Sunalco Alloys Plant I at Wada from the air

Scale built over decades

INDIA’S SECOND LARGESTALUMINIUM RECYCLER.

Industrial scale. Circular thinking. Aluminium built for another life.

A block of aluminium

The Sunalco Group

ONE ELEMENT.ENDLESS POSSIBILITIES.

Two businesses. One material. A wider aluminium ecosystem.

Molten aluminium inside a furnace at Wada

Built heat by heat

WE DON’T JUST MELT ALUMINIUM.WE ENGINEER IT.

1,40,000 MT of aluminium a year, with the chemistry verified on every heat.

The solar farm at the plant

Green aluminium

RECYCLED ALUMINIUM.POWERED RESPONSIBLY.

Recycled aluminium supported by solar power, cleaner fuel and on-site rainwater harvesting.

01 / 04
The future forged from the pastMaharashtra, India

Circular aluminium

METAL THAT COMES BACK.

Aluminium can be recycled again and again without losing its essential properties. Recycling it requires around 95% less energy than producing primary aluminium.

At Sunalco, aluminium doesn’t reach an end. Scrap returns as engineered metal, transformed into alloy, billet or profile, ready for another life.

Recycled aluminium can carry a fraction of the carbon intensity of conventional primary production.

The difference is not a label. It is measurable.

Indicative carbon intensity

Industry benchmarks · tCO₂e / tonne aluminium

Indian primary~20
Global primary14.8
Low-carbon primary≤4
Recycled aluminium~0.5

~97% lowerindicative carbon intensity vs. conventional Indian primary aluminium

Industry reference values shown for context. Actual footprints vary by energy source, recycled content, process and methodology. These values do not represent a verified Sunalco product carbon footprint.

The Sunalco filmWATCH THE GROUP AT WORK.Film releasing very soon

Talk to Sunalco

ONE GROUP.
EVERY FORM OF ALUMINIUM.

Tell us what you’re looking for. We’ll connect you with the right team across recycling, alloys, billets and extrusion.

In numbers

THE GROUP, IN NUMBERS.

India’s second largest secondary aluminium recycler · est. 2005

0+YEARS
0PLANTS
0+ACRES
0+FURNACES
0+MT / YEAR
0+PEOPLE

Who we are

SCRAP TO SHAPE. ONE GROUP.

Sunalco is an aluminium group from Wada, Maharashtra. It began in 2005 as a recycler making secondary alloy ingots for die casters, and it now runs two companies and three plants that take the metal from scrap to ingots, and billet, and from billet to finished profile.

Sunalco Alloys Pvt. Ltd. is the parent company; Sunalco Alu Product Pvt. Ltd. is its sister concern. Separately run, with their own boards and customers, and a shared principle for everything they make.

Mission, vision & commitment

THE PRINCIPLES BEHIND SUNALCO.

OUR MISSION Mission

Creating greater value from aluminium.

To process and manufacture aluminium efficiently, responsibly and precisely, delivering dependable products that meet customer needs.

OUR VISION Vision

To be a trusted and progressive aluminium group.

Recognised for quality, reliability, responsible growth and lasting relationships.

OUR COMMITMENT Commitment

Quality without compromise. Trust without exception.

Consistent quality, timely delivery, dependable performance and complete customer satisfaction.

Our story

TWENTY YEARS, ONE METAL.

2005

A furnace at Lakhampur

Sunalco Alloys began the way most good foundries do: with a single plant, a few people who understood metal, and customers who needed alloy they could trust. Sandeep Jain and Hitesh Kachhara set up at Lakhampur, in the Wada industrial belt north of Mumbai, making 6,000 tonnes of secondary aluminium alloy a year for the die-casting industry. The furnaces were Skelner, the feedstock was scrap, and the promise was simple: the chemistry on the certificate would be the chemistry in the ingot.

Plant I at Lakhampur from the air
The years after

Sorting before melting

Growth came from discipline rather than size. The company learned that a clean melt starts long before the furnace, and invested upstream: X-ray transmission and XRF sorters, induction sorting, heavy media separation and colour sorting, so that tramp elements never reached the metal. A spectrometer checked every heat. Customers noticed. Automotive OEMs and their die casters became regulars, and a fifth of the output began to travel: to Japan, to the United States, to Europe, through Nhava Sheva port a hundred kilometres away.

Inside a furnace at Wada
2021

Plant II, Nehroli

A second plant at Nehroli added rotary and electric furnaces for what the big Skelner furnaces were not built for: niche alloys, small heats, chemistry held to a customer’s own specification. With it, Sunalco Alloys reached eight furnaces on 26 acres and a capacity of 1,20,000 tonnes a year, and became India’s second largest secondary aluminium recycler.

