01 – Our Casting Heritage
Five Decades of GettingThere First.
Founded in 1984 on Bill Coors’ vision that recycled aluminum could be continuously cast into high-quality sheet, efficiently and at scale. Today, we continue that legacy.
- 1984
Golden Aluminum founded. Original Lauener blockcaster commissioned in Fort Lupton.
- 1987
Golden acquires Lauener's blockcasting technology.
- 2012
Infinity Alloy Series launched. AA5016 made from 75%+ recycled cans.
- 2016
Partnership with SMS group begins. Nexcast® development starts.
- 2024
$22.3M DOE grant awarded for industrial decarbonization.
- 2025
Nexcast® goes into commercial operation.
02 – The Install
What It Takes toReplace a Caster.
The original plan called for five weeks. Getting there meant fully decommissioning and removing the old caster. Months of prep work brought it in ahead of schedule.
3
Weeks of installation
27,000
Man-hours.
03 – The Technology
The Most Advanced Casterin Operation.
Nexcast® isn’t just an upgrade for Golden Aluminum — it’s a step forward for the entire flat-rolled aluminum industry. Here’s what sets it apart.
Click to compare footprint between casters.
01
Compact By Design
Nexcast® runs molten metal to finished coil on one consolidated line, with no ingot casting, no reheat furnaces, and no storage in between.
02
Intelligent Process Controls
Operations that once took a person now run themselves. Controls adjust in real time.
03
Proven In Production
Nexcast® is capable of running extended continuous casting campaigns and switching between a wide diversity of alloys without stopping.
04
Moving Copper Mold Design
A proprietary moving mold casts high-alloy and heat-treatable grades, including AA5182, that conventional continuous casters can’t.
05
Higher Recycled Content
Rapid solidification takes more scrap than DC casting can handle. More than 80% recycled content, depending on alloy.
06
Built For Continuity
Campaigns designed for fewer stops, fewer consumables, and a caster built to run for the next 50 years. Continuous casting efficiency with direct casting quality.
Golden Aluminum has always been at the forefront of sustainability. It was a vision of Bill Coors to utilize scrap and lower-energy processes to make coil for cans. We have that in our DNA.
Golden Aluminum has always been at the forefront of sustainability. It was a vision of Bill Coors to utilize scrap and lower-energy processes to make coil for cans. We have that in our DNA.
Golden Aluminum has always been at the forefront of sustainability. It was a vision of Bill Coors to utilize scrap and lower-energy processes to make coil for cans. We have that in our DNA.
Golden Aluminum has always been at the forefront of sustainability. It was a vision of Bill Coors to utilize scrap and lower-energy processes to make coil for cans. We have that in our DNA.
04 – Built For Your Market
Better Technology.Better Product.Every Application.
Packaging
Can body, end, and tab stock with high recycled content. Surface quality and consistency the market demands.
Automotive
High-alloy and heat-treatable grades for lightweight, high-strength applications — from heat shields to EV battery closures.
Building Products
Tighter tolerances and broader options for roofing, siding, rainware goods, and architectural applications.
05 – Sustainability By Design
Efficiency Isn't an Add-On.It's the Architecture.
Every design decision started with resource efficiency like the compact footprint, the elimination of intermediate steps and the tolerance for high scrap content.
This isn’t new for Golden. The mill was built in 1984 around a single premise: that recycled cans could be cast into new sheet using a fraction of the energy.
Sustainability isn’t a strategy we adopted. It’s the reason we exist.
06 – Our People
“All the technology that goes into the new machine is inherently safer. Less interaction with the machine keeps people safer.”
— Jeff Frim, President & CEO
Built for the PeopleWho Run It.
A new operator pulpit puts the full process in view. Automated controls handle most of what used to be done by hand. Every change makes this caster safer for operators.
Cameras
20
Real-time
Automated Block Cleaning
Once done by hand
07 – Engineered Together
Co-DevelopedWith SMS group.
Nexcast® was co-developed with SMS group, a global leader in metallurgical plant engineering with over 150 years of experience. They bring the engineering depth and global support to advance the platform for decades.
08 – Open To Partnership
Now Availableto Select Partners.
Nexcast® is now available to select partners exploring next-generation continuous casting for flat-rolled aluminum production. The technology can be engineered around different mill configurations, product mixes, throughput targets, and facility footprints — including wider formats up to 2 meters.
Nexcast® Inquiry
Tell us a bit about your needs and we’ll be in touch.
09 – In The Press
The Industry Weighs In.
U.S. Dept. Of Energy
