Released on October 16, 2009

BMW’s Landshut metalcasting facility in Munich, Germany, has introduced a new sand core production method that will eliminate 98% of its emissions, according to a press release issued by the company.

The light-alloy casting facility produces approximately 1.8 million aluminum and magnesium castings a year, with a total weight of almost 50,000 tons, in the semi-permanent mold process. About half of the castings require sand cores, and the facility uses more than 130 tons of sand daily in sand core production. The new core producing system, which includes new shooting tools and equipment, will use eco-friendly inorganic binders in place of conventional organic binders. The new system will allow the plant to decommission its current waste air treatment systems by 2010.

“Inorganic sand core production positions us at the forefront of the [metalcasting] industry,” said Wolfgang Blümlhuber, the plant’s manager. “We see inorganic sand core production as key to competitive operation, particularly in highly industrialized countries with stringent environmental regulations, where manufacturing costs are correspondingly high.”

BMW’s Landshut facility employs 1,300 in the production of engine components, such as cylinder heads and crankcases, structural components, and chassis parts, such as suspension strut supports, tailgate frames, corner castings and casting nodes for the front and rear axle.