Hydro Aluminum Metals USA LLC, a producer of recycled aluminum products, will expand its manufacturing operation in Henderson with an $85 million investment creating 31 high-wage Kentucky jobs.
The investment will see Hydro Aluminum expand its current Henderson facility by 80,000 square feet, bringing the total operational sq.ft. to nearly 200,000. The additional room will allow the company to introduce HyForge technology to the Henderson plant, following in the footsteps of the successful implementation of the HyForge casting technology at the company’s primary plant in Norway and recycling plant in Germany.
The new HyForge casthouse at the Henderson facility is expected to become operational in 2026. When in operation, the new addition will serve the automotive market’s need for smaller diameter, high-quality billets that can be forged directly into high-quality automotive components. This process will help reduce the number of processing steps needed for the operation, leading to a more cost-efficient, higher-quality product compared with the traditional process. The more efficient process will come without compromising safety, and by using a high share of end-of-life scrap, Hydro Henderson will deliver HyForge billets with a low carbon footprint.
“This investment is another step along Hydro’s journey to change the game in aluminum production. Recycling more end-of-life scrap reduces emissions, strengthens security of supply and enables us to deliver new, cutting-edge products to our U.S. customers, made right here in Kentucky,” said Hydro president and chief executive officer Eivind Kallevik. “Hydro Henderson has been at the forefront of producing recycling-based automotive products for nearly 20 years. We work closely with the automotive industry, and introducing Hydro’s HyForge technology will provide Hydro and our partners with a greener advantage – Made in America.”
Hydro’s investment supports production of recycled, low-carbon aluminum, including Hydro CIRCAL, the company’s proprietary advanced material. Hydro CIRCAL is made with a minimum of 75 percent recycled, post-consumer aluminum scrap. Once in full production, Hydro’s Henderson facility will produce 2,000 to 4,000 tons of Hydro CIRCAL products annually.