminium alloy was a key component chosen for its strength and lightness. The Star Wars universe featured aluminium in the iconic ships, and even in Star Trek, it was a staple in Starfleet's starships. And in WALL-E, the 2008 Pixar classic, aluminium was integral to the small, endearing robot himself. In every universe - real or imagined, aluminium continues to shape new worlds, proving that this remarkable metal is far more than meets the eye.

Let's explore more to see how the green-metal is shaping every sector of the industry:

Light and clear: Aluminium steers transport greener gear

Aluminium, the "green metal," has become a game-changer in transforming the transportation sector. From the wheels to the frame, aluminium's lightweight properties reduce vehicle mass, boosting fuel efficiency and slashing emissions—a win for both drivers and the environment.

Gemilang International Ltd (GML), a Malaysian bus and bus body manufacturer listed on the Hong Kong Stock Exchange, announced a new contract with Al-Futtaim Auto & Machinery Company, a leading mobility provider in the United Arab Emirates. Through this agreement, Gemilang will supply 76 Volvo double-decker buses to the Dubai Roads and Transport Authority (Dubai RTA). Ramez Hamdan, FAMCO's Regional Managing Director, highlighted that this project is about more than just delivering buses; it's aimed at enhancing Dubai's entire public transportation network. The Dubai RTA initiative will include double-decker buses built on Volvo chassis and equipped with GML's advanced aluminium superstructure.

Norwegian aluminium and renewable energy company Norsk Hydro has signed a letter of intent with Dutch yacht builder Vaan Yachts BV to promote circularity within the yachting industry. Building on a five-year partnership, the two companies aim to create high-quality aluminium sheet material for Vaan's premium catamarans, prioritising the use of recycled post-consumer scrap. In Europe alone, approximately 80,000 recreational boats reach the end of their life cycle annually, presenting major environmental challenges due to limited recycling options for hulls made primarily of non-recyclable materials like fibreglass. Vaan Yachts is dedicated to addressing this issue by adopting a fully circular approach to boat building. Their mission is to use only recycled and recyclable materials, aligning with a responsible, low-impact lifestyle and paving the way for more sustainable sailing practices.

September 2024 saw a commercial revival in the Chinese market, fuelled by a recent economic stimulus package, with robust growth in car sales—especially in battery-electric and plug-in electric vehicles. Enhanced vehicle trade-in policies have also positively impacted domestic car sales and production, as reflected in a Shanghai Metals Market (SMM) survey. This boost in vehicle production, particularly in the electric sector, suggests a potential rise in aluminium demand, a vital material in automotive manufacturing. Data from SMM, based on the China Passenger Car Association survey, reveals that China's new energy passenger vehicle (NEPV) production surged by 51.5 per cent year-on-year and increased 16.2 per cent month-on-month, reaching 1.219 million units in September. This brings the total NEPV output for the first three quarters to 785.9 million tonnes, marking a 32.8 per cent increase year-on-year.

Ducab Group CEO Mohammed AlMutawa has projected a significant surge in aluminium demand, driven by the rise of electric vehicles (EVs). AlMutawa, who leads one of the UAE's largest manufacturing companies specialising in aluminium and copper wire and cable products, predicts that aluminium demand could increase tenfold from 2017, reaching nearly 10 million tonnes by 2030. This expected growth aligns with government policies aimed at reducing carbon emissions. AlMutawa noted that the use of primary extruded and rolled aluminium products in EVs will far surpass current levels in internal combustion engine (ICE) vehicles, with plug-in hybrid and fully battery-operated cars requiring 25 to 27 per cent more aluminium than ICE models. He also emphasised the potential shift toward primary aluminium over recycled scrap in EV production, reflecting a growing preference for premium materials in the sector.

