Alcoa came to Southwestern Indiana at a time of economic distress for the region. Major manufacturers had closed or curtailed operations, eliminating thousands of jobs. So, when Alcoa announced on April 17, 1956, that it would build in Warrick County, it was a major boost for both the economy and the community morale.
Today, Warrick Operations is one of the largest aluminum facilities in the world with more than 1,100 employees working for the Alcoa Global Packaging business unit, a component of Alcoa’s Global Rolled Products. The plant produces coiled aluminum sheet for beverage and food cans and other flat-rolled products, including lithographic sheet and industrial products.
The facility includes an on-site power plant operating as part of Alcoa Power Generating Inc., serving the industrial load at the facility. Of the four generating units, three are owned fully by APGI and the fourth, Unit 4, is a utility boiler that is owned 50-50 by APGI and Vectren.
The facility includes the re-melting of purchased aluminum and scrap to prepare the molten metal for one of two state-of-the art electromagnetic casting complexes. Metal is cast into ingots as long as 30 feet and weighing up to 44,000 pounds. Warrick casts a variety of aluminum alloys, and those other metals, such as magnesium and zinc, are mixed with the molten metal to produce specific alloys, depending on customer requirements.
The ingots are sent through a scalper, where the surface of the metal is shaved to improve surface quality. They are then sent through Warrick's Reversing Mill, where the ingot is reduced to a slab about 1 1/2" thick. The Continuous Mill transforms the slab into an 1/8" thick coil in less than four minutes.
From the Hot Mill, the coil is further processed on one of two Cold Mills. The Cold Mills reduce the metal to its final gauge, only a few thousandths of an inch thick.
Finally, the coils may go through several processes in the Finishing Department, which is Warrick’s largest department. Coils may be coated at one of three coating lines, cleaned, leveled, dried and recoiled through Warrick’s prepline or slit to a specific width at either the 64-inch slitter of the Super Slitter, a state-of-the-art facility that cuts coils to specifications for employees before being packed for shipment to customers around the world.
Warrick Operations ... Tomorrow
Warrick Operations has grown from a simple producer of aluminum to a recognized world leader in the production of high quality, flat-rolled aluminum sheet.
From Warrick Operations, Alcoa produces and delivers aluminum sheet for products on store shelves across America, Europe and the Far East. Even while competing worldwide, Alcoa continues to keep strong roots in the Warrick community, where our people live and work.