Plant II at Nehroli from the air
2022

The next generation, downstream

The obvious question was what the metal could become. The answer was Sunalco Alu Product, a sister concern set up on six acres at Nehroli by Dinesh Jain, Dev Kachhara and Dhrish Jain, casting billets and extruding them into profiles. It inherited the metallurgy next door and added its own: homogenising, a press, ageing, and the same rule about certificates.

Cast billets at the extrusion plant
Today

One name on the gate

Three plants, ten furnaces, 1,40,000 tonnes of aluminium a year and more than 900 people. Two companies with their own boards, and group ventures in special alloys and lead. What has not changed since 2005 is the reason customers come back: the metal is what the paper says it is, and it arrives when promised.

The Sunalco team at the plant

Six reasons

WHY SUNALCO.

0120+ yearsSince 2005

A proven track record

Two decades of aluminium recycling and manufacturing for industrial customers.

02Advanced sortingFlotation · XRT · XRF · ISS

Better metal starts upstream

Technology-led sorting improves feed quality before the metal reaches the furnace.

03Multi-plant scaleThree manufacturing facilities

Capacity with continuity

Multiple plants give the group greater production flexibility and supply resilience.

04Customer firstSpecification · consistency · service

Built around customer requirements

Across every product, we focus on meeting specifications consistently, reliably and on time.

05Recycled by natureCircular · efficient · responsible

Lower-impact aluminium

Recycled feed, efficient processing and cleaner energy form the foundation of our manufacturing approach.

06Global reachIndia · international markets

Built to move

Strong logistics and proximity to Nhava Sheva support dependable domestic and export supply.

Businesses

TWO COMPANIES. ONE STANDARD.

Sunalco Alloys makes the metal. Sunalco Alu Product shapes it. Each has its own plant, board, certifications and team; both carry the Sunalco name.

Sunalco Alloys Pvt. Ltd. · parent company · est. 2005

BUILT FOR SCALE.

ISO 9001:2015 · ISO 14001:2015 · ISO 45001:2018 · D-U-N-S 67-739-2310

0MT / YEAR
0+CUSTOMERS
0ACRES
0FURNACES
0%EXPORT
0+PEOPLE

Sunalco Alloys Pvt. Ltd. · the parent company · est. 2005

Sunalco Alloys.
Where the group began.

Founded in 2005, Sunalco Alloys Pvt. Ltd. is a non-ferrous metal recycling unit and a leading secondary aluminium alloy manufacturer in India, and the foundation on which the entire Sunalco Group is built.

From 6,000 tonnes per annum in 2005 to 120,000 tonnes per annum today, across two plants and eight furnaces at Wada, Palghar, Maharashtra. Every tonne produced is metal given a second life: recycled aluminium takes a fraction of the energy of primary metal, so keeping it in circulation is the most direct contribution the group can make to a genuinely circular supply chain.

Two decades of metallurgical knowledge, furnace control and quality discipline sit behind every billet we extrude at Sunalco Alu Product. Our material expertise did not start with us, it was inherited.

01What we makeAlloy ingots for die casting

ADC-12, the LM series and grades made to a customer’s own chemistry, for die casters and foundries.

02Beyond aluminiumCopper · brass · zinc · steel

An established recycler of copper, brass, zinc and stainless steel as well, closing the loop between collectors and manufacturers.

03Who we supplyIndia and abroad

National automakers and die casters at home; customers in Japan, the United States and Europe through Nhava Sheva.

04How we workClose to the furnace

Quick decisions on the floor, auto-charging, punch-tracked despatch and a Kaizen culture with monthly recognition.

The Alloys Story

FROM SCRAP
TO INGOT.

How Sunalco Alloys turns mixed scrap back into aluminium alloy: sorted, melted, alloyed to grade, checked by spectrometer and cast into ingots. Pause, jump between stages or scrub the timeline below.

Sunalco Alloys · 01 — Scrap Arrival
SCRAP IN. ALLOY OUT.
THE METAL THE WHOLE GROUP IS BUILT ON.
01 / 07

Manufacturing

BUILT AROUND THE MELT.

From the scrap yard to the despatch bundle, every heat sorted, verified and traceable.

Click any stage for details

Our capabilities

SORTED BEFORE THE MELT. VERIFIED AFTER IT.

Two plants, eight furnaces and a sorting line that takes tramp elements out of the scrap before the furnace ever sees it.

Sunalco Alloys Plant I at Lakhampur, from the air
Plant I · Lakhampur · 2005

Volume production

Six Skelner furnaces, 16 MT a batch, on 11 acres.

Sunalco Alloys Plant II at Nehroli, from the air
Plant II · Nehroli · 2021

Niche alloys

Rotary and electric furnaces, 5 MT a batch, for small, closely controlled heats.

Flotation plant, XRT, XRF and ISS sorting lines
Sorting · XRT · XRF · ISS

Clean feed

Sensor sorting after flotation and heavy-media separation removes tramp elements upstream of the furnace.

