Focus on the Future: How Breyden GmbH is driving forward its strategic transformation from a traditional foundry to a supplier of braking systems

During an in-depth interview and an extensive tour of the foundry, Sebastian Simon, Steffen Sasse and Jan-Christopher Schwehn provided fascinating insights into the strategic reorientation and technical development of Breyden GmbH – formerly Buderus Guss – under its new owner, AEQUITA.

New brand, new values – Breyden realigns itself within the SME sector
“We had to reinvent ourselves to some extent,” explains Jan-Christopher Schwehn regarding the name change to “Breyden GmbH”. The new name draws on the company’s location in Breidenbach and emphasises its regional roots – whilst also aiming to project a more international image. The rebranding was necessary to move away from the company’s previous image (as a heating supplier) and to position itself as an innovative partner to the automotive industry. Initial feedback – both from the region and from customers – has been very positive.

New owners, new momentum – Buderus becomes Breyden
Following the change of ownership from Bosch to AEQUITA in May 2024 and the re-registration as Breyden GmbH at the end of October 2024, the long-established foundry site in Breidenbach is presenting itself with a new name, a clear focus and ambitious investment plans.
Sebastian Simon, Director at AEQUITA and project manager for the site, describes the new corporate culture as “agile, fast-paced and entrepreneurial”. Decisions are now being made with significantly greater flexibility. The aim is to deliver more than just castings – the intention is to offer technologically sophisticated products with genuine depth of value creation.

Substantial investments – new aluminium casting line

Brake disc production is to be consolidated at the Breidenbach site.

One example of this new strategic direction is the investment in a new horizontal aluminium casting line, which will be used in future to manufacture lightweight brake discs combining grey cast iron, stainless steel and aluminium. The line is due to come on stream in the first half of 2026 and will eventually operate on a three-shift basis.

The impetus came from the market; the company supplies well-known OEMs. This represents a first for the traditional iron foundry, which in itself underscores the strategic significance of this development: Lightweight brake discs are manufactured by casting an aluminium shell onto a grey cast iron friction ring fitted with stainless steel pins.
In addition, a comprehensive modernisation project is underway for ‘Foundry 1’ in collaboration with GEMCO, under the motto ‘Make the Concept Stronger’. The aim is to automate processes, make them more efficient, reduce CO₂ emissions and, at the same time, meet economic requirements.

Performance figures and focus

Breyden GmbH currently produces 13–14 million brake discs per year (capacity: up to 16 million with 15 shifts) – around 60,000 to 65,000 units daily. The planned consolidation of brake disc production at the Breidenbach site is intended to further increase efficiency. Steffen Sasse, head of the foundry since 2018, emphasises the plant’s technological flexibility. Nevertheless, the clear focus remains on brake discs: “Foundries that try to spread themselves too thin across the market struggle in times of overcapacity.”

Digitalisation with a sense of proportion

Rather than resorting to digital actionism, those in charge at Breyden GmbH are focusing on targeted digitalisation with clear benefits. Process data is collected from existing control systems, analysed and used, amongst other things, for AI-supported scrap analysis. In the melting shop, too, production is made more efficient through intelligent material composition.

The future of the brake disc

Brake discs are also needed in electric mobility – in some cases even larger ones due to heavier vehicle weights. Problems such as corrosion caused by reduced brake wear or surface rust remain challenges, but also present opportunities for innovation. The lightweight composite brake disc is a concrete response to the demand for weight reduction.
The issue of particulate matter (keyword: Euro 7 standard) is not yet resolved with iDisc II . OEMs are currently focusing on series production approval, but the long-term aim is to reduce costs whilst maintaining the same environmental impact. New powders, processes and close development partnerships with TMD Friction – another company in the AEQUITA portfolio – are driving this further development forward.

Germany as an industrial location: clear positioning despite challenges

AEQUITA and Breyden GmbH are firmly committed to Germany as a production location. However, much depends on political framework conditions such as electricity costs and CO₂ allowances. Mr Simon warns: “Foundry work is a basic industry – if we lose that knowledge, we lose more than just a product.”

Strategic focus and collaboration as the key

A defining element of the discussion was the company’s self-image as a partner. During the rebranding process, customers had reflected that Breyden is a company “you can work well with”. The aim is to be involved even earlier in the OEMs’ development processes in future.
Breyden GmbH sees itself not merely as a foundry, but as a technology and development partner that is also becoming more deeply involved in the value chain. Nevertheless, its core business with cast blanks remains essential for maintaining plant capacity utilisation. Innovation and new business models are to build on this foundation.

Conclusion

Breyden GmbH demonstrates how tradition, technology and transformation can be successfully combined. Under the umbrella of AEQUITA, the company is evolving into a forward-looking, technologically ambitious foundry with a clear positioning in the European brake disc market – and with a strong commitment to innovation, quality and loyalty to its local community.

Interview: Foundry-Planet | Interviewees: Sebastian Simon, Steffen Sasse, Jan-Christopher Schwehn

About Breyden GmbH

Breyden was founded in 1913 and has several sites in Hesse: state-of-the-art foundries, production and machining facilities in Breidenbach and Lollar, as well as our innovation centre for brake discs in Ludwigshütte.

• Employees: 560
• Brake discs in 2024: approx. 13 million
• Product portfolio:
  • EU7-coated brake discs (iDisc II)
  • Lightweight brake discs
  • GG brake discs (vented and solid)