Zhejiang Jinfei Kaida Wheel Co., Ltd. recently revealed that local market demand has surged, fuelled by major Chinese automotive brands such as Chang'an, Great Wall, and BYD establishing production bases in Thailand. As a result, the China-based manufacturer and distributor of automotive components, specialising in aluminium alloy wheels for cars, motorcycles, and electric vehicles, has announced plans to significantly increase investment in its Thai facility and enhance its production and delivery capabilities. The project, with a total investment of RMB 557.18 million, is progressing as planned and is set for completion in the fourth quarter of 2025. The facility is on track to meet its production target of 2 million new energy vehicle wheels annually. The plant will feature a "future factory" model, incorporating cutting-edge international processing equipment and a highly digitalised, intelligent control management system.

France, Greece, Italy, and Poland are among the major EU countries expected to support the imposition of up to 45 per cent tariffs on imports of Chinese-made electric vehicles (EVs), while Germany is likely to abstain. Despite concerns over potential retaliation from Beijing, the European Union is poised to approve the tariff proposal. The European Commission, which is conducting an anti-subsidy investigation into Chinese EVs, submitted the plan for a vote to the EU's 27 member states on October 4. Under EU regulations, the Commission can impose these tariffs for up to five years unless a qualified majority—15 member states representing 65 per cent of the EU population—votes against it. Sources and officials confirmed that France, Italy, Poland, and Greece are expected to back the measure, which together represent 39 per cent of the EU's population.

On October 14, 2024, Stellantis CEO Carlos Tavares warned that the European Union's decision to impose tariffs on Chinese-made electric vehicles (EVs) could accelerate plant closures across Europe. He cautioned that these tariffs might push Chinese automakers to build manufacturing facilities within Europe, further exacerbating local carmakers' overcapacity issues. As the tariffs come into effect, European governments, including Italy, are actively courting Asian automakers to establish regional production plants. This strategy could not only help these companies bypass the EU's import tariffs on EVs but also strengthen their presence and contribute to the growth of the European automotive sector, provided specific conditions are met.

Aluminium's spark: Powering the electrical mark

TrinaSolar, a global leader in photovoltaic and energy storage solutions, has announced the successful production of the world's first fully recycled crystalline silicon (c-Si) solar module. The innovation was developed by TrinaSolar's Research Centre Academy, leveraging their advanced in-house recycling technology. The module is crafted from recovered materials sourced from waste solar panels, including aluminium frames, silicon, silver, and glass. The process enables the full recycling of high-value materials from discarded photovoltaic panels, using innovative techniques such as proprietary interlayer separation reagents, chemical etching, and wet chemical silver extraction. The resulting recycled PV module features n-type TOPCon technology with a golden-size design, offering an impressive efficiency of 20.7 per cent and a power output exceeding 645 W.

Vishay Intertechnology, Inc. has expanded its 299 PHL-4TSI series of snap-in, four-terminal aluminium electrolytic capacitors, now offering voltage ratings of 350 V, 500 V, 550 V, and 600 V. This expansion provides designers with more flexible options for a range of applications. These capacitors are ideal for use in power supplies and inverters for both industrial and home appliance sectors. With the introduction of these higher voltage ratings, Vishay aims to help designers reduce component count, cut costs, and enhance the mechanical stability and longevity of end products.

Oman Cables Industry SAOG, a leading cable manufacturing company based in Al Rusayl Industrial City, has announced a strategic investment of RO 1.9 million (USD$4.94 million) into its subsidiary, Oman Aluminium Processing Industries SPC (OAPIL). Approved by the Board of Directors, this initiative is projected to achieve a 75 per cent internal rate of return (IRR) over the next three years, as stated in a recent filing with the Muscat Stock Exchange (MSX). The investment will fund the development of a state-of-the-art production facility in Sohar dedicated to manufacturing advanced composite core conductors. These innovative conductors are designed to boost energy grids' capacity, reliability, and resilience, supporting the global transition to sustainable energy solutions.

Pro-Ject Audio Systems has introduced The Classic Reference turntable, an extensively upgraded version of its Classic EVO and a refined successor to the VPO 175 limited edition. This model features the EVO 9 AS HG tonearm, which is equipped with high-precision ABEC 7 bearings housed in a robust aluminium gimbal, ensuring smooth, resonance-free performance. The turntable also boasts an internally-damped, S-shaped aluminium arm tube with a removable headshell, allowing users to swap cartridges easily. The high-mass aluminium alloy platter, damped with a thermoplastic elastomer (TPE), effectively minimises unwanted resonance. Additionally, the turntable includes a clamp and leather record mat to enhance stability, further improving resonance control and delivering exceptional sound quality.