Molten alloy being tapped from the furnace
Melting · 8 furnaces

Alloyed to grade

LM, ISO, EN, JIS or the customer’s own specification.

Spectrometer in the quality lab
Spectro · every heat

Checked before casting

Optical emission spectrometry on every heat, released only within limits.

Ingot laser marking line
Laser marking · heat number

Traceable to dispatch

Every ingot carries its heat number back to the furnace.

Wet scrubber and stack on the furnace exhaust
Pollution control · scrubber

Cleaner air

Wet scrubbers on the furnace exhaust and a monitored stack.

Automatic ingot stacking machine
Stacking · automated

Bundled by machine

The auto-stacker builds and straps every bundle the same way; a person only checks it.

Directors of Sunalco Alloys

The people behind the parent company.

The Sunalco Alloys team at the plant
The Sunalco Alloys team, Wada
Sandeep Jain, Director

Sandeep Jain

Director

Starting his journey in the United Kingdom, Mr. Jain provided the expertise and network that helped Sunalco become an industry leader in a short span. He has over 30 years of experience in the metal and recycling industry and is currently a director at MRAI.

Hitesh Kachhara, Director

Hitesh Kachhara

Director

With over 30 years of experience in both the ferrous and non-ferrous metal industry, Mr. Kachhara has been a leading trader in metal scrap since 1995. His focused work in this field has built a strong network across more than 50 countries on 5 continents.

Certifications

CERTIFIED, AND AUDITED.

01

Management Systems

ISO 9001:2015 — quality management, certified by TÜV NORD.

ISO 14001:2015 — environmental management.

ISO 45001:2018 — occupational health and safety.

D-U-N-S 67-739-2310 — registered with Dun & Bradstreet.

02

Health & Safety

Protective equipment compulsory across the production facility, and health insurance for all workers and employees.

Doctors and counsellors on standby, with a 6S lean workplace and TPM embedded plant-wide.

03

Recycling At The Core

Producing aluminium from recycled metal uses a small fraction of the energy required for primary aluminium.

The environmental case is built into the process itself, not added afterwards.

Recognised by
the customers
we supply.

Bajaj Auto — 'Q' Award in Bronze (2011–12), Silver (2012–13) and Gold (2014–15), and Best Ingot Supplier for three consecutive years.

Honda — Long Standing Association awards in 2016, 2017, 2019 and 2020.

Mahindra CIE Group — ESG for a Sustainable Future, 2021–22.

Supplying national automakers, national die casters and international customers across Japan, the United States and Europe.

Where to find us

Three addresses. One company.

Corporate officeGhatkopar West, Mumbai

114, Swastik Disa Corporate Park
L.B.S. Marg, Opp. Shreyas Cinema
Ghatkopar West, Mumbai
Maharashtra — 400 086

On the map →
Plant I · 2005Lakhampur, Wada

Survey No. 75, 76, 78 (P)
Mauje Village Lakhampur
Taluka Wada, Dist. Palghar
Maharashtra — 421 303

On the map →
Plant II · 2021Nehroli, Wada

Gut No. 321, Plot No. 1
Village Nehroli
Taluka Wada, Dist. Palghar
Maharashtra — 421 303

On the map →

Sunalco Alu Product Pvt. Ltd. · sister concern · est. 2022

THE PLANT, IN NUMBERS.

0+ SQ.FT.
Manufacturing infrastructure
0MT
Annual installed billet capacity
0MT
Annual installed extrusion capacity
0+EMPLOYEES
Skilled people behind every profile
Aluminium expertise · backed by the Sunalco ecosystem

About Sunalco Alu Product

Aluminium is simple.
What we do with it isn't.

Sunalco Alu Product combines modern extrusion capabilities, process control and extensive aluminium knowledge to manufacture profiles engineered around the requirements of modern industry.

Established in 2022, we manufacture a wide range of customised and standard aluminium profiles for industries including construction, electrical, automotive, engineering and industrial applications, supported by strict process controls and a commitment to consistent quality.

Sunalco Alu Product builds on the rich aluminium legacy of the Sunalco Group, with roots tracing back to Sunalco Alloys and decades of experience in aluminium manufacturing. This strong foundation gives us deep material knowledge, industry expertise and an understanding of aluminium that extends across the complete value chain.

Extruded aluminium sections, anodising-ready surface

The Extrusion Story

FROM SCRAP
TO PROFILE.

Watch the full journey of our aluminium play out, from the scrap truck to the dispatch crate, with quality checked by people at every critical stage. Pause, jump between stages or scrub the timeline below.

01 — Scrap Arrival
WE DON'T JUST EXTRUDE ALUMINIUM.
WE ENGINEER WHAT IT CAN BECOME.
01 / 16

Manufacturing

BUILT AROUND THE
EXTRUSION PROCESS.

