Alcoa's Tennessee Operations has existed in the foothills of the Great Smoky Mountains for 100 years.

 

Located 15 miles south of Knoxville, Tennessee Operations occupies more than 2,000 acres, with close to 200 under roof, and produces enough aluminum sheet through its Continuous Cold Mill every minute to produce 95,000 cans. 

 

Can Recycling
Used beverage cans collected from around the country are recycled in Tennessee Operations' Can Reclamation process. Can Rec remelts enough used beverage cans each year to make billions of new cans. Recycling aluminum saves 95 percent of the energy it takes to make new aluminum from raw materials. Recycled cans return to store shelves as new products in as little as 60 days. 
 
The Cycle of Can Recycling 

Aluminum is Infinitely Recyclable

The History of Can Recycling 

 

Ingot
Molten metal that is produced in Tennessee's Smelter and Can Reclamation facility is used to produce high-quality aluminum can sheet. The metal is first cast into ingots, that can be up to 25 feet long and weigh 44,000 pounds.

 

Hot Rolling
The ingots are first sent through a Scalper, where the surface of the metal is shaved to remove impurities in the metal. They are then sent through a series of three rolling mills on the Hot Line. The Hot Line transforms the 21" thick ingot into a 3,000 foot long, 1/8" thick coil in about seven minutes.

 

Cold Rolling
Tennessee's Continuous Cold Mill (CCM) is the most modern rolling facility in the world. Coils of aluminum are run through the CCM at speeds up to 60 miles per hour to reduce the metal to its final gauge, only a few thousandths of an inch thick. Enough sheet goes through the mill to produce 95,000 cans every minute.

 

Finishing
Finally, the coils are trimmed on high speed slitting equipment, packaged and shipped to beverage can makers throughout the world. Some of Tennessee Operations' customers include Anheuser-Busch, American National Can, and Crown Cork Seal.

  

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Used Beverage Cans

Used Beverage Cans

 

 

Ingots

Ingots
 

 

Hot Line 80-inch Mill

Hot Line 80-inch Mill 

 

 

Continuous Cold Mill

Continuous Cold Mill

 

 

Aluminum Coil

Aluminum Coil