The chip melting furnace at the Kassel foundry, which has been in operation since June 2024, represents significant progress in the recycling cycle. The implementation of this furnace will reduce energy requirements by around 3,250 MWh per year, which will not only optimize operating costs but also reduce the environmental impact. In addition, CO2 emissions will be reduced by over 1,400 tonnes per year, making a significant contribution to achieving climate targets.
Volkswagen's ‘goTOzero’ mission statement
These measures support Volkswagen's ‘goTOzero’ mission statement, which aims to drastically reduce CO2 emissions in production and to promote sustainable, resource-conserving production. The Kassel foundry is thus positioning itself as a pioneer in the implementation of environmentally friendly technologies and is actively contributing to the transformation towards a more sustainable industry.
An important step towards a circular economy and sustainability
The return of all aluminium chips produced at the Kassel plant to the casting process is an important step towards a circular economy and sustainability. Thanks to this innovative melting process, which takes place directly on the factory premises, not only reduces energy requirements by around 3,250 MWh per year but also cuts CO2 emissions by over 1,400 tonnes per year.
Reduction of transportation costs
Another advantage of this measure is the reduction in truck traffic, as transportation to external recycling companies is no longer necessary. This not only helps to reduce transportation costs, but also reduces the environmental impact through less traffic. Overall, this project shows how Volkswagen is actively working on implementing sustainable production methods at the Kassel plant and increasing efficiency at the same time.
Melting down aluminum chips in-house
Mirco Wöllenstein, the foundry manager in Kassel, emphasizes the importance of the decision to melt down aluminium chips on such a large scale himself. He describes this step as courageous and pioneering, as the process is both innovative and complex. One crucial aspect is that no corrosion is allowed to form, as the corrosion must not form on the chips in order to guarantee the quality of the melting process.
The importance of collaboration
Wöllenstein also emphasizes the importance of cooperation across different plants and business areas in order to achieve maximum CO2 savings. This demonstrates the Kassel foundry's commitment not only to increase efficiency, but also to actively contribute to reducing environmental impact.
Info foundry Kassel
Every day, around 20 tons of aluminium chips are produced in Kassel alone, which are melted down in the plant. In the medium term, the foundry plans to melt down an additional 40 tons of material from other European Volkswagen plants. In the long term, the quantity should increase to up to 80 tons of chips. “By eliminating an additional external remelting process, we will remain more ecological and economical than before, despite the transportation routes to Kassel that will then be required,”