From scrap to dispatched profile, one continuous discipline, checked for quality by people at every critical stage.

Click any stage for details

Our capabilities

INFRASTRUCTURE
BUILT FOR SCALE.

Directors of Sunalco Alu Product

PEOPLE BUILD PRECISION.

Machines extrude aluminium; people engineer outcomes. At Sunalco Alu Product we invest in the growth, skill and wellbeing of the team behind every profile, because consistent quality begins with people who take ownership of it. Training, safety and long careers are part of how we manufacture.

The Sunalco Alu Product team at the Nehroli plant
The Sunalco Alu Product team, Nehroli
Dinesh Jain, Director

Dinesh Jain

Director

Dinesh anchors Sunalco Alu Product's long term direction. Drawing on the Sunalco Group's deep roots in aluminium, he sets the standard the company holds itself to, dependable quality, straight dealing and relationships that outlast individual orders. His conviction is simple: build carefully, deliver consistently, and growth follows.

Dev Kachhara, Director

Dev Kachhara

Director

Dev drives the operational discipline behind every profile that leaves the plant. From raw material to dispatch, his focus is process control, capacity and the daily rigour that turns capability into consistency. He believes a promise made to a customer is engineered on the shop floor first.

Dhrish Jain, Director

Dhrish Jain

Director

Dhrish leads Sunalco Alu Product's push into new applications, industries and ways of working. He connects customer requirements with the company's extrusion capability, keeping the organisation curious, quick to respond and focused on where aluminium goes next.

Where to find us

Two addresses. One company.

Corporate officeGhatkopar West, Mumbai

111, Swastik Disa Corporate Park
L.B.S. Marg, Opp. Shreyas Cinema
Ghatkopar West, Mumbai
Maharashtra — 400 086

On the map →
Extrusion plant · 2022Nehroli, Wada

Gut No. 321, Plot No. 1
Village Nehroli
Taluka Wada, Dist. Palghar
Maharashtra — 421 303

On the map →

Products

WE BUY IT. WE MAKE IT. WE SHAPE IT.

Four forms of the same metal. Scrap comes in at Sunalco Alloys and leaves as alloy ingot; Sunalco Alu Product casts billet and extrudes the billet into finished sections.

What we buy

SCRAP IN. ALLOY OUT.

Sunalco buys aluminium, copper, brass, zinc and stainless steel scrap in the ISRI grades below, across three receiving yards. Every lot is weighed, sampled and sorted before it goes anywhere near a furnace, so the price you are quoted is for the metal that is actually there.

0MT / YEAR
Scrap taken in across the sorting lines
0METALS
Aluminium, copper, brass, zinc and stainless steel
0ISRI GRADES
From old aluminium sheet to stainless turnings
0RECEIVING YARDS
Lakhampur and Nehroli, at Wada, Palghar

ISRI grades we buy

FIVE METALS. FORTY GRADES.

Choose a metal, then the ISRI code you are offering. Each grade shows what a lot must consist of, what it must be free of, and where the limits sit.

Grade definitions follow the ISRI Scrap Specifications Circular (isrispecs.org). Anything outside a definition is agreed between buyer and seller before shipment.

How it comes in

WEIGHED. SAMPLED. SORTED.

Around 1,50,000 MT of scrap a year goes across the sorting lines before anything is charged. Sensors read each piece and the diverters send it to its own bin. Click a bin to follow one metal through the line.

  1. 01Weighed

    Every truck crosses the weighbridge in and out; the lot is booked on net metal, not gross.

  2. 02Sampled

    A sample from each lot goes to the lab, so recovery and chemistry are known before it is priced.

  3. 03Sorted

    The lot crosses the XRT, XRF and ISS lines; tramp elements leave before anything is charged.

The receiving yard from above: trucks, bales and wheels waiting to be sorted
The receiving yard, from above

Made by Sunalco Alloys Pvt. Ltd. · Wada

ALUMINIUM INGOTS.

Secondary aluminium alloy ingots for die casters and OEMs, melted from sorted scrap across eight furnaces at two plants, alloyed to the grade you specify and analysed on every heat before casting.

Cast alloy ingots stacked at the plant
0FURNACES
Six Skelner at 16 MT, two rotary and electric at 5 MT
0+GRADES
LM, ISO, EN, JIS, US and customer chemistry
0%HEATS TESTED
Spectrometer check on every heat before casting
0MT / YEAR
Alloy ingot capacity across all Plants

Quality

Verified on every heat.

01Sorted before melting

XRT, XRF and induction sorting, heavy media and colour sorting take tramp elements out upstream of the furnace.

02Spectrometer before casting

Every heat is analysed and alloyed to the grade before anything is poured. The certificate follows the metal.

