Volkswagen’s Kassel Foundry Introduces Energy-Efficient Chip Melting Furnace
The Kassel foundry has made significant strides in advancing recycling efforts with the installation of a chip melting furnace, which has been operational since June 2024. This innovative furnace is expected to lower energy consumption by approximately 3,250 MWh annually, leading to significant reductions in operating costs and environmental impact. Additionally, the new system will help reduce CO2 emissions by over 1,400 tonnes per year, contributing substantially to Volkswagen's climate goals.
The on-site melting process at the Kassel foundry is a key milestone in promoting circular economy practices and sustainability. By recycling all aluminum chips produced at the Kassel plant back into the casting process, the foundry significantly cuts energy usage and emissions, aligning with Volkswagen's 'goTOzero' mission. This initiative reflects the company's commitment to reducing CO2 emissions in production and fostering resource-efficient manufacturing through the adoption of environmentally friendly technologies.
One of the notable advantages of this on-site melting process is the elimination of transportation to external recycling facilities. By keeping recycling operations entirely in-house, the foundry reduces truck traffic, leading to lower transportation costs and a smaller carbon footprint. This initiative demonstrates Volkswagen's proactive approach to sustainability, positioning the Kassel foundry as a leader in efficient, eco-friendly industrial practices.
Currently, the Kassel foundry melts approximately 20 tonnes of aluminum chips per day. In the medium term, the facility plans to process an additional 40 tonnes of material from other Volkswagen plants across Europe, with the eventual goal of handling as much as 80 tonnes. Foundry manager Mirco Wöllenstein emphasized the importance of melting aluminum chips at such a large scale, describing the process as a bold yet necessary step towards reducing the environmental impact of industrial production. Wöllenstein highlighted the collaboration between different plants and business units as critical to achieving the highest possible CO2 savings, underscoring the foundry's dedication to improving efficiency and sustainability.
Wöllenstein also noted the challenges of preventing corrosion on the aluminum chips, as any corrosion could affect the quality of the melted product. Nevertheless, the project remains a significant achievement for the Kassel foundry, setting a new standard in sustainable aluminum recycling.
