Case Study


Novelis is the global leader in the production of innovative aluminium products and solutions and the world’s largest recycler of aluminium. They are a global business with locations across Europe, Asia, and North America to name a few. Their aluminium products are predominantly used in the aerospace, automotive and beverage can industries.

The Novelis recycling plant in Warrington UK, is an essential part of Novelis’ European production system and is playing a key role in increasing the recycled content in Novelis’ products and lowering their carbon footprint. It has enough capacity to recycle every aluminium beverage can sold in the UK – this means around nine billion cans.

The Brief

Sudlows were instructed by Novelis to design, supply and install a new blown fibre system across the Novelis Warrington site to upgrade the current fibre system, provide connectivity to new cabinet locations and provide resilience across the network.

The Project

Sudlows’ highly qualified and experienced Design and Delivery teams, including a dedicated Project Manager were deployed to complete the project.

We have supplied and installed 2no. 24 core 5/3.5mm blown fibre tubes from the two main core comms locations on site forming a ring around the site.

The tubes were installed between each location via either an existing or new duct network through new or existing containment.

From each cabinet location 2no. 2 core 5/3.5mm blown fibre tubes were installed via diverse routes back to separate local BFTMP’s.

Once all the tubes were completed, we installed 2no. 12 core blown fibre units one from each of the core comms locations to all of the edge cabinets. This design allowed for a diverse route to all cabinets on site.


Valerie McGinty, EHS Leader at Novelis said;

“This was a difficult project that had to be implemented during working hours. The issues faced included multiple mobile equipment movements/working around hot furnaces/working at height, and working during a Pandemic. From the start we incorporated EHS into the daily activities, Sudlows embraced and demonstrated compliance not to just our site rules but to our values. When faced with a new hazard at height, the Sudlows team immediately brought it to my attention. We re-assessed the situation and accepted why I stopped the job, supporting to find a safer alternative route. The project was delivered safely thanks to safe behaviours, good communication and collaboration.”


Dave Dixon, Shift Leader at Novelis commented;

“I have worked throughout this installation with Allan Milne then with Tony during the later stages. Both ensured EHS was followed at all-times any issues that arose were dealt with and resolved quickly. Sudlows worked very well with the Novelis Production Teams, liaising with me and the area Team Leaders each morning detailing the scope of work for the day. The work was planned each day to ensure there was minimal disruption to production. Sudlows were very accommodating at times when production plans changed and there work had to be interrupted.”


William Brett, Technical and Casting Leader at Novelis added;

“I would also say that Sudlows have worked seamlessly, hardly disrupted my team and been a pleasure to work with in the office space. They even went the extra mile by delivering ad hoc tasks such as installing a TV mount.”


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