Mumbai, November 11, 2025: RUSAL, one of the world’s largest aluminium producers, has implemented two significant innovation in its digitalization journey, leveraging Artificial Intelligence (AI) to enhance operational efficiency and product quality.
A core innovation is the AI-based technology developed by RUSAL’s Engineering Department for efficient container control, which significantly reduces the time needed to dispatch containers from the terminal for loading with finished products.
This technology centres on creating a virtual twin of the terminal, where high-precision positioning systems and machine vision recognize and track containers. The system records the location and identification numbers of all containers awaiting loading with aluminium.
Prior to the launch of this project, containers were not systematically organized, and their locations were unrecorded, often delaying the finding of required containers and impacting terminal throughput. Locating and preparing a container for loading previously took an average of 30 minutes; the new technology drastically reduces this duration.
In parallel with its logistics innovations, the Russia-headquartered company with global operations, has deployed AI to significantly enhance its quality control processes.
The Company now utilizes artificial intelligence for the microstructure analysis of aluminium ingots. This proprietary technology offers a major time-saving advantage, reducing the required analysis time from several hours to just 15 minutes. This efficiency gain streamlines quality control procedures and minimizes the need for repetitive manual tasks.
RUSAL’s focus on digital logistics and advanced quality analysis showcases the crucial role digitalization plays in promoting the potential and practical applications of artificial intelligence within heavy industry.
By transforming complex, time-consuming processes into highly accurate and rapid digital tasks, RUSAL sets a new benchmark for operational excellence in aluminium production.
About RUSAL
RUSAL is a leading company in the global aluminium industry and the world’s largest producer of low-carbon aluminium. The Company has its own resource base and carries out the entire production cycle, from extraction of bauxite to the production of high value-added products, which ensures maximum control over product quality at all processing stages. More than 90% of the Company’s aluminium is produced with energy from renewable sources.
RUSAL reduces greenhouse gas emissions at all production stages by implementing innovations and energy-saving technologies. This has enabled the Company to become one of the pioneers in the production of ‘green’ metal which is available on the market under the ALLOW brand. 1
100% of RUSAL’s metal meets the low-carbon aluminium (LCA) benchmark of less than 4 t CO2-eq./t within Scopes 1&2, aligning with those of the leading international analytical agencies. Throughout its regions of operation, RUSAL is actively implementing social investments and initiatives, supports local communities and their projects in various sectors.