Building Bright, building green: Aluminium's sustainable scene

Insolation Energy (INA Solar), a leading Indian solar energy provider and manufacturer, has announced the establishment of a 3 GW photovoltaic (PV) module manufacturing facility in Rajasthan's Jaipur district. The company, known for developing, engineering, and deploying solar PV modules, also plans to set up a 12,000 metric tonne per annum (mtpa) aluminium frame plant in the region. With an investment of INR 400 crore, the groundbreaking ceremony for this state-of-the-art facility was recently held. INA Solar's current PV module manufacturing capacity stands at 1 GW, and with the addition of this new plant, its total capacity will increase to 4 GW annually.

On September 10, Liu Jicheng, Deputy General Manager of Guiyang Institute, attended the groundbreaking ceremony for Guangxi Huasheng New Material Co., Ltd.'s distributed photovoltaic power generation project. The successful launch of this project marks a significant milestone in optimising energy structures and advancing the company's green, low-carbon development, receiving high praise from the client. The Guiyang Institute's technical team, driven by innovation, sustainability, and efficiency, played a crucial role in the project design, offering enterprises cost-effective and eco-friendly energy solutions. Through continuous research and development, they made breakthroughs in photovoltaic technology, particularly in utilising red mud stockpiles. The Institute's distributed photovoltaic designs are expanding rapidly, covering rooftops, ground installations, and even water surfaces.

Vision Art Aluminum, a leader in premium outdoor solutions, is proud to unveil its custom-designed sunrooms and pergolas, designed to elevate outdoor spaces for homeowners and businesses. Committed to quality, innovation, and personalised service, Vision Art Aluminum is setting new standards for the beauty and functionality of outdoor living. The company's sunrooms and pergolas are crafted using the finest materials, including high-quality German hardware and top-grade aluminium, ensuring exceptional durability and timeless elegance. Each structure is meticulously engineered to endure harsh weather conditions while enhancing energy efficiency, providing year-round comfort and beauty.

On September 26, the highly anticipated 20MW photovoltaic project was officially launched with a groundbreaking ceremony at the Sichuan Zhongfu factory. This ambitious initiative will make use of approximately 180,000 square meters of rooftop space within the factory area, with a total investment of around RMB 70 million and an expected installation capacity of 20MW. Once completed, the project is projected to generate approximately 15 million kilowatt-hours of electricity annually, reducing the consumption of over 1,800 tonnes of standard coal each year. Upon connection to the grid, this project will significantly lower the company's products' carbon footprint and enhance the green credentials of the aluminium industry supply chain.

Alummikon, a Massachusetts-based brand, has introduced innovative above-ground walkways and bridges designed to offer safer and more accessible solutions for traversing challenging terrains like waterways and uneven landscapes. Crafted from sustainable aluminium, these structures are both strong and, lightweight and fully recyclable, helping reduce waste and lessen their environmental impact. The design of these walkways and bridges allows for the continued growth of natural vegetation beneath them while providing pedestrians with a skid-resistant path. By keeping foot traffic above exposed ground, these elevated structures help prevent soil erosion and protect fragile ecosystems such as wetlands and streams. This thoughtful approach ensures the conservation of wildlife habitats, allowing animals to move freely through their environment without disruption.

Digger Specialties Inc. (DSI), a leading manufacturer of outdoor living products, is thrilled to announce the launch of a new 3-5/8″ mesh infill option for the Westbury® Sorrento Mesh Aluminium Railing, available starting November 1, 2024. This new option brings a sleek, modern look to decks, balconies, and porches, elevating the aesthetic appeal of outdoor spaces. The Westbury Sorrento Mesh Railing is renowned for its durability and resistance to various weather conditions. Alongside the new 3-5/8″ stainless steel mesh railing, DSI continues to offer the 2-3/8″ stainless steel mesh infill, introduced in May 2024, providing customers with versatile design options to suit their outdoor needs.

