The official launch of the innovative large-scale project was marked by the signing of a contract between Phil Limbach, a member of the Beinbauer Group’s executive board, and Till Schreiter, CEO of ABP, as well as a joint site visit by the project teams from Beinbauer Casting and ABP Induction. The Schwerte foundry will undergo a profound technological transformation in the coming months. The current cupola furnace will be replaced by a modern, electrically powered induction melting facility, a measure that could result in reduced CO₂ emissions by nearly 90% in the future.
A Wave of Optimism Is Sweeping Through Schwerte
For Beinbauer Casting, this project means much more than a simple technological upgrade. The new electric foundry paves the way for more sustainable production, meeting new customer demands, and the long-term growth of the German plant: “Despite the current economic challenges facing energy-intensive industries, we are deliberately investing in modern and sustainable technologies – for the sake of the environment, our employees, and the long-term future of the Schwerte plant,” explains Phil Limbach, a member of the Beinbauer Group’s management board.
To protect the climate and ensure long-term competitiveness, this investment had therefore been a strategic decision by the Beinbauer Group. Growing demands throughout the entire supply chain and increasing interest from original equipment manufacturers in low-carbon components have recently increased the pressure for this transformation. At the same time, the foundry is located right in the heart of the city, which is an additional reason to significantly reduce emissions and pollution.
“The order placed by Beinbauer Casting GmbH with ABP Systems GmbH is a strong commitment to Germany as a business location and underscores the metallurgical industry's determination to press ahead with decarbonization in Germany despite adverse conditions,” explains Till Schreiter, Chief Executive Officer of ABP Induction Systems GmbH. "Both companies share a long history of trust-based cooperation and cultural similarities. ABP would like to express its gratitude for the trust placed in our employees and our technological expertise, and we look forward to successfully completing this project together.
Cooperation dates back to 2021: Advanced Engineering Based on Real Operational Data
Already in 2021, Beinbauer had commissioned ABP to conduct a comprehensive engineering study. The study’s aim was to develop a viable concept that considered both structural conditions and ongoing production operations. Using the simulation software developed by ABP, the ABP Meltshop Designer, numerous variants were simulated and tailored to the customer’s specific requirements.
“Special attention was paid to maximizing the flexibility of the future melting operation,” explains Alexander Keller, Head of System Sales at ABP Induction. “Fluctuating sales volumes, the reuse of scrap and charging areas, and energy efficiency played a key role in this.” The integration of existing storage furnaces was examined as well to optimize investment costs. “The new electric smelting plant is designed to adapt optimally to changing production volumes. This creates an extremely flexible, future-proof system for Beinbauer," explains Alexander Keller, who has been involved in the project from the outset.
Plant Capacity and State-Of-The-Art Induction Melting Technology
The new melting facility will have a capacity of 25 tons of molten metal per hour. To take into account both operational safety and flexibility, the design is based on two independent melting systems, comprising a total of three ABP IFM 7 series crucible furnaces. The modern extraction hoods meet the strictest requirements of the TA Luft (Technical Instructions on Air Quality Control), while ensuring optimized occupational safety and environmental protection. The power will be supplied by two powerful MF converters, each with a capacity of 8,000 kW. The plant’s technology is complemented by Prodapt Enterprise digital control software, which enables the long-term storage of all relevant operating and production data. The software is a crucial element for efficiency, process stability and traceability.
A Cooling Concept Representing a Significant Technical Advancement
The newly developed cooling and heat recovery concept has been given a lot of attention, which resulted in the concept perfectly complementing modern electric melting technology. Instead of the old cooling tower solution, which required considerable maintenance, high water consumption, and water treatment, air/water coolers equipped with high-efficiency speed-controlled fans will now be used.
In addition, each of the two furnace systems will be equipped with an additional regulated water/water heat exchanger capable of storing up to 2,000 kW of waste heat. Performance-based single-pipe regulation enables a return temperature of nearly 80 °C, an exceptionally high value that eliminates the need for an additional heat pump. To reduce energy consumption, all pump stations will be equipped with frequency converters.
Integrated into the new concept will be the cooling of existing systems, including the ABP holding and casting furnaces, as well as the hydraulic station in the molding shop. Furthermore, the coolers installed on the building’s roof will comply with all noise limits, guaranteeing low-emission operation right in the heart of the city.
Next Steps in the Beinbauer Casting Transformation
By the ed of 2026, the construction and installation work is expected to be completed, with production set to begin in early 2027, when molten iron will flow from the new electric arc furnace in Schwerte for the first time. Beinbauer Casting and ABP Induction are sending a clear message with this project: transformation is possible when courage, technology and collaboration go hand in hand.
Next Steps on the Way to CO2-Friendly Production:
- Construction work at Beinbauer Casting expected to be completed by mid-September 2026.
- Delivery of plant components beginning in late September 2026
- Completion of installation work by early December 2026
- Start of plant commissioning beginning in late November 2026
- Completion of the “cold commissioning” of the furnace systems by December 23, 2026
- Renovation of the refractory lining and sintering of the crucible furnaces in early 2027
- The scheduled date for the first liquid metal pour from the two furnace systems is set for calendar week 3/27.
- Full-scale production will begin at the new foundry in late January 2027.
About the Beinbauer Group
With over 100 years of experience, the Beinbauer Group combines proven tradition with state-of-the-art manufacturing technology. With five locations, the group is one of Europe's leading providers of casting and machining solutions.
The full range of services extends from mechanical processing and coatings to the logistics of cast and forged parts. From raw material procurement to just-in-time delivery, the Beinbauer Group develops customized solutions for high-quality components – both in large and small series.
Quality and sustainability are at the heart of everything we do: with certifications according to IATF 16949, ISO 50001, ISO 45001, ISO 14001, and TISAX, the company meets the highest standards and takes responsibility for the environment and safety. Strict quality controls and continuous improvement processes ensure first-class results.
For further information about the Beinbauer Group: www.beinbauer-group.de
About ABP Induction
ABP Induction is a leading provider of induction melting and heating equipment, aftermarket services and digitalization solutions for the global foundry, forging and steel industries. ABP has sales, production and customer service locations in the USA, Germany, Sweden, Mexico, Thailand, India, China and South Africa. Further information about ABP Induction can be found at www.abpinduction.com.