03Laser-marked to dispatch

Ingots are marked and bundled by heat, so what reaches the die caster traces back to the furnace.

Chemical composition

PICK A GRADE. SEE ITS CHEMISTRY.

Every grade is a recipe. Choose one and watch the composition build up element by element, with the range each element may sit in, what the alloy is recommended for, and the names it goes by in other standards.

LM2BS 1490 · UK LM series

Composition in % by weight; aluminium is the balance. A single figure is a maximum. Published limits; tighter windows can be agreed for an order.

Recommended end use

Also known as

Sunalco Alloys · what we sell

ALLOY INGOTS, TO ANY STANDARD.

The same alloy carries a different name in every market. The table reads across the standards, so a buyer in Japan, Germany or the United States can find the grade they already specify.

UK (LM)ISOEN ACFranceGermanyItaly UNIUSA AA / ASTMUSA SAEJapan
LM0Al 99.5A53950150
LM2Al-Si10Cu2Fe46 100A-S9U3-Y45076384383ADC 12
LM4Al-Si5Cu345 200A-S5U3G-AlSi6Cu4 (225)3052319326AC 2A
LM5Al-Mg5Si1 / AlMg6A53950150
LM6Al-Si12 / Al-Si12Fe44 100AS 13G-AlSi12 (230)4514A413AC 3A
LM9Al-Si10Mg43 100A-S10GG-AlSi10Mg (233)3049A360309AC 4A
LM12Al-Cu10Si2MgA-U10G304122234
LM13Al-Si12Cu / Al-Si12CuFe48 000A-S12UN3050336321AC 8A
LM16Al-Si5Cu1Mg45 300A-S4UG3600355322AC 4D
LM20Al-Si12Cu / Al-Si12CuFe47 000A-S12-Y4G-AlSi12(Cu) (231)5079A413305
LM21Al-Si6Cu445 000A-S5U2G-AlSi6Cu4 (225)7369/4308326AC 2A
LM22Al-Si5Cu345 400A-S5UG-AlSi6Cu4 (225)3052319326AC 2A
LM24Al-Si8Cu3Fe46 500A-S9U3A-Y4G-AlSi8Cu3 (226)5075 / 3601A380306AC 4B / ADC10
LM25Al-Si7Mg42 000A-S7GG-AlSi7Mg3599A356323AC 4C
LM26Al-Si9Cu3MgA-S7U3G3050332332
LM27Al-Si7Cu2Mn0.546 6007369AC 2B
LM28Al-Si19CuMgNi6251
LM29Al-Si23CuMgNi6251
LM30Al-Si17Cu4Mg390
LM31Al-Zn571 000A-Z5G3602712310

How to read the table

UK (LM)
British Standard BS 1490 casting alloys. The LM numbers are the names most Indian foundries and die casters specify by.
ISO
ISO 3522 designation by chemistry. Al-Si10Cu2Fe reads as aluminium with about 10% silicon, 2% copper and controlled iron.
EN AC
European standard EN 1706 numeric code for aluminium casting alloys.
France
NF A57-702 designation used by French foundries.
Germany
DIN 1725 G-Al designation, with the DIN material number in brackets.
Italy UNI
Italian UNI standard alloy numbers.
USA AA / ASTM
Aluminum Association three-digit casting alloy numbers, as used in ASTM B85 and B26.
USA SAE
SAE J452 casting alloy numbers used by American automotive buyers.
Japan
JIS H 5302 (ADC, pressure die casting) and JIS H 5202 (AC, casting) designations.

A blank cell means that standard publishes no direct equivalent. Equivalents are indicative; grades are produced to the customer’s own specified chemistry on request.

Cast by Sunalco Alu Product Pvt. Ltd. · Wada

ALUMINIUM BILLETS.

Billets cast for our own presses and supplied to other extruders. Four diameters, cut to any length you specify, and produced in any alloy grade you require, including grades developed with you, where we work from your application backwards to a chemistry that suits it.

0MT / YEAR
Billet casting capacity
0+SIZES
Billet diameters, hot-top cast
0+ALLOYS
6061, 6063, 6082, 6005, 2024 and customer grades
0+CUSTOMERS
Our own presses and other extruders

Billet Sizes Available

Drag to rotate

Selected Billet

Diameter5″
Metric diameter127.0 mm
Cross section126.7 cm²
Mass per metre34.2 kg/m
Log lengthAny length
CastingHot-top casting
AlloyAny grade · custom chemistry
Mass of one billet205 kg

Mass calculated at 2.70 g/cm³. Lengths outside this range are produced to order.

Cast billet logs, each end marked with alloy and length

Standard Alloy Grades

Composition in % by weight. Aluminium is the balance. Grades are produced to these published limits; tighter internal windows can be agreed for a specific order.

