Remal Alcast Private Limited has commenced operations at a new integrated aluminium billet casthouse at Vile Bhagad in Maharashtra, marking its entry into billet manufacturing. The facility, developed under the Remal brand and backed by the Star Group, adds new domestic capacity to India’s aluminium value chain and is positioned to serve extrusion and downstream manufacturing sectors.
The company said the casthouse has been developed in collaboration with Almex Inc. of the United States and Swastik Furnaces Private Limited of India, combining imported casting technology with locally engineered systems. The plant includes an in-house laboratory and operates in technical collaboration with Secat Inc., a metallurgical research institution based in the United States, to support billet quality and alloy development.
In its first phase, the facility is producing primary remelt aluminium homogenised billets, with around 2,300 tonnes supplied to customers since the start of operations. The second phase, scheduled for April 2026, is expected to raise production capacity to 4,500 tonnes per month and add customised alloy development capabilities. A third phase planned for November 2026 will integrate an advanced scrap sorting system and renewable energy inputs aimed at producing lower-carbon aluminium billets.
The project represents an investment of around USD 50 million and is designed for a final capacity of 7,800 tonnes per month. The plant will manufacture billets across the 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, and 7xxx aluminium alloy series, targeting applications in aerospace, automotive, renewable energy, and extrusion markets. The facility operates under AS9100D, ISO 45001, and ISO 14001 certifications and incorporates controls for carbon oxides and nitrogen oxides emissions.
Parthiv Samir Rokadia, Managing Director of Remal, said the project reflects the company’s focus on building advanced casting and metallurgy capabilities in India while embedding sustainability into its operations. He added that the company aims to support the development of skilled talent alongside capacity expansion.
Once fully operational, the casthouse is expected to generate around 400 direct and indirect jobs. The project is aligned with domestic manufacturing and circular economy objectives by combining primary metal processing with future scrap utilisation and energy transition measures.
Founded in 2022, Remal is headquartered in Maharashtra and operates through two divisions: a master alloys and cast alloys business serving the titanium and superalloy industry, and an aluminium alloy homogenised billet division. The company is AS9100D certified and draws on prior experience in aluminium trading, with a strategy focused on backward integration and expansion into higher-value manufacturing segments.
