Remal Alcast Pvt Ltd has begun operations at its newly commissioned integrated aluminium billet casthouse in Vile Bhagad, Maharashtra, under the Remal brand. Backed by the Star Group, the facility represents a significant addition to India’s aluminium manufacturing landscape, emphasizing high-quality production, sustainability, and advanced metallurgical capability.
Developed with technical collaboration from Almex Inc, USA, and Swastik Furnaces Pvt Ltd, India, the plant integrates globally proven casting technologies with precision engineering to deliver consistent metal purity and billet quality. An in-house laboratory and a strategic partnership with Secat Inc., a globally recognized metallurgical research organization, further strengthen quality assurance and process optimization.
Phase 1 of operations has commenced with the production of primary remelt aluminium homogenized billets, with 2,300 tonnes already supplied to customers. Phase 2, scheduled for April 2026, will raise capacity to 4,500 tonnes per month and introduce customized alloy development. By November 2026, the facility plans to integrate advanced scrap sorting systems and renewable energy sources to produce low-carbon billets, positioning Remal among India’s early adopters of sustainable billet manufacturing.
The casthouse is designed to reach a final capacity of 7,800 tonnes per month as part of a USD 50 million investment. Certified to AS9100D, ISO 45001, and ISO 14001 standards, the facility incorporates strict COx and NOx emission controls and will manufacture billets across the 2xxx to 7xxx alloy series. The project supports India’s Make in India and circular economy objectives, serving aerospace, automotive, renewable energy, and extrusion sectors.
Once fully operational, the facility is expected to generate approximately 400 direct and indirect jobs, setting new benchmarks for environmentally responsible aluminium production in India. Remal Alcast is a specialised aluminium casting company known for delivering high-quality, precision-engineered components to demanding industrial applications.
Leveraging advanced casting technologies, robust quality systems, and in-house machining capabilities, the company caters to sectors such as automotive, industrial equipment, electrical, and engineering. Remal Alcast focuses on consistency, metallurgical excellence, and tight dimensional control, enabling customers to meet performance, safety, and durability requirements. With an emphasis on process optimisation, sustainability, and long-term partnerships, the company supports clients from design and prototyping through to scalable production, positioning itself as a reliable manufacturing partner in India’s evolving metal casting ecosystem.