01

Tailored Chemical Compositions

Billets produced to a chemistry window you specify within these grades, where your process or downstream temper requires it.

02

Custom Lengths & Surface Finishes

Cut lengths and surface condition set to suit your press, your handling and your yield.

03

Specific Mechanical Properties

Where an application is driven by strength or formability rather than grade name, we work to the property targets instead.

Extruded by Sunalco Alu Product Pvt. Ltd. · Wada

EXTRUDED SECTIONS.

Our presses run 7″ and 9″ sections. Billets cast on site move straight to the press, so chemistry, temper and section come from one continuous process rather than three separate suppliers, and a die developed with you stays with us for every repeat order.

0"Press section
0"Press section
0MTCapacity per year
Extrusion press
On the press

What We Run

  • Solid sectionsBars, angles, tees, channels and flats.
  • Hollow sectionsTubes and closed profiles drawn over a mandrel.
  • Semi hollow & complexMulti cavity sections and thin wall geometry.
  • Customer sectionsExtruded to your drawing, die developed with you.

Find A Profile

Profiles are organised by the industry they serve.

Pick a sector and you will land on its profile list, its 3D views and its specification sheet.

Interactive

EXPLORE THE PROFILES

Choose an industry to see the profiles we extrude for it. Select any profile to open it in 3D, drag to rotate, or switch to front, side and cross section views.

02Profile family

Profiles for Electrical

03View and download

Size rangeone section
Weight8.74 kg/m
In the catalogue1 drawing
Profile geometryFinned heat sink

Ranges are the lowest and highest drawing in the family. Exact dimensions and tolerances are on each drawing in the PDF.

W 60.0 mm
H 40.0 mm
t 4.0 mm
Drag to rotate

Industries

ENGINEERED ACROSS
INDUSTRIES.

Custom Extrusion

YOUR DESIGN.
OUR EXTRUSION.

Every application creates different requirements. Our manufacturing approach allows us to work with customers on aluminium profiles developed around specific dimensional, functional and performance requirements.

Send a drawing and our technical team reviews section geometry, alloy, temper and manufacturability before coming back to you.

Industry · 01

ConstructionAluminium formwork

Monolithic aluminium formwork lets a builder cast walls and slabs together, floor after floor, with the same panels. Every soldier, side rail, corner and channel panel has to be straight, flat and identical to the last one, and stay that way through hundreds of pours.

Aluminium formwork in place on a high-rise slab
What the industry needs
  • Repeatable panels: the same section, the same tolerance, order after order.
  • Flatness, straightness and twist held tight enough that panels close without shims.
  • 6061-T6 that takes the pour pressure and the crane without deforming.
  • Long service life: a system that survives a full tower, then the next one.
How Sunalco supplies it
  • Billets cast in-house from Sunalco Alloys metal, so the 6061 chemistry is controlled before the press.
  • Extruded on our 7″ and 9″ presses, aged to T6, cut to the length the system needs.
  • Every drawing carries flatness ±1.0 mm, straightness ±1.7 mm/m and twist ±1.25 mm/m, checked before dispatch.
  • Die development with you for a new system component, then repeat orders from the same die.
Industry · 02

IndustrialGeneral engineering

Machine builders, fabricators and component makers want stock they can cut and machine without surprises: round bar that turns clean, flat bar with square edges, tube with a consistent wall, and the odd special section that saves an assembly.

Aluminium extrusion profiles for industrial use: tubes, channels, heat sinks and framing sections
What the industry needs
  • Bar and tube that machines cleanly, with hardness and UTS on the certificate.
  • Consistent wall and diameter along the length, lot after lot.
  • Short runs and repeat runs from the same die.
  • Special sections that replace a fabricated assembly with one extrusion.
How Sunalco supplies it
  • Round bar Ø19 to Ø110 mm, flat bar from 40×10 to 210×28.5 mm and square and rectangular tube 100×100 and 150×100 in 6061-T6, hardness 80 BHN, UTS 260 MPa.
  • Round tube Ø29 to Ø45 mm, clamp sections, motor housings, the SN enclosure set and finished parts such as the Bullet parts, from the same billet.
  • Ultrasonic-tested billets and a certificate per heat, so what is machined is what was specified.
  • A die and a first lot, then stock on call.
Industry · 03

ElectricalThermal and enclosure hardware

For electrical manufacturers, Sunalco Alu Product extrudes the sections their products are built around: finned heat sinks, round motor housings and the SN enclosure set of main body, covers and side rail. Every section is pressed from billets we cast ourselves from Sunalco Alloys metal, so the 6063 chemistry is controlled at the furnace, not taken on trust from a supplier.

