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EUROGUSS 2020 Product News CO2-Neutral with New Technologies

Editor: Nicole Kareta

At EUROGUSS 2020, Föhl, specialist for zinc die casting and plastic injection molding, presents a green alternative to electroplating with "Föhlan" nano-coating. Triggered by the Europe-wide ban on substances for surfaces containing chrome-VI, the process for coating zinc components was developed in-house and offers savings potential as well as corrosion resistance.

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The new "Föhlan" coating technology saves up to 70 % energy and 90 % material compared to conventional electroplating.
The new "Föhlan" coating technology saves up to 70 % energy and 90 % material compared to conventional electroplating.

In addition to economic advantages, the new passivation method is also ecologically on the right side and works in an energy-saving and resource-conserving manner. For example, the new "Föhlan" coating technology saves up to 70 % energy and 90 % material compared to conventional electroplating. "We are very much looking forward to working climate-neutrally from 1.1.2020 and to being one of the first, or perhaps even the first foundry not to leave a CO2 footprint. Environmental protection and energy management are close to my heart and are integral parts of our corporate policy. We see this challenge not as a braking factor, but on the contrary as a driver of innovation. Every employee is encouraged to contribute to this and this is not only reflected in small things, but often also in great ideas and new impulses that lead to the optimization of our portfolio. Our nanocoating "Föhlan" is just one example, our hot runner technology is another. Because here, too, we save up to 50 % energy and large quantities of material compared to the conventional zinc printing process," says Dr. Kirkorowicz, CEO of Adolf Föhl GmbH & Co KG.

From 14th to 16th January 2020 in Nuremberg, Föhl will show its way to improving its CO2 footprint. A path that has long been taken. For example, the company was one of the first foundries ever to be certified according to the Eco Audit EMAS in 1996, and the second company in the Rems-Murr district to do so. At that time, the company already formulated its environmental policy for resource-saving production and since then has published an annual environmental statement based on the validation of an independent expert.

Great Savings Potential

Accordingly, the environmental management of the german company, which is certified according to ISO 14001 and EMAS, has its sights set on the energy turnaround and has already invested in the past. The company has thus been able to exploit great savings potential through various plant conversions. For example, the completed conversion of the entire production lighting achieves savings of 150,000 kWh (66 tons CO2) per year and the conversion to a new, energy-optimised ventilation system in one hall alone achieves 470,000 kWh (200 tons CO2) per year. The next hall is already being planned, so that after implementation a total of 270 tons CO2 will be saved. In 2020, the company will not only switch completely to green electricity, but will also ensure a further significant reduction in energy consumption with further conversion measures. This includes the generation of electricity and heat by using production-related waste heat, the savings of which amount to 1.25 million kWh per year - which corresponds to an annual reduction of around 260 tons CO2.

New Burner Technology

The focus is also on optimising the production technology itself. For example, the development of a new burner technology for the remelting plants is already in progress, which will result in savings of 645,000 kWh per year. Last but not least, the vehicle fleet is being successively expanded to include vehicles with alternative drives. With the above-mentioned measures alone, which represent only part of the environmental management, the specialist for zinc die-casting is saving around 740 tons Co2per year.

In order to guarantee the CO2 neutral position as early as 2020, unavoidable CO2 emissions from the consumption of other energy sources such as oil and natural gas will be offset with compensation measures, for example by promoting wind power projects.

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