Raw materials & energy

Each year, around 20 vessels arrive at KUBAL carrying alumina, the main raw material used in aluminium production.

Together with renewable electricity, alumina forms the foundation of our process.

The raw material is prepared for production and fed into our electrolysis plants, where aluminium is produced continuously – 24 hours a day, all year round.

Electrolysis – production of molten aluminium

Aluminium is produced in two electrolysis plants with a total of 298 electrolysis cells.

In each cell, alumina is dissolved in a molten bath at around 960°C and converted into molten aluminium using direct current.

Each cell consists of a carbon-lined steel cathode and 16 carbon anodes.

Through careful control of temperature, current and the distance between the anode and cathode, the alumina is separated into aluminium and oxygen.

The molten aluminium collects at the bottom of the cell and is tapped regularly for further processing.

Anode Service - keeping production running

The anode workshop supports continuous production by supplying the electrolysis process with carbon anodes and maintaining and preparing them for operation.

At full capacity, around 1,200 anodes are handled each week.

As the anodes are gradually consumed during electrolysis, they are replaced regularly to ensure stable operation, high efficiency and consistent product quality.

This enables a combined daily production of around 360 tonnes of molten aluminium from the two plants.

The Cast House

In the cast house, the molten aluminium is converted into extrusion ingots and rolling slabs.

Production is carefully planned and coordinated to meet customer specifications for alloy composition, dimensions and further processing.

The cast house has five furnaces, two of which also have the capacity to remelt and upgrade aluminium, including internally generated extrusion scrap.

This flexibility enables KUBAL to optimise material use while maintaining high quality standards.

Metal treatment & purity

Before casting, the molten aluminium is treated to ensure high purity and consistent quality.

The metal passes through filtration systems where argon gas is added to reduce hydrogen content and remove inclusions.

A modern ceramic filter then removes both metallic and non-metallic particles, resulting in very pure aluminium tailored to customer requirements.

Quality Control in the Cast House

Quality assurance is fully integrated into the casting process.

The first quality checks are carried out directly in the furnace before tapping, where the metal’s composition and temperature are verified.

The on-site laboratory performs continuous analyses of raw materials, alloys and molten metal to ensure that all specifications are met.

Throughout the casting process, parameters are monitored carefully to ensure consistent quality, traceability and reliability in every product delivered.

Finished Products & Delivery

KUBAL produces a wide range of aluminium ingots and rolling slabs in several dimensions and alloy compositions for use in various industrial applications.

On average, around 10,000 tonnes of aluminium products leave the plant each month, primarily by vessel and truck to customers around the world.

Responsible Production & Emissions Control

Over time, we have continuously upgraded our facilities with the best available technology, significantly reducing emissions of dust, tar-related substances and fluorides.

PAH emissions have been almost eliminated.

Advanced gas treatment systems capture and recover fluorides with an efficiency of up to 99 percent.

Emissions are monitored continuously, together with regular environmental controls such as groundwater monitoring and filter inspections, to ensure compliance and responsible operations.

From Process to Performance

Every step of our process is designed to deliver high-quality aluminium with consistency, efficiency and care.

Through advanced technology, integrated quality control and responsible production, KUBAL delivers aluminium solutions trusted by customers around the world.