Aluminium extrusion for the electrical sector: heat sink and motor casing
What the industry needs
  • Fins that extrude straight and stay straight at the length you cut.
  • An alloy that conducts, anodises evenly and machines for mounting.
  • Enclosure and mounting sections that suit your assembly, not a stock size.
  • Chemistry that behaves the same lot after lot.
How Sunalco supplies it
  • Finned heat sinks and round motor housings in 6063-T6, from the catalogue or to your drawing.
  • Enclosure sections such as the SN set (main body, upper and side covers, side rail), and mounting sections developed with you: one die, repeat orders.
  • Chemistry held to the grade on every billet, so conductivity and anodising behave the same lot after lot.
  • Cut lengths and drilled or tapped parts on request.
Industry · 04

AutomotiveIngots for die casters, sections for builders

Automotive is the one industry the group serves from both ends: Sunalco Alloys melts the ingot that becomes the casting, and Sunalco Alu Product extrudes the sections that go on and around it.

Aluminium in a vehicle: die-cast parts from ingots and extruded sections from billets
Sunalco Alloys · ingots

For the die caster

ADC-12, the LM series and customer chemistry for engine, transmission and structural castings. Every heat verified on the spectrometer, every ingot marked with its heat number.

  • Bajaj Auto ‘Q’ Award, Gold 2014–15; Best Ingot Supplier three years running.
  • Honda Long Standing Association awards, 2016 to 2020.
  • Mahindra CIE Group, ESG for a Sustainable Future 2021–22.
Sunalco Alu Product · extrusion

For the vehicle builder

Round bar, tube and square tube for machined and fabricated parts, motor housings, and custom sections developed to your drawing for rails, frames and carriers. Billets cast from the same group metal, extruded and aged in one plant.

  • Round bar Ø19–110 mm, round tube Ø29–45 mm and square tube 100×100 from stock dies; finned motor housings.
  • Custom profiles: die developed with you, first lot inspected, then repeat.
  • Ultrasonic-tested billets, hardness and UTS on the certificate.
In the catalogue · extrusion sections

Why Sunalco Alu Product

FIVE THINGS WE
HOLD OURSELVES TO.

01

Precision Engineering

Accurate control of chemical and mechanical specifications, verified before dispatch.

02

100% Recycled Aluminium

Our extrusions are manufactured from recycled metal, a fraction of the energy of primary aluminium.

03

BIS Certified

Guaranteed compliance with national standards, with ISO certification for this facility in progress.

04

Flexible Customisation

Chemistry, length, finish and section designed around your specific project needs.

05

Reliable Delivery

Integrated billet casting and extrusion under one roof, so lead times are planned, not hoped for.

Quality

PRECISION IS NOT
INSPECTED IN.
IT IS BUILT IN.

Consistency in aluminium extrusion depends on control throughout the manufacturing process. From billet preparation and extrusion parameters to dimensional verification and final inspection, Sunalco Alu Product focuses on establishing process discipline at every critical stage. Quality raw material, sorting expertise and heavy machinery come first, then spectrometer analysis, billet end cutting, ultrasonic crack detection, homogenisation and processing at controlled temperature engineer quality into the material before it is ever extruded.

CHECKED AT EVERY GATE.

Only material within tolerance ships

Sustainability

TOMORROW DEPENDS ON WHAT WE DO TODAY.

Sunalco exists to keep aluminium in circulation. Every tonne the group makes is metal that did not have to be mined, and everything around the furnace, the power, the water, the air and the people, is run to the same standard. This page is what the group has done, what it is doing, and what comes next.

0MT CO₂
Avoided to date at the Wada plants
0.00MWp SOLAR
Group solar farm near Wardha
0WATER DISCHARGE
ETP and STP on site; rainwater harvested
0%CARBON CUT
Group target by 2030 against the 2022 baseline

Circular metal

THE LOOP IS THE BUSINESS.

Sunalco is not a manufacturer with a recycling programme. The circle is the model: scrap in, alloy out, billet, profile, product, and back again. Follow the metal around the loop, or pick a stop.

01

Collect

Scrap arrives from collectors and processors across India and abroad: sheet, castings, cans, wheels, wire and shredded Zorba.

Sunalco · three receiving yards

Energy to make one tonne

Primary aluminium smelted from ore~14,000 kWh
Recycled aluminium remelted from scrap~700 kWh

Industry reference values for context (about 95% less energy); actual figures vary by process and energy source and are not a verified Sunalco product footprint.

Energy & water

WHAT THE PLANTS DO ABOUT IT.

Recycled feed is the biggest lever. These are the others, at the Wada plants, with where each one stands.

Rows of solar panels at the Sunalco solar farm
Live

Solar farm

A 2.45 MWp solar farm near Wardha feeds the plants. 60% of the group’s power is to come from solar by 2026.

Rainwater harvesting: modular tank under the ground, inspection and reuse wells
Live

Zero discharge, zero waste

Effluent and sewage treated on site, rainwater harvested and reused, and organic waste composted instead of leaving as refuse.

