Hand in Hand into a Green Wonderland?

According to the German Federal Statistical Office, more than a quarter of the total energy consumption in Germany is dedicated to industrial production. Among manufacturing sectors, the metal industry, including foundries, and the chemical industry are the largest energy consumers. This high energy demand contributes to the industry’s poor reputation regarding environmental impact. Yet, Europe’s die casting industry has the potential to change this perception and even lead the way in sustainable practices.

The Image of Smoke and Fire 

Breaking outdated stereotypes is the first step toward improving the industry’s reputation. Many companies have already implemented technologies that are more energy-efficient and environmentally friendly. These include improved production processes, reduced material waste, circular economy initiatives, and innovative casting methods with a smaller environmental footprint. While these advancements are known within the industry, they remain under-communicated to the public. Still, companies like GF Casting Solutions and Nemak are already addressing this issue by publishing sustainability reports.

Building and Retaining Sustainable Production Expertise

Becoming a leader in sustainability requires consistent progress rather than one-time successes. Processes like megacasting and additive manufacturing demonstrate how material and energy savings can be achieved. At the same time, companies are developing recyclable alloys to create lightweight, durable, and sustainable components. These innovations are critical for the automotive and aerospace industries, as they reduce energy consumption and emissions throughout the product lifecycle. By improving environmental performance while cutting costs, these unique advancements create a competitive edge that is hard to replicate.

Easier Said Than Done

With furnaces, recycling processes, and production running at full capacity, the die casting industry faces not only high CO2 emissions but also a heavy reliance on energy prices. This poses significant challenges for European foundries, as energy costs in Europe are among the highest globally. Meanwhile, countries like China and India benefit from lower energy prices and less stringent environmental regulations.
European companies are calling for more subsidies for green technologies to finance the transition to sustainable processes. Sweden, for example, relies on intensive collaboration between government and industry. Initiatives like "Fossilfritt Sverige" (Fossil-Free Sweden) aim to develop measures to enhance competitiveness without relying on fossil fuels.

It Takes Both Words and Action

Shifting production abroad does not solve environmental problems – it merely relocates them. For Europe’s die casting industry to become a leader in sustainable production, it must position itself accordingly. Sustainability could be the key to strengthening the sector while reducing its ecological footprint. However, given the speed of global developments, achieving this goal is a monumental task.
To address these challenges, initiatives like the Executive Circle have emerged, fostering collaboration between OEMs, suppliers and foundries. This network of C-level decision-makers agrees that the adage “stronger together” must go hand in hand with enhanced communication with the public and policymakers. Now, these words must grow louder, and actions must follow.