Dr Robert Makila Sambian
The Volta Aluminium Company Limited (VALCO) has introduced a 1:4:4 shift system to support round-the-clock operations at its new Continuous Casting and Rolling (CCR) Electrical Grade Rod Mill, as the company expands its production capacity and workforce.
The development was highlighted on November 3, 2026, by VALCO Chief Executive Officer, Dr Robert Makila Sambian, during the Progress Series organised by the Ministry of Lands and Natural Resources to showcase developments across Ghana’s industrial sectors.
The initiative aligns with President John Dramani Mahama’s agenda to promote value addition, domestic processing and industrial transformation rather than the export of unrefined raw materials.
The installation of the CCR Electrical Grade Rod Mill enables VALCO to process primary liquid aluminium directly into high-grade electrical rods for domestic and international markets.
Speaking on the commercial prospects of the new production line, Dr Sambian said VALCO was now supplying electrical rods to Ghana’s power and construction sectors while also fulfilling orders for European markets.
“Through the operationalisation of the CCR rod mill, VALCO is no longer merely an exporter of primary metal. We are supplying high-grade electrical rods to fuel Ghana’s domestic power and construction sectors while simultaneously fulfilling orders for European export markets.
This dual-market focus strengthens our foreign exchange earnings and positions Ghana as a competitive player across the global aluminium value chain,” he said.
The introduction of the CCR rod mill has also led to changes in the company’s work arrangements to support continuous 24-hour manufacturing.
Under the 1:4:4 shift system, four workers are assigned to each operational role across four rotating shifts, allowing the plant to maintain continuous production.
Dr Sambian said the arrangement was intended to ensure operational consistency, improve worker safety, reduce fatigue and create stable employment opportunities.
“Running a 24-hour continuous casting process requires absolute consistency, and assigning four dedicated personnel to every role across four rotating shifts allows us to maintain non-stop production while prioritising worker safety, mitigating fatigue, and directly expanding stable job opportunities for our workforce,” he said.
VALCO’s overall workforce increased to 848 employees by October 2026, from 785 in December 2025, following the introduction of the value-addition line and retooling efforts across the plant.
Management projects that the full restoration of all five potlines, alongside the expansion of downstream manufacturing, will increase the company’s direct workforce to 1,500 and support more than 6,000 indirect jobs nationwide.
To support the expanded production programme, VALCO has added equipment to its operations. These include 16 lift trucks, two payloaders, two melting furnaces, a centrifuge system, mobile crushing equipment, cranes and natural gas pipeline infrastructure.
The company has also secured 5,000 metric tonnes of imported carbon anodes to support the ramp-up of its reduction cells towards a target of 150 operating units.
VALCO said it remained on course to close October with 98 active reduction cells, following efforts to stabilise plant operations and lay the foundation for further growth across Ghana’s aluminium value chain.
