Chip melting furnace at the Kassel foundry for Volkswagen Group Components
The scrap melting furnace at the Kassel foundry, which has been in operation since June 2024, represents a significant step forward in the recycling process. The implementation of this furnace reduces energy consumption by around 3,250 MWh per year, which not only optimises operating costs but also reduces the environmental impact. In addition, CO2 emissions are reduced by over 1,400 tonnes annually, making a significant contribution to achieving climate targets.
Volkswagen’s ‘goTOzero’ vision
These measures support Volkswagen’s ‘goTOzero’ vision, which aims to drastically reduce CO2 emissions in production and promote sustainable, resource-efficient manufacturing. 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 recycling of all aluminium chips generated at the Kassel plant back into the casting process is an important step towards a circular economy and sustainability. This innovative smelting process, which takes place directly on the plant site, not only reduces energy consumption by around 3,250 MWh per year, but also cuts CO2 emissions by over 1,400 tonnes annually.
Reduction in transport costs
A further benefit of this measure is the reduction in lorry traffic, as there is no longer any need for transport to external recycling companies. This not only helps to reduce transport costs but also minimises the environmental impact through reduced traffic. Overall, this project demonstrates how Volkswagen at the Kassel plant is actively working to implement sustainable production methods whilst simultaneously increasing efficiency.
Remelting aluminium swarf in-house
Mirco Wöllenstein, the foundry manager in Kassel, emphasises the significance of the decision to remelt aluminium swarf in-house on such a large scale. He describes this step as bold and pioneering, as the process is both innovative and complex. A crucial aspect is that no corrosion must form on the shavings in order to ensure the quality of the melting process.
Importance of collaboration
Wöllenstein also emphasises the importance of collaboration across different plants and business areas in order to achieve maximum CO2-reductions. This demonstrates the Kassel Foundry’s commitment not only to increasing efficiency but also to actively contributing to the reduction of environmental impact.
Info on the Kassel Foundry
Every day, around 20 tonnes of aluminium shavings are generated in Kassel alone, which are remelted at the plant. In the medium term, the foundry aims to remelt a further 40 tonnes of material from other European Volkswagen plants. In the long term, the volume is set to rise to up to 80 tonnes of shavings. “By eliminating the need for an additional external remelting process, we remain more environmentally friendly and cost-effective than before, despite the transport distances to Kassel that will then be involved,” said Wöllenstein.