Novelis manufactures premium and specialty products for our customers around the world. Our specialties include bottle and cartridge production, as well as a host of converted products. Our converted products employ different manufacturing processes used either independently or in combination and include:
- Extrusion Coating
- Impact Extrusion
At Novelis, converted products are sold to customers all over the world. We produce our converted products with different manufacturing processes used either independently or in combination with each other. Our offerings include:
- Extrusion Coating
- Impact Extrusion
- Tube winding
- Extrusion laminating
Lamination is the process used to bond together paper, cardboard or plastic films (e.g. PP, PE, PET, PVC), with or without aluminum foil, in gauges from six to 300 microns. We can provide glue, dry-bond and extrusion lamination. With these variations Novelis is able to fulfill all potential lamination needs for our customers.
A typical example of this process in use is the tobacco inner-liner produced in the Novelis European plants of Berlin and Lüdenscheid, in which the laminating process can be combined with the lacquering process.
Lacquering can be done during the laminating process or separately, and Novelis has its own lacquering center of excellence in Lüdenscheid, Germany. Typical examples of lacquered products include lidding and container foils for human and pet food applications. It involves water-based or solvent-based lacquers of different formulations to match precise customers’ needs, including:
- Polyvinylchloride (PVC)
- Nitrocellulose (NC)
Flavoring is another offering Novelis provides. We employ Reel to Reel Process to transfer flavors to the coating paper side of certain products, such as menthol for tobacco inner-liner.
Metalizing allows for the deposit of very thin layers of aluminum on coated paper of 40 to 80 g/m² or plastic films with gauges of 12-250 µm (e.g. PET, OPP, OPA, LDPE, PVC). Metalizing is typically used for tobacco inner-liners or beverage labels at Novelis’ European plants in Berlin and Lüdenscheid. Learn more about Novelis’ metalizing capabilities.
This process is used at Novelis’ plant of Lüdenscheid to apply different coatings on aluminum foil or paper-cardboard with gauges ranging from 30 to 300 microns. Typical coatings include Polyethylene (LDPE, PE-Copo) and Polypropylene with weights between 15 g/m² and approximately 200 g/m² on each side. Up to four layers can be coated (either two on each side of the substrate or four on one side). Typical products include cable strip used by cable manufacturers looking for superior adhesion between polymers and aluminum foil.
Novelis is one of the world’s leading producers of aluminum bottles and cartridges. To manufacture these products, Novelis uses a process called impact extrusion and employs forward, backward and combined extrusion processes. Learn more about our production process.
The Novelis Ohle plant in Germany uses this process to produce containers and lids for human or pet food markets in plain, lacquered and coated aluminum foil. Our presses are equipped with modern process control and use a variety of tools to form containers of different sizes and shapes matching our customers’ precise needs. The containers will be either deep-drawn or folded.
This process allows the Novelis Ohle plant to produce tubes of different diameters, lengths and shapes for exhaust gas routing, heat protection, heat insulation, air intake or coil core applications in the transportation and rolling industries.
Bottle & Cartridge Production
Novelis is one of the world’s leading producers of aluminum bottles and cartridges. To manufacture these products, we use a process called impact extrusion.
The impact extrusion process can be employed for a variety of manufacturing needs—from cans and tubes to bottles and cartridges. It can also be used to manufacture other engineering components from aluminum alloys. The benefits of impact extrusion include:
- A high level of dimensional accuracy and the possibility to achieve a close approximation to the final shape
- High degree of transformation in a single production step
- High operating speed and low unit costs
- Minimum tools costs with high output
- Numerous shaping and design possibilities
- Compact structure, smooth surface, no soldered or welded seams, excellent stability
In the cold impact extrusion process, aluminum slugs, bar sections or rough pressed blanks are liquefied under high pressure from the descending punch. This process results in formed parts with forged bases and extruded walls. On the return stroke, the formed part is withdrawn from the mold and ejected.
Novelis employs three different kinds of impact extrusions to manufacture our products:
- Reverse Impact Extrusion: Impact extrusion against the die movement
- Forward Impact Extrusion: Impact extrusion with the die movement
- Combined Impact Extrusion: Impact extrusion with and against the die movement