Efficiency and sustainability redefined: FRECH ZPF sets new standards in aluminium processing

Since acquiring ZPF GmbH from Siegelsbach in January 2022, FRECH ZPF has established itself as a key player in thermal process technology. The formation of the new company, based in Schorndorf, marked a decisive step in expanding the company’s portfolio and opened up new markets in the foundry sector.

The roots of today’s FRECH ZPF date back to 1993, when the former ZPF Therm Maschinenbau GmbH was founded. Since then, the company has established itself as a specialist in holding and melting units in the large-furnace segment, with a melting capacity of up to 20 tonnes. With over 800 systems installed worldwide, FRECH ZPF ranks among the leading suppliers in the aluminium foundry industry. In addition to melting, holding and alloying furnaces, the wide-ranging product portfolio also includes state-of-the-art chip and wheel recycling systems, as well as bespoke special-purpose plants. The company’s innovation strategy is clearly focused: energy efficiency, CO_₂-neutrality and sustainable process recycling are at the heart of its ongoing development.

Innovation live at GIFA 2023: Premiere of a highly efficient melting unit

At GIFA 2023, the world’s leading trade fair in Düsseldorf, FRECH ZPF presented a groundbreaking prototype for the process recycling of aluminium (Figure 1). With a capacity of up to 12 tonnes of molten aluminium and an impressive melting rate of 0.7–1.2 tonnes per hour, this innovative melting unit sets new standards in the industry.

At the heart of the plant is an innovative burner control technology combined with optimised temperature control. This enables particularly energy-efficient processing of aluminium chips from process recyclates, as well as flexible blending of various secondary materials such as wheels, scrap or shredded material.

A particular milestone: thanks to the newly developed burner air preheating system and a special insulation structure, energy consumption has been significantly reduced. Whilst previously around 800 kWh per tonne of aluminium was required, consumption is now below 600 kWh – a saving of up to 25 per cent. Furthermore, passive exhaust gas purification ensures compliance with the TA-Luft guidelines without the need for additional filter systems.

With this innovative approach, FRECH ZPF not only underlines its leading role in the development of sustainable technologies, but also makes a decisive contribution to the ‘green foundry’ of the future. The combination of energy efficiency, emissions reduction and intelligent recycling sets new standards for the aluminium industry and impressively demonstrates how sustainability and economic efficiency can go hand in hand.