Improving sustainability in our die casting and machining manufacturing processes.
Our manufacturing process is continually being refined to produce the best sustainability results possible for our employees, customers, and the environment. We have invested heavily in ensuring our die casting and machining technology and processes are as optimised as possible, and we’ve plenty more ideas in the pipeline as well!
A remarkable 98% of the metal that we use in production is secondary, recycled aluminium. This metal requires 80% less energy to melt.
We’ve reduced our C02 emissions by 500 tonnes a year since 2019 due to investment in innovative technology. The carbon content of the secondary alloy we use represents only 20% of that apparent in pure grade aluminum alloy.
Aluminium is the most recycled metal in the world. Amazingly, 90% of the aluminium in circulation today was in use in the 1990s.
Sustainability in Die CastingCastAlum2023-01-26T12:14:11+00:00
Upgrading our Technology
A large investment in voltage optimisation system has resulted in reduction of 500 tonnes of C02 per year.
In the past few years alone, we have invested £4,000,000 to date in new energy efficient equipment.
We replace all our factory and office lighting with LED systems.
An air flow control system has been installed. This further reduces energy consumption and improves the working conditions.
Several insulation upgrades have been installed, including our warehouse in 2021.
Improving our Systems
We ensure our quality standards are the best in the business. This leads to minimal customer rejections, resulting in reduced energy required to process returns through transport costs.
The amount of water that we expend is quantified and recorded for monthly review. This helps us to reduce the quantity of water wastage and continually define areas for improvement.
We are members of our national trade association’s “zero carbon” committee.
As we are able to provide cast and machined products, we have optimised communication between both production processes to reduce coolant and energy costs by synchronising production demands.
Our logistical expertise ensures that we fit the maximum numbers of parts per bin and therefore optimise our usage of transport for delivery.
Our unique external pond feature has been dredged to enable the local wildlife to benefit.
We continue to employ personnel from the local area and have a long-standing apprenticeship programme with links to nearby schools and colleges.
On weekends, CastAlum’s internal roads and car parks provide the ideal training site for our local cycle club!
We ensure compliance with external validators of our environmental credentials, including ISO 14001 certification. We also work with the Powys environmental board to identify ongoing improvements.
Looking to the Future
We are always monitoring and improving our key performance indicators. Specifically, we look to optimise our Overall Equipment Efficiency (OEE) and Cost of Quality (COQ) to reduce our overall energy usage.
Our cooling towers and pumps are scheduled to be upgraded in 2022, which will result in lower energy usage through innovative technology.
Much of our factory has been insulated already, but we are continuing to identify areas that we can improve and minimise energy wastage.
We have an ongoing plan to improve our own understanding of CastAlum’s overall carbon footprint with external assessment and validation.
In-house initiatives have been suggested to further reduce our use of transport and packaging during 2022.
CastAlum is an internationally acclaimed aluminium Diecaster, located in Mid Wales.
In die casting, managing heat effectively is a crucial part of the production process. An often-overlooked part of our fully automated cell is the quench tank. Quench tanks are used immediately after a component has been cast. Our extract robots take the part from the die, and then cool them in a quench tank, before taking them over to the trimming tool.
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