On June 8, 2006, Matalco Inc., Canada’s largest aluminum remelt plant, held an opening ceremony and plant tour. Top aluminum industry executives were in attendance along with elected government officials.
Located on Intermodal Drive in Brampton, Ontario, Matalco is strategically situated within the heart of Canada’s aluminum extrusion industry, over 60 per cent of which is located in the Greater Toronto Area. Construction on the plant was completed late 2005 following a formal groundbreaking ceremony in November of 2004. Since pouring its first metal last December, Matalco has quickly ramped-up production to about half of its rated annual capacity level of 200 million pounds of primary-quality aluminum billet, making it the largest producer of its kind in Canada. The $65-million, 110,000 sq. ft. facility employees approximately 50 people. Triple M Metal Inc. holds a majority principal interest in the company.
“The market for metals including aluminum is red hot,” said President and CEO Leon Kozierok. “The timing of Matalco’s entry into the marketplace couldn’t have been better. With aluminum prices at all-time highs, our billets provide the extrusion industry with a stable, cost effective and comparable alternative to the primary metal.”
Matalco uses a variety of aluminum scrap metal as inputs into its operations. In addition to the scrap returns from customers for toll conversion back into high quality extrusion billet, most of the metal is sourced from Triple M Metals, which has built a new scrap processing plant adjacent to Matalco. Using advanced technology it can accept difficult-to-recycle material such as polycoated, painted and mixed alloy products. Through a series of processes that includes remelting in its state-of-the-art furnaces, degassing, continuous homogenization and automated sawing and packaging, the company produces a uniform, primary-grade product tailored to its customer’s specifications.
By incorporating the most advanced thermal processes available to recycle energy used in production, the plant is extremely energy efficient. Additionally, remelted aluminum requires one-twentieth the energy needed to produce primary grade aluminum and the entire process generates virtually no waste. Applications for aluminum extrusions are expanding. Automobile manufacturers are increasingly favouring aluminum because of its superior strength-to-weight ratio and ability to provide improvements to performance and vehicle weight. Since 1991 aluminum use has doubled in cars and tripled in sport utility vehicles. (The chassis in Ford’s 2005 GT Sports Car is made totally from aluminum.)
Waste managers will want to visit the plant and see the new state-of-the-art pyrolitic gasification delaquering machine from Chinook & Sciences that removes paint and other coatings from the aluminum before it’s remelted. High temperature ceramic filters prevent the formation of dioxins and furans.