Wet scrubber and stack on the furnace exhaust
Live

Clean exhaust

Wet scrubbers on the furnace line and a monitored stack, so nothing leaves the roof that should not.

Tree cover around the plant
Underway

Green cover

Tree planting and reforestation across the factory district, run with IIT.

Biofuel pellet feed on the furnace line
Next

Biofuel

Wood pellets pressed from sawdust and agricultural waste, in place of fossil fuel on the furnace line.

Fuel conversion from oil firing to gas firing
Next

Oil to gas

The oil-fired furnaces converted to gas: cleaner fuel, lower emissions, less downtime.

Roadmap

DONE. UNDERWAY. NEXT.

What the group has committed to, in the order it is happening.

  1. 2005Founded on recycled feed

    Sunalco Alloys starts at Lakhampur making alloy from scrap, never from ore.

  2. 2022Sort before you melt

    Heavy-media and induction sorting, auto-stacking and laser marking go in; XRT, XRF and ISS follow.

  3. LiveSolar, water, air

    2.45 MWp solar farm, zero water discharge, compost unit and scrubbers on the furnace line.

  4. 202660% solar power

    Share of the group’s electricity from the solar farm.

Community

AROUND THE PLANT, NOT JUST INSIDE IT.

The plants sit among the villages of Wada taluka, and the group treats that as an obligation rather than a location. A share of what Sunalco earns goes back out, mostly to children.

“Our tomorrow depends on what we do today.”The Sunalco mantra
The Sunalco team at the Wada plant
01Children firstHealth · education

Support for children’s health and education charities, and for the events that fund them.

02Village schoolingAround the plants

Sponsorship and school needs for underprivileged children from the towns and villages near the Wada plants.

03A share of profitsNGO partners

A portion of profits goes to established NGOs working on social relief.

04Work close to home900+ people

Three plants in Palghar district that employ locally, train on the job and keep careers long.

People

SAFE BY DESIGN.

Health and safety at Sunalco is machine-based rather than reminder-based: the layout, the automation and the rules are built so the safe way is the easy way.

PPE, no exceptions

Protective equipment is compulsory across every production area.

Health insurance for all

Every worker and employee is covered.

Doctors on standby

Doctors and counsellors available at the plants.

6S and TPM

A lean workplace with total productive maintenance embedded plant-wide.

Machines do the heavy lifting

Auto-charging, auto-stacking and auto-punching keep hands away from hot metal and heavy loads.

Kaizen, every month

Ideas from the floor, a monthly award and incentives for the people who make them work.

Careers

BUILD WHAT'S NEXT.
WITH US.

Extrusion is a craft, and crafts are carried by people. At Sunalco Alu Product you'll work with modern equipment, learn the discipline of precision manufacturing and grow with a company that is building for the long term.

We value ownership, safety and steady skill development, and we promote from within wherever we can.

Contact

TALK TO SUNALCO.

Two companies, one enquiry form. Tell us what you need in the form below and it goes straight to the right team.

Sunalco Alloys Pvt. Ltd.

Alloy ingots

Office114, 1st Floor, Swastik Disa Corporate Park, L.B.S. Marg, Opp. Shreyas Cinema, Ghatkopar West, Mumbai, Maharashtra 400086 Factory · Plant ISurvey No. 75, 76, 78 (P), Village Lakhampur, Taluka Wada, Dist. Palghar, Maharashtra 421303 Factory · Plant IIGut No. 321, Plot No. 1, Village Nehroli, Taluka Wada, Dist. Palghar, Maharashtra 421303
Sunalco Alu Product Pvt. Ltd.

Billets · extrusions · scrap

Office111, 1st Floor, Swastik Disa Corporate Park, L.B.S. Marg, Opp. Shreyas Cinema, Ghatkopar West, Mumbai, Maharashtra 400086 FactoryGut No. 321, Plot No. 1, Village Nehroli, Taluka Wada, Dist. Palghar, Maharashtra 421303

Enquiry

GET IN TOUCH.

Leave your details and what you need, and our team will come back to you.

Please fill in your name, company (not needed for careers), a valid email, phone number and the product.

Sorry, your enquiry could not be sent just now. Please try again in a few minutes.

By sending this form you agree that we may use these details to respond to your enquiry, as set out in our Privacy Policy.

Thank you. Your enquiry has been sent.

It has gone to the right team at Sunalco, and they will get back to you shortly on the email or phone number you gave.

Legal

Privacy Policy

Effective 12 October 2026 · Last updated 12 October 2026

How the two Sunalco companies collect, use, share and protect personal data received through this website, and the rights you have over it.

Legal

Terms of Use

Effective 12 October 2026 · Last updated 12 October 2026

The terms on which you may use this website and the information, catalogues and documents on it.