First published in the June  2026 issue of International Aluminium Journal

Steel, aluminium, and other critical materials remain essential for developing infrastructure and accelerating electrification. With smelters operating continuously and requiring highly stable power supply, energy-intensive operations like aluminium production are grappling with uncertainty in energy prices, and grid reliability has become a defining operational risk. Demand remains structurally strong, yet volatile in pricing. Persistent energy constraints, unplanned downtime, tightening capital discipline and grid limitations impact product consistency reshaping what is feasible – and when.

Decarbonization remains a priority, but its pace is uneven. Some producers are advancing pilot technologies, while others are prioritizing asset performance and liquidity. Across the industry, the conversation has moved from ambition to execution, keeping production economics in mind. In 2026, the reality for the metals industry is that survival has become the first sustainability test.

Automation as the foundation of resilience

For metals producers, reliability, productivity and quality remain non-negotiable. The economics are stark – recent ABB research found that unplanned stoppages in large integrated facilities can cost up to $500,000 per hour. In this context, automation is the foundation of operational resilience.

In aluminium smelting operations, downtime carries similar consequences. Power interruptions or process instability can damage pots, disrupt production for extended periods, and require costly recovery processes. The strongest performers are those prioritizing process stability and predictability. Advanced automation platforms are being used to reduce variability across the production chain, from smelting and refining through to rolling and finishing, ensuring that operations run consistently within defined parameters.

Automation also plays a particularly important role for aluminium producers, managing complex electrolysis processes, and maintaining consistent performance. Stable current distribution and temperature control are critical to maximizing output while minimizing energy consumption.

This stability directly impacts both cost and sustainability. With aluminium production accounting for 3% of the world’s direct industrial CO₂ emissions, making it one of the most carbon intensive materials in the industrial landscape, even small improvements in process control and efficiency translate into meaningful impact. A stable process consumes less energy per metric ton, generates less waste and reduces rework, strengthening both financial and environmental performance.

Increasingly, producers are looking to upgrade these capabilities without disrupting production. This is driving demand for automation architectures that allow new functionality to be introduced incrementally, preserving proven control systems while enabling the integration of advanced analytics, AI and digital applications over time. In practice, this approach is becoming central to how plants evolve – modernizing without exposing operations to unnecessary risk.

Projects such as the first prospective primary aluminium smelter to be built in continental Europe in over 30 years illustrate the attention being paid to this matter. ABB, along with a group of partner companies, are currently carrying out feasibility studies to assess the case for its development. By assessing the automation and electrification possibilities at the site, the plant has the chance to be designed for centralized, data-driven operation from the outset, laying the foundation for more connected and responsive production.

Digitalization that earns its place

Digitalization remains a powerful enabler, but its adoption has become more disciplined. Investments are being prioritized where they deliver clear operational outcomes such as improving yield, reducing downtime or optimizing energy use.

Energy management systems provide an example of measurable impact. By linking real-time energy data with production planning, these systems enable more efficient load management and cost optimization. In practice, they have delivered productivity increases of 25%, gross reduction of 15% and energy savings of 10%.

Building capability for more autonomous operations

Alongside technical challenges, the industry faces a growing skills gap. As experienced personnel retire, the loss of operational knowledge is becoming a constraint to modernization.

Automation is increasingly helping to address this challenge by embedding expertise into systems. Generative AI-driven tools, such as ABB Ability™ Industrial Knowledge Vault, are enabling plants to capture and structure critical knowledge, making it accessible in real time. In practice, this has been shown to reduce workflow creation effort by up to 85 percent, cut human error by up to 90 percent, and improve workforce productivity by 45 percent.

In aluminium operations, process expertise has historically relied heavily on operator experience, therefore capturing this knowledge digitally is becoming a strategic advantage. Structured operational insights can help newer operators manage complex smelting environments more confidently while maintaining consistent performance across potlines and casthouse operations.

At the same time, automation is supporting a further shift toward more autonomous operations. Routine decisions, process adjustments and fault responses can increasingly be managed within defined parameters, reducing variability and limiting exposure to hazardous environments. Importantly, this is about augmenting operator capabilities – enabling safer, more consistent execution.

Measured progress, engineered for reality

In 2026, the competitive landscape is defined by the ability to execute reliably, efficiently, and with precision. Automation sits at the heart of this, integrating electrification and digitalization into a coherent operational framework.  This approach is becoming essential to managing both profitability and long-term viability, especially for aluminium producers navigating volatile energy markets and growing decarbonization pressure.

There is no single breakthrough that will transform the industry overnight. Instead, progress is being achieved through incremental improvements: stabilizing processes, optimizing energy use, enhancing visibility, and building workforce capability.

In this environment, survival and sustainability are not opposing goals. They are two sides of the same equation. Increasingly, it is automation that is making that equation work.