Nexcast is Getting a Major Upgrade

Why Nexcast?

Nexcast changes the game. By transforming molten aluminum directly into a thin strip and then into a hot coil, Nexcast eliminates ingot casting, sawing, storage, scalping, reheating, and large-scale rolling equipment.

This streamlined process helps lower capital investment and equipment costs, cut emissions and water usage, and increase throughput and alloy versatility.

With Nexcast, we’re making the production of flat-rolled aluminum faster, more efficient, and better for the planet.

What’s New with Nexcast?

Our upgraded blockcaster technology, set to go live in July 2025, represents the biggest achievement in our casting system in over 40 years.

Built on decades of proven, continuous casting expertise at Golden Aluminum, our new Nexcast system is engineered for versatility and high-performance manufacturing. Designed for agility and space-efficiency, the entire system spans just 175 feet—bringing smarter, more compact casting to the heart of our operations.

The system also incorporates more than 80% end-of-life scrap into production, delivering significant sustainability benefits: ~60% reduction in carbon intensity, and ~86% decrease in process water usage.

This upgrade marks a key step in our long-term strategy, allowing us to increase production efficiency, enhance precision and consistency, and strengthen our competitive edge.

Designed for a Circular Economy

At the heart of Nexcast is our commitment to sustainability. We’re building systems that not only perform, but also help protect the planet.

The Nexcast system significantly reduces land use and minimizes the environmental impact of construction, while also cutting emissions across the entire value chain. It’s built to align with the needs of environmentally conscious industries, from electric vehicles and renewable energy, to sustainable construction and infrastructure.

The Future of Aluminum Manufacturing Starts Here

For over 40 years, Golden Aluminum has led the way in continuous casting, developing systems that are efficient, adaptable, and environmentally responsible.

Now, with our Nexcast upgrade, we’re taking everything we’ve learned and applying it to a smarter, more technologically advanced casting system—one that’s built to meet the demands of modern markets and future-focused industries.

Visit goldenaluminum.com to learn more about our innovative approach to responsible aluminum production.