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Released October 10, 2025 | SUGAR LAND
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Researched by Industrial Info Resources (Sugar Land, Texas)--A September fire at Novelis Incorporated's (Atlanta, Georgia) aluminum plant in Oswego, New York, will halt the production of roughly 40% of aluminum sheet used by U.S. automakers until early next year and has the potential to impact production from Ford Motor Company (Dearborn, Michigan), the plant's largest customer, as well as other major automakers.
News reports indicate the September 16 fire "leveled" the plant's hot mill. In an October 6 statement on the company website, Novelis said: "Based on what we know today, we expect the hot mill to be back in operation in early Q1 of calendar year 2026."
The Oswego hot mill is used to roll and shape large blocks of solidified aluminum, known as aluminum ingots, into sheets.
"We are urgently taking steps to minimize the impact of the recent fire at our Oswego facility on our customers," the company continued. "We have activated Novelis' global network of plants and are also partnering with industry peers to source material in order to help mitigate the gap in supply."
In a September 30 statement, Novelis said the cold mill and finishing areas were back online and power was being restored to the remelt/recycle area, which Novelis expected would "restart soon."
The fire did not cause any injuries, and the cause is under investigation.
Subscribers to Industrial Info's Global Market Intelligence (GMI) Metals & Minerals Database can click here for more information on the Oswego plant and here for an offline event related to the fire.
Rebuilding the hot mill, which the fire rendered unusable, or constructing a new one entirely, would likely come at a significant cost. Novelis has not announced what it plans to do, nor has it confirmed any impacts to planned projects at the Oswego plant.
Regardless, the hot mill outage most likely has put an early end to the plant's 2025 maintenance outage, as well as delaying the start of a project aimed at upgrading the rail track. Subscribers can read more information on the maintenance and rail track upgrade projects, the latter of which could have kicked off by the end of the year.
Novelis provides roughly 40% of the aluminum sheet used by U.S. automakers, according to news reporting regarding the fire, and the Wall Street Journal on October 6 reported the outage would "disrupt business" for Ford, the Oswego plant's largest customer, and other automakers "for months to come."
Novelis also produces aluminum sheet in Davenport, Iowa and Kingston, Ontario, respectively, although the company has not said whether those locations will be used to make up for the lost production. Subscribers can read more information on the plants in Iowa and Ontario, Canada.
Ford relies on aluminum for the exterior of its F-150 pickup truck, its top-selling and most profitable vehicle.
However, a Ford spokesperson sought to downplay the impact, telling the Wall Street Journal: "Novelis is one of several aluminum suppliers to Ford. Since the fire nearly three weeks ago, Ford has been working closely with Novelis, and a full team is dedicated to addressing the situation and exploring all possible alternatives to minimize any potential disruptions."
On October 8, Reuters reported Ford planned to pause production the following week at its Dearborn Truck Plant in Michigan, which makes the company's F-150 Lightning electric pickup. Subscribers can click here for the plant profile. The company has declined to say whether production changes are planned at any other locations.
Meanwhile, an investor note from Evercore ISI that same day indicated the fire could potentially cut $1 billion from Ford's bottom line. "We believe this is largely a Ford issue, at this time being, although we are continuing to check knock-on effects for [Stellantis] and Toyota as well," Chris McNally, head of global auto mobility & mobility research for Evercore, said in the note.
Ford reports third-quarter earnings results on October 23, when it could discuss repercussions from the aluminum supply disruption.
Toyota and Stellantis have reported they are adjusting supply chains and working with alternative sources.
Canada is a major producer of primary (raw) and secondary (recycled) aluminum and accounted for 58% of aluminum imports into the U.S. in 2024 (according to U.S. International Trade Administration), although it produces aluminum sheet on a smaller scale.
Facilities in Canada producing aluminum sheet for the North American automotive market include Stelco Incorporated's (Hamilton, Canada) Hamilton Works and Lake Erie Works in Ontario. Subscribers can read more information on the Hamilton and Lake Erie steel works.
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking over 200,000 current and future projects worth $17.8 Trillion (USD).
News reports indicate the September 16 fire "leveled" the plant's hot mill. In an October 6 statement on the company website, Novelis said: "Based on what we know today, we expect the hot mill to be back in operation in early Q1 of calendar year 2026."
The Oswego hot mill is used to roll and shape large blocks of solidified aluminum, known as aluminum ingots, into sheets.
"We are urgently taking steps to minimize the impact of the recent fire at our Oswego facility on our customers," the company continued. "We have activated Novelis' global network of plants and are also partnering with industry peers to source material in order to help mitigate the gap in supply."
In a September 30 statement, Novelis said the cold mill and finishing areas were back online and power was being restored to the remelt/recycle area, which Novelis expected would "restart soon."
The fire did not cause any injuries, and the cause is under investigation.
Subscribers to Industrial Info's Global Market Intelligence (GMI) Metals & Minerals Database can click here for more information on the Oswego plant and here for an offline event related to the fire.
Rebuilding the hot mill, which the fire rendered unusable, or constructing a new one entirely, would likely come at a significant cost. Novelis has not announced what it plans to do, nor has it confirmed any impacts to planned projects at the Oswego plant.
Regardless, the hot mill outage most likely has put an early end to the plant's 2025 maintenance outage, as well as delaying the start of a project aimed at upgrading the rail track. Subscribers can read more information on the maintenance and rail track upgrade projects, the latter of which could have kicked off by the end of the year.
Novelis provides roughly 40% of the aluminum sheet used by U.S. automakers, according to news reporting regarding the fire, and the Wall Street Journal on October 6 reported the outage would "disrupt business" for Ford, the Oswego plant's largest customer, and other automakers "for months to come."
Novelis also produces aluminum sheet in Davenport, Iowa and Kingston, Ontario, respectively, although the company has not said whether those locations will be used to make up for the lost production. Subscribers can read more information on the plants in Iowa and Ontario, Canada.
Ford relies on aluminum for the exterior of its F-150 pickup truck, its top-selling and most profitable vehicle.
However, a Ford spokesperson sought to downplay the impact, telling the Wall Street Journal: "Novelis is one of several aluminum suppliers to Ford. Since the fire nearly three weeks ago, Ford has been working closely with Novelis, and a full team is dedicated to addressing the situation and exploring all possible alternatives to minimize any potential disruptions."
On October 8, Reuters reported Ford planned to pause production the following week at its Dearborn Truck Plant in Michigan, which makes the company's F-150 Lightning electric pickup. Subscribers can click here for the plant profile. The company has declined to say whether production changes are planned at any other locations.
Meanwhile, an investor note from Evercore ISI that same day indicated the fire could potentially cut $1 billion from Ford's bottom line. "We believe this is largely a Ford issue, at this time being, although we are continuing to check knock-on effects for [Stellantis] and Toyota as well," Chris McNally, head of global auto mobility & mobility research for Evercore, said in the note.
Ford reports third-quarter earnings results on October 23, when it could discuss repercussions from the aluminum supply disruption.
Toyota and Stellantis have reported they are adjusting supply chains and working with alternative sources.
Canada is a major producer of primary (raw) and secondary (recycled) aluminum and accounted for 58% of aluminum imports into the U.S. in 2024 (according to U.S. International Trade Administration), although it produces aluminum sheet on a smaller scale.
Facilities in Canada producing aluminum sheet for the North American automotive market include Stelco Incorporated's (Hamilton, Canada) Hamilton Works and Lake Erie Works in Ontario. Subscribers can read more information on the Hamilton and Lake Erie steel works.
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking over 200,000 current and future projects worth $17.8 Trillion (USD).
