ABB is strengthening its industrial automation portfolio for the aluminium industry through measurement, process control, digitalization, and electrification technologies showcased at ALUMINIUM 2026 in Düsseldorf, Germany, from October 6–8.

The company’s solutions are designed to help aluminium producers improve product quality, increase manufacturing efficiency, reduce material waste, and maintain stable production in demanding rolling and smelting operations.

Precision Measurement for Better Product Quality

Aluminium production requires accurate measurement and control throughout the manufacturing process. In rolling mills, small deviations in strip thickness, flatness, or tension can affect product quality, increase scrap, and lead to additional processing.

ABB is highlighting technologies including its Stressometer flatness measurement systems, strip tension measurement solutions, and Millmate Thickness Gauge (MTG) Box Gauge.

These technologies provide measurement data that can help operators maintain tighter process tolerances and improve consistency across production runs.

For manufacturers producing thin aluminium foil, automotive materials, packaging products, and industrial sheet, reliable measurement is particularly important because product specifications can be demanding and material losses can be costly.

Automation Technologies for Aluminium Rolling Mills

Modern rolling mills combine mechanical equipment, electrical drives, instrumentation, process controllers, and supervisory software. Maintaining consistent output requires these systems to operate in a coordinated manner.

Measurement technologies provide real-time information about material behavior, while automation systems can use this information to support process adjustments and maintain target operating conditions.

ABB’s broader portfolio combines measurement and analytics with automation and electrification technologies, helping producers connect individual instruments with larger production systems.

For automation engineers, integration planning should address measurement accuracy, communication interfaces, control-loop performance, and the response of the rolling process to changes in operating conditions.

Improving Furnace Efficiency and Metal Recovery

ABB is also highlighting its AL-EMS electromagnetic stirring technology for aluminium furnaces.

Electromagnetic stirring promotes controlled movement of molten metal without direct mechanical contact with the material. This can help improve metallurgical process consistency and support more efficient furnace operation.

ABB reports that its technology has demonstrated potential benefits of up to 25% higher productivity, up to 15% less dross generation, and up to 10% lower energy consumption in relevant applications. Actual results depend on furnace design, operating conditions, material characteristics, and process configuration.

For aluminium producers, improvements in metal recovery and energy efficiency can contribute to lower operating costs and reduced environmental impact.

Digitalization and Industrial Data

Digitalization is becoming increasingly important as aluminium producers seek better visibility into production performance.

Measurement data can be used to monitor process stability, identify deviations, and investigate recurring quality problems. When combined with production records and equipment operating information, this data can also support root-cause analysis and maintenance planning.

For example, engineers may analyze thickness measurements alongside rolling parameters to identify patterns associated with product variation. Similar approaches can be applied to furnace performance, equipment availability, and energy consumption.

However, the value of digital analytics depends on reliable instrumentation, consistent data collection, and appropriate interpretation by process specialists.

Supporting More Sustainable Aluminium Manufacturing

Aluminium production is energy-intensive, and manufacturers face increasing pressure to improve resource efficiency while maintaining product quality.

Automation can contribute by reducing process variation, limiting unnecessary rework, improving metal recovery, and helping operators use energy more efficiently.

Accurate measurement is especially important in rolling operations, where poor process control can lead to scrap or additional processing. Improved furnace performance can also support better use of energy and raw materials.

ABB’s approach combines measurement, automation, electrification, and metallurgical technologies to address these challenges across different stages of aluminium production.

Conclusion

ABB’s showcase at ALUMINIUM 2026 highlights the importance of precision measurement and integrated automation in modern metal manufacturing.

By combining flatness, tension, and thickness measurement with electromagnetic stirring and broader industrial automation technologies, ABB aims to help aluminium producers improve process control, increase productivity, and reduce waste.

For industrial automation professionals, the development demonstrates how sensors, control systems, process analytics, and electrical technologies can work together to improve manufacturing performance.

As aluminium producers pursue greater efficiency and more sustainable operations, reliable instrumentation and well-integrated automation systems will remain essential to maintaining quality, reducing costs, and improving plant reliability.