The Evolution of the European Foundry: Structural Transformations and New Industrial Balances (2002-2024)
Between 2002 and 2024, the evolution of the European foundry underwent a period of profound structural transformation, characterized by a significant contraction in ferrous casting production and greater resilience in the non-ferrous sector. This period of over two decades has painted a complex picture, rich in signs of change, in which the widespread decline was triggered by shifts in demand, cost pressures, and geopolitical instability.
Data collected from the main European foundry producing countries belonging to the EFF (European Foundry Federation) reveal foundry trends from 2002 to 2024, which may indicate increasing production diversification and a transition toward lighter, higher-value castings. This evolution represents the sector's strategic response to contemporary challenges and the new needs of the global market.
Structural Changes in the Foundry Sector: The Non-Ferrous Materials Revolution
One of the most significant structural changes in the foundry sector observed between 2002 and 2024 concerns the gradual but steady transformation in the composition of European castings production. There has been a progressive shift from the almost exclusive dominance of ferrous materials to a greater proportion of non-ferrous materials.
In 2002, ferrous castings accounted for 81% of total European production, while non-ferrous materials accounted for only 19% of the market. In 2024, this ratio has changed significantly: the proportion of ferrous materials has fallen to 73%, while that of non-ferrous materials has risen to 27%, highlighting a far-reaching structural transformation.
In absolute terms, this transformation translates into telling numbers: ferrous castings production has decreased by approximately 2.75 million tonnes, while non-ferrous castings production has increased by approximately 500,000 tonnes. Although ferrous metals remain dominant, the trend towards the production of lighter castings appears irreversible and strategically oriented towards future market needs.
Two Decades in Review: Long-Term Numbers and Trends
In 2002, total casting production in Europe exceeded 15 million tonnes, with a clear predominance of ferrous metals. By 2024, production had fallen to approximately 13 million tonnes, with ferrous metals decreasing to 9.5 million tonnes and non-ferrous metals remaining relatively stable at 3.45 million tonnes.
The average annual decline in total production is around -0.9%, but this average masks substantial differences between the two sectors. The decline is much more pronounced for ferrous castings, which are progressively losing ground year after year, primarily due to declining demand from the automotive and traditional mechanical industries.
Foundry trends from 2002 to 2024 show that, while the long-term trend is linear and progressive, the short-term trend is more dramatic. Between 2021 and 2024, overall production declined by 4.1% annually, reflecting the impact of recent crises affecting the sector.
The main causes of this acceleration include rising energy costs, growing regulatory and bureaucratic pressures, weak domestic demand, geopolitical shocks stemming from the war in Ukraine, tensions with China, instability in the Middle East, and prolonged stagnation in the automotive sector.
Non-Ferrous Metals: Resilience and Strategic Repositioning
Unlike ferrous metals, non-ferrous castings demonstrate greater stability and resilience to market turbulence. Average annual growth of 0.7% from 2002 to 2024 indicates stronger and more diversified demand, supported by the expansion of emerging strategic sectors.
The sectors driving this growth include electromobility and lightweight components, aerospace and defense, electrical engineering, and thermotechnology. These sectors represent the future of European manufacturing and explain the growing importance of non-ferrous materials in the evolution of the European foundry.
Geographical Concentration and Competitive Dynamics: The Top 6 Producers
The European foundry sector remains highly geographically concentrated. In 2024, six countries—Germany, Turkey, Italy, France, Spain, and Poland—together account for 84% of total ferrous and non-ferrous casting production. However, data analysis reveals different dynamics by alloy type and country, highlighting the structural evolution underway in the sector.
Ferrous Castings: German Leadership in a Shrinking Market
In the ferrous alloy castings segment (iron and steel), 2024 saw a sharp decline compared to 2023, with production in the top six falling by 13.8%, from 9.1 to 7.9 million tons.
Germany remains the undisputed leader with 2.6 million tons, equal to 33% of the total, despite a significant decline of 15.3% compared to 2023. Turkey maintains second place with 1.8 million tons (24% of the total), but records the most significant decline, falling by 19.7%.
France, Spain, Italy, and Poland complete the top six producers, with production of:
- France 1.1 million tons;
- Spain 1 million tons;
- Italy 900,000 tons;
- Poland 400,000 tons, respectively.
All countries recorded significant declines, with the exception of Spain, which limited its loss to -2.2%, demonstrating greater stability in the domestic market.
Non-Ferrous Metals: Relatively Resilient, with Turkey Bucking the Trend
In non-ferrous alloy castings (aluminum, copper, magnesium, zinc), the trend among the main European producers is less negative, with a 3.8% decline in production, bringing production from 3.1 to 3.0 million tons.
Germany and Italy dominate this segment, each with a 26% market share, despite declines of -4.0% and -6.1%, respectively. Turkey, the third-largest producer with a 25% market share, is the only country to show growth, with a +1.3% increase, likely driven by expanded production capacity and increased cost competitiveness.
France and Poland saw production declines of -5.1% and -10%, respectively, while Spain limited the loss to -1.2%, confirming the greater resilience of the non-ferrous sector compared to ferrous castings.
Adapting to Changes in the Foundry Market: Strategies for the Future
Total production data reveal that in 2024, the top six producers in Europe produced a combined 10.9 million tons of castings, down 11.2% from 2023. This represents a loss of nearly 1.4 million tons in a single year, highlighting the urgent need to adapt to changes in the foundry market.
These six countries remain very high in total production (84%), but all have seen significant declines: Germany -12.8%, Turkey -14.6%, Italy -12.2%, France -6.6%, and Spain -2.1%. Only Spain has managed to contain its losses, a sign of greater stability in the internal market and more effective industrial policies.
The evolution of the European foundry industry between 2002 and 2024 clearly highlights the need for a strategic transformation of the sector. The growing importance of non-ferrous materials, competitive cost pressures, the need for technological innovation, and the challenge of environmental sustainability represent the pillars on which to build the future of the European foundry industry.
Companies that adapt to changes in the foundry market through investments in research and development, production diversification toward high-value-added materials, and process optimization will be best positioned to address future challenges. The transition to lighter, more technologically advanced castings is not only a market necessity, but a strategic opportunity to boost European competitiveness globally.
Foundry trends from 2002 to 2024 indicate that the sector is at a crucial turning point, where strategic choices over the coming years will determine its ability to maintain a leadership role in global manufacturing and effectively contribute to the transition to a more sustainable and technologically advanced economy.
Source: In Fonderia – Il magazine dell’industria fusoria italiana