From wraps to packs: Aluminium makes the impact

Nespresso, famous for its iconic coffee machines, is making its debut in the ready-to-drink (RTD) market with the launch of its Master Origins Colombia Ready to Drink Coffee in aluminium cans. This new product marks a significant step in the brand's evolution. It is known for delivering premium coffee experiences worldwide, whether in homes or offices. Crafted from Colombian coffee beans and sweetened with locally sourced honey, this limited-edition RTD beverage highlights Nespresso's commitment to quality and sustainability. Available exclusively in the US for a limited time, the drink also aligns with the company's eco-conscious practices, using 80 per cent recycled aluminium in its coffee capsules.

Trivium Packaging, a global leader in metal packaging with a $3.1 billion valuation, has been recognised by the International Metal Decorating & Packaging Association (IMDPA) for its continuous innovation in packaging design. At this year's Annual Conference, the company received an Award of Excellence for its Conejo Verde aluminium wine bottles, produced at Trivium's facility in Argentina. These bottles feature a 59×225 ROPP 38 Pacific Round aluminium design, incorporating 8-10 per cent recycled content. Manufactured in a facility certified for energy efficiency (ISO 50001) and environmental management (ISO 14001), the production process also utilises about 80 per cent green energy.

The Ministry of Investment, Industry, and Trade of Uzbekistan has finalised an investment agreement with Ernest Packaging Solutions to establish a state-of-the-art aluminium beverage can manufacturing facility at the Navoi Industrial Development Complex. With a total investment of approximately $100 million, the plant will have an annual production capacity of over 1.5 billion aluminium cans. The project is expected to create more than 200 skilled jobs, contributing to the local economy. Set to become operational by fall 2025, the facility will mark a significant technological leap for Uzbekistan's aluminium beverage packaging industry, according to Khurram Teshabaev, Deputy Minister of Investments, Industry, and Trade.

Crown Holdings Inc., a leading American manufacturer of metal beverage and food cans, closures, and speciality packaging, has reported strong third-quarter financial results, surpassing initial expectations across its global beverage can business. For the quarter ending September 30, 2024, net sales reached $3,074 million, up slightly from $3,069 million in the previous year. This growth was driven by increased shipments of global beverage cans and food cans in Brazil, Europe, Mexico, and the United States. In the first half of 2024, Brazil saw a rise in beverage can sales, boosted by favourable macroeconomic conditions. According to the Brazilian Association of Aluminum Can Manufacturers, beverage can sales are expected to grow by 5 per cent by year-end, a significant increase compared to last year's 1.65 per cent rise.

Pakistan Aluminium Beverage Cans Limited (PABC), the first can manufacturing plant in Pakistan with an annual production capacity of 1.2 billion cans, has reported strong financial results for the September quarter of 2024. The company posted a net profit of PKR 1.71 billion (US$6.15 million), reflecting a 15.1 per cent year-on-year (Y-o-Y) increase from PKR 1.48 billion (US$5.3 million). Revenue grew by 6.5 per cent Y-o-Y to PKR 5.77 billion (US$20.7 million), up from PKR 5.42 billion (US$19.48 million), while gross profit surged by 8.2 per cent to PKR 2.24 billion (US$8 million). The gross profit margin remained steady, maintaining a strong 38.2%, consistent with last year's performance. The quarter also marked significant growth in other income, which soared by 418.6% to PKR 597.46 million (US$2.1 million), underscoring the company's overall financial strength.

Ball Corporation, a global leader in sustainable aluminium packaging for beverages, personal care, home products, and aluminium cups, has announced the re-launch of its proprietary printing technology, Dynamark™, for beverage cans in Europe, the Middle East, and Africa (EMEA). This enhanced technology introduces advanced printing capabilities, offering greater flexibility and added value for brands. Dynamark™ Advanced Pro further solidifies Ball Corporation's position as an industry innovator, providing effective solutions that exceed consumer expectations. This technology reflects Ball's commitment to understanding consumer behaviour, as studies show that shoppers make in-store decisions in under 6 seconds, with 80% of their choices influenced by visual shelf impressions.

i2r, a leading manufacturer of aluminium foil trays, is gearing up to launch a new range of premium trays tailored for the food service industry. The sleek silver and gold-black polished designs, available in five variants, offer both style and functionality. These premium trays come with durable clip-on polypropylene lids and industry-standard sizing and are crafted from 100 per cent recycled materials. This innovative blend of aesthetic appeal and practicality makes them the perfect sustainable solution for Quick Service Restaurants (QSR) and food delivery services.

