Pan Shot Foundry. Smeltery, filling of liquid metal, several shots. Mixing of Sand, several shots. Sand-core production, several shots.

Casting in conventional production procedure, several shots. Removal of sand-core pieces, several shots.

Casting in odourless and emission-free production procedure, several shots. Removal of sand-core pieces, several shots.

Left side: conventional production Right side: odourless and emission-free production procedure

Tests with various mixtures of sand, several shots.

Translation: “Since 2010, we at the BMW Landshut plant have been using novel, environmentally-friendly inorganic adhesives for an odourless production – a world first. It is our emission-free foundry for moulding sand cores. We have replaced our old smoke-emitting adhesive agents, thereby reducing the emissions produced during casting by 98 percent. This enables us to completely deactivate high-energy emission treatment.” Translation: “We use sand cores on 50 percent of our cast components. Every day we use 120 tons of sand for casting, 90 percent of which is recycled.” Translation: “We consider ourselves a forerunner in the European foundry industry. At locations like Germany where there are high demands on environmental compatibility as well as high personnel costs, the inorganic sand core production is – in our view – an extremely important factor in giving us a competitive edge.” Translation: “This new process makes various other processes easier for our employees. First of all, there’s a direct effect on the workplace as emissions have been reduced. Secondly, cleaning the tools has become easier, too. So far, tools had to be cleaned in a very strenuous and time-consuming process. This cleaning process is virtually no longer necessary.” Translation: “This new process is a sustainable one, which has positive effects on the environment, the workforce and productivity. Reduced cycle times have helped to reduce productivity by approx. 10 percent. Costs for cleaning the tools have dropped by 50%.”