Large-Scale Crane and Automation Integration for Novelis

Novelis required multiple crane systems for its new aluminum recycling and rolling mill in Bay Minette, Alabama, including 18 custom cranes ranging from 10 to 200 tons. We engineered and delivered the complete solution, integrating mechanical, structural, and semi-automated systems to meet Novelis’ stringent production, quality, and safety standards.

As the first major collaboration following DESHAZO’s acquisition of Integrated Machinery Systems (IMS), the industry-leading custom hoist and trolley equipment manufacturer, this project showcased the combined capabilities of all of our teams. The Alabaster and Bessemer, Alabama facilities fabricated the crane girders, IMS supplied hoists and trolleys from Azle, Texas, and the DESHAZO automation group in Huntsville, Alabama provided controls and integrated automation systems.

Through weekly coordination between Novelis, DESHAZO, and key component suppliers, the project stayed aligned on performance, quality, and fluid delivery expectations. Representing our largest single purchase order project to date, the Novelis Bay Minette installation reinforces our reputation for delivering turnkey, heavy-duty crane systems with unmatched in-house engineering, project management, and manufacturing expertise.

The Opportunity

Novelis, a global leader in aluminum manufacturing, began construction of a new aluminum recycling and rolling mill in Bay Minette, Alabama. The facility required a comprehensive overhead crane system capable of handling a wide range of loads and incorporating advanced automation features. The scope included 18 custom cranes, ranging from 10 to 200 tons, with spans up to 120 feet. Novelis sought a partner who could design, engineer, fabricate, and support these cranes for heavy-duty, high-volume production while managing complex logistics, coordination, and safety requirements throughout the project.

Our Solution

We engineered and manufactured custom cranes and associated hoists and trolleys for Novelis, seamlessly integrating mechanical, electrical, and automation solutions. The project marked a milestone as the first major collaboration uniting DESHAZO’s three core divisions: IMS supplied hoists and trolleys from Azle, Texas, our Alabaster and Bessemer, Alabama facilities fabricated the crane girders, and the DESHAZO automation group in Huntsville, Alabama provided controls and integrated automation systems.

Critical innovations in this project included:

• Advanced project coordination, with weekly meetings spanning over two years, ensuring alignment with Novelis expectations and multiple engineering entities
• State-of-the-art design, safety, and material innovations
• Robust logistics planning, including bulk steel purchasing to manage supply costs and storing large crane components safely for phased installation

Key Takeaways

The Novelis project underscores our ability to tackle large, technically demanding projects, delivering integrated solutions that span design, manufacturing, automation, and lifecycle service under one roof.

1. In-House Synergy
   Cross-divisional collaboration enabled custom solutions without outsourcing, ensuring speed and flexibility.
2. Technical Agility
   Our team adapted to customer-specified technologies, expanding capabilities in Siemens-based automation.
3. Scalability
   We successfully executed the largest project in company history, managing complex logistics and production schedules.
4. Customer Trust
   Through this project, we established a strong working relationship with Novelis, becoming a preferred service and manufacturing partner for them post-installation.

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