Our further development

ecoCasting for commercial vehicles

After the ecoCasting technology has been applied since 2015 already for the series production of passenger car cylinder blocks, it has been consistently further developed in the past years in order to be able to also produce heavy commercial vehicle cylinder blocks.

The new ecoCasting foundry resulting from these efforts offers ideal conditions in order to meet the future requirements of the customers from the commercial vehicle sector.

For FW as a recycling company from the very beginning, the subjects »sustainability« and »environmental protection« have always counted among the cornerstones of our corporate philosophy. This means: create economic and ecological solutions for the future.
Richard Pausch, Director Sales

Iron Foundry 4.0

The most sustainable foundry process

Our innovative pouring procedure gets along without mould sand. Thus, no sand has to be transported or deposited later on. The used core sand is completely recycled. Due to this mono-sand-system with a closed circuit of materials, the ecoCasting process is the new benchmark for sustainable pouring processes.

Lighter products

Our product is considerably lighter than a conventional grey cast iron cylinder block. This does not only save resources but also sustainably supports our customers in reaching their environmental targets.

Lower energy costs

By eliminating the need for mould sand, making more efficient use of all materials and using less return material, our innovative ecoCasting process saves significant amounts of energy, CO2 and other resources compared to the conventional manufacturing method.

Precise with a low wall thickness

The engine block is the biggest and heaviest component of a combustion engine. Our unique technology ensures highest precision and allows to reduce the wall thickness to only 4.0 mm – and this with a tolerance of only +/- 0.5 mm.

More favourable materials

A cost saving of at least 28 percent in comparison with an aluminium cylinder block represents a considerable cost efficiency – with a standardized but flexible process and a guaranteed outstanding quality.

Recyclable raw materials

Our raw materials consist of recycling material which means that our products are 100 percent recyclable. With this, we protect the environment and require less energy than for the conventional iron casting process or in comparison with the production of aluminium.

Product and process available worldwide

Our high quality standards of the innovative light-weight construction of cast iron are available worldwide. The standardization of our processes and tools guarantee a high process reliability – from the development to the series

Saving Drinking Water

Drinking water is a natural product and one of the most valuable goods which we cannot replace. Our innovative process does not produce any spare molding sand and allows us to save at least 22 million liters of drinking water in one ecoCasting line alone.

100 % Green Electricity

Our ecoCasting process relies 100% on electricity from renewable sources. As a global company, we are thus making an important contribution to reducing non-renewable fossil fuels.

CO2 Reduction

We save thousands of tons of CO2 not only through our lightweight design concepts for vehicles but also during the manufacturing process itself. Positive effects such as the elimination of waste disposal transports also contribute to a better CO2 balance.

We support you in achieving your emission goals

By means of the oriented integration of components as well as the utilization of clearly lower production tolerances, we are in a position to support our global customers in achieving their CO2 emission goals by means of significant weight savings.

The further development of the ecoCasting technology does not only offer technical advantages but also considerably benefits the sustainability. The process consumes less energy and the component itself plays its advantages as lightweight. By means of the pouring process without mould sand, we save tons of CO2, millions of litres of water and close circuits of materials. This also leads to a reduction of the consumption of resources such as sand.

The high savings of water and CO2 have been rewarded with a six-digit subsidy amount from the Federal Office of Economics and Export Control.