Beinbauer Casting is setting up climate-friendly production: ABP supplies an electric melting plant

The official go-ahead for this innovative large-scale project was given with the signing of the 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 is set to undergo a far-reaching technological transformation in the coming months. The existing cupola furnace is being replaced by a modern, electrically powered induction melting plant – a measure that could reduce CO₂ emissions by almost 90 per cent in future.

A wave of optimism in Schwerte

For Beinbauer Casting, this project means far more than just technological modernisation. The new electric foundry paves the way for more sustainable production, meets new customer requirements and secures the long-term growth of the German plant: “Despite the current economic challenges facing energy-intensive industries, we are making a conscious decision to invest in modern and sustainable technologies – for the benefit 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 was therefore a strategic decision by the Beinbauer Group. Rising requirements throughout the entire supply chain and the growing interest among original equipment manufacturers in low-carbon components have recently increased the pressure for this transformation. At the same time, the foundry is located in the heart of the city, which is a further reason to significantly reduce emissions and environmental impact.

“The contract awarded by Beinbauer Casting GmbH to ABP Systems GmbH is a strong commitment to Germany as a business location and underlines the metallurgical industry’s determination to drive forward decarbonisation in Germany despite challenging conditions,” explains Till Schreiter, Managing Director of ABP Induction Systems GmbH. “Both companies share a long history of trusting cooperation and cultural affinities. ABP is grateful for the trust placed in our staff and our technological expertise and looks forward to a successful collaboration on this project.”

The collaboration began as early as 2021: Advanced development based on real operational data

As early as 2021, Beinbauer commissioned ABP to carry out a comprehensive engineering study. The aim of the study was to develop a viable concept that took into account both the structural conditions and ongoing production operations. Using the ABP Meltshop Designer simulation software developed by ABP, numerous variants were simulated and adapted to the customer’s specific requirements.

“Particular attention was paid to ensuring maximum flexibility in the future melting process,” explains Alexander Keller, Head of Systems Sales at ABP Induction. “Fluctuating sales volumes, the reuse of scrap and charging areas, as well as energy efficiency, played a key role in this.” The integration of existing holding furnaces was also examined in order to optimise investment costs. “The new electric melting plant is designed to adapt optimally to fluctuating production volumes. This provides Beinbauer with an extremely flexible and future-proof system,” explains Alexander Keller, who was involved in the project from the outset.

Plant capacity and state-of-the-art induction melting technology

The new melting plant has a capacity of 25 tonnes of molten metal per hour. To ensure operational reliability and flexibility, the plant is based on two independent melting systems comprising a total of three crucible furnaces from the ABP IFM 7 series. The modern extraction hoods meet the strictest requirements of the TA Luft (Technical Instructions on Air Pollution Control) whilst ensuring optimum occupational safety and environmental protection. Power is supplied by two high-performance MF converters, each rated at 8,000 kW. The plant technology is complemented by the digital control software Prodapt Enterprise, which enables the long-term storage of all relevant operational and production data. The software is a crucial factor for efficiency, process stability and traceability.

The cooling concept as a significant technical advance

Great attention has been paid to the newly developed cooling and heat recovery concept, which perfectly complements modern electric smelting technology. Instead of the old cooling tower solution, which required high maintenance, high water consumption and water treatment, air/water coolers with highly efficient, speed-controlled fans are now used.

In addition, each of the two furnace systems is equipped with a further controlled auxiliary water-to-water heat exchanger, which can store up to 2,000 kW of waste heat. The output-based single-pipe control system enables a return temperature of almost 80 °C – an exceptionally high figure that eliminates the need for an additional heat pump. To reduce energy consumption, all pump stations are fitted with variable-frequency drives.

The new concept also integrates the cooling of existing systems, including the ABP holding and casting furnaces as well as the hydraulic station in the moulding shop. The coolers installed on the roof of the building also comply with all noise protection regulations, thus ensuring low-emission operation in the heart of the city.

Next steps in the transformation of Beinbauer Casting

Construction and installation work is due to be completed by the end of 2026. Production is set to begin in early 2027, when molten iron flows from the new electric arc furnace in Schwerte for the first time. With this project, Beinbauer Casting and ABP Induction are sending a clear message: transformation is possible when courage, technology and collaboration go hand in hand.

Next steps towards CO₂-friendly production at Beinbauer:

• Construction work at Beinbauer Casting is expected to be completed by mid-September 2026.
• Delivery of the plant components will begin at the end of September 2026.
• Installation work is expected to be completed by early December 2026.
• Commissioning of the plant is expected to begin by the end of November 2026.
• The cold commissioning of the furnace systems will be completed by 23 December 2026.
• The renewal of the refractory lining and the sintering of the crucible furnaces will take place in early 2027.
• The first liquid metal casting from the two furnace systems is scheduled for the calendar week of 27 March.
• Series production at the new foundry will commence at the end of January 2027.

About the Beinbauer Group

With over 100 years’ experience, the Beinbauer Group combines time-honoured tradition with state-of-the-art manufacturing technology. With five sites, the group is one of Europe’s leading providers of casting and machining solutions.

Its full-service portfolio ranges from mechanical machining and coatings to the logistics of cast and forged components. From the procurement of raw parts to just-in-time delivery, the Beinbauer Group develops bespoke solutions for high-quality components – in both large and small production runs.

Quality and sustainability are at the heart of everything we do: with certifications 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.

Further information about the Beinbauer Group: www.beinbauer-group.de

About ABP Induction

ABP Induction is a leading supplier of induction melting and heating systems, aftermarket services and digitalisation solutions for the global foundry, forging and steel industries. ABP has sales, production and after-sales service locations in the USA, Germany, Sweden, Mexico, Thailand, India, China and South Africa. Further information about ABP Induction is available at www.abpinduction.com.