United Airlines has embraced a sustainable shift by replacing plastic wine bottles with aluminium cans, responding to the increasing demand for eco-friendly packaging. The airline has also updated its wine list for the domestic economy cabin, adding new selections, including a rosé and brut bubbles, exclusively available on its flights. Beginning in October, passengers will enjoy premium aluminium canned wines from women-owned brands Just Enough Wines and Maker Wine. This transition is expected to eliminate approximately 4.7 million single-use plastic bottles annually.

Aluminium and its surprising capabilities

POSCO Future M Co., based in South Korea, has announced the early production of nickel, cobalt, and aluminium (NCA) cathode materials at its Pohang factory, completing the milestone three months ahead of schedule. On October 12, the company successfully manufactured high-nickel materials with an 88% nickel content, which boosts energy density and output, making them ideal for high-performance electric vehicle batteries. In addition to its existing lines of nickel, cobalt, manganese (NCM), and nickel, cobalt, manganese, aluminium (NCMA) materials, POSCO Future M is diversifying its product range by introducing NCA materials to meet growing customer demands. The use of single-crystal cathodes improves battery stability and lifespan by integrating raw materials into a unified particle structure. POSCO Future M aims to achieve a total NCA production capacity of 248,500 tonnes by 2026.

Nokia, the Finnish multinational corporation, is set to launch its latest 5G-enabled smartphone, the Nokia X60 Pro. This model combines sleek, modern design with practicality, crafted from aerospace-grade aluminium and a unique blend of recycled materials, reflecting Nokia's commitment to sustainability without compromising on a premium feel. The X60 Pro features a 6.7-inch AMOLED display, providing ample screen space while maintaining a slim profile. The screen is protected by Corning Gorilla Glass Victus, ensuring durability against daily wear and tear. The aerospace-grade aluminium used in the device is sourced from specialised alloys, such as 2024, 6061, 7050, and 7075, which are renowned for their high strength-to-weight ratios, excellent corrosion resistance, and ability to withstand extreme conditions.

The United States International Trade Commission (USITC) has upheld substantial tariffs on imported aluminium printing plates from China and Japan, addressing concerns that unfairly low-priced imports are harming the last remaining US producer, Kodak. The tariffs, which will affect approximately $100 million in imports, are aimed at protecting domestic jobs and maintaining production standards. This dispute began last year when Kodak, the sole US manufacturer of aluminium printing plates, filed a petition claiming that imported plates were being sold at artificially low prices, undermining US market competitiveness and threatening the sustainability of local production.

Zimbabwe, a landlocked country in southern Africa, is taking significant measures to regulate the importation of aluminium sulphate to reduce cost barriers for local manufacturers and boost their competitiveness in domestic and international markets. During a recent visit to Chilmund Chemical, a water treatment chemicals manufacturer in Bindura, Industry and Commerce Minister Mangaliso Ndlovu highlighted the importance of supporting local production. He emphasised the government's commitment to addressing cost-related challenges faced by Zimbabwean manufacturers, ensuring they are well-positioned to export their products effectively.

Conclusion

Aluminium is more than just a material; it's a catalyst for progress, transforming industries and sparking innovation across the globe. From the soaring heights of skyscrapers to the eco-conscious designs of marine infrastructure and from hi-tech advancements in transportation to sustainable packaging, aluminium is a key pillar of the modern economy. Its expanding presence in space exploration, electric vehicles, and urban metro systems highlights its limitless potential. With its unique combination of lightweight strength and recyclability, aluminium drives technological leaps and champions sustainability. As demand continues to rise, aluminium is firmly positioning itself as the material of the future, paving the way for a greener, more advanced world.