A second catastrophic fire has erupted at a crucial aluminium plant in upstate New York, dealing another severe blow to automaker Ford, which could face losses running into the billions.
Inferno at a Key Manufacturing Hub
On Thursday, Novelis, the world's largest aluminium recycler and a major supplier to American car manufacturers, reported that its massive 1.5-million-square-foot facility in Oswego was engulfed in flames. The fire brigade was alerted just before 9am as thick smoke and intense flames burst from the plant's hot-rolling area. This is the section where heated aluminium slabs are pressed into long sheets specifically for automakers.
More than 80 firefighters from 20 different departments fought the five-alarm blaze for nearly nine hours. They deployed tanker trucks and multiple ladder trucks to douse the roof with water. All 1,100 workers on site were safely evacuated, according to local officials.
Ford's Production Nightmare Deepens
This fire marks the second significant blaze at the plant since September, creating yet another major disruption for Ford's already struggling truck production. The Oswego plant is central to the manufacturing of Ford's most profitable vehicle—and America's best-selling truck—the F-150.
A decade ago, Ford made a significant bet on lighter, more fuel-efficient body panels for its pickup trucks, and Novelis became its key partner in producing them. Novelis was the main supplier of that lightweight aluminium. When a fire hit the same part of the plant in September, it severely choked the supply of these essential sheets, forcing Ford to slow F-150 output. At that time, Ford estimated the disruption would cost between $1 billion and $2 billion.
The September outage had already forced temporary shutdowns at Ford auto plants in Tennessee and Michigan.
Timeline and Financial Fallout
In October, Novelis had told the Daily Mail it expected the plant to be operational by December, beating some analyst forecasts that predicted a March 2026 restart. However, Thursday's fire throws that optimistic timeline into serious doubt. Novelis did not immediately respond to a request for an updated timeline on Friday.
A Ford spokesperson stated on Friday morning, 'We're aware of the situation and working with Novelis to learn more.' The company is now assessing the damage from this new incident. Ford's stock dropped more than two percent on Thursday following the news, though it recovered by one percent in early Friday trading.
Novelis had been running an around-the-clock repair effort since the first fire, complete with stadium lights to enable night work. The repeated disruption underscores the vulnerabilities in a supply chain already strained by international trade policies. In March, President Donald Trump added 25 percent tariffs on foreign-made aluminium, later doubling them to 50 percent in May, making it more expensive and difficult for companies to find alternative suppliers.
