How to calculate the carbon footprint of die casting: Assofond's new tool for aluminum foundries

In a European regulatory context marked by the Green Deal, Assofond continues its commitment to supporting companies in the ecological transition. Following the success of its tool for iron castings, the Association has launched a new tool for aluminum foundries.

This process, initiated by Assofond in 2017 with its participation in the LIFE EFFIGE project, now provides companies with the tools they need to address the challenges of environmental reporting. Assofond's tool for aluminum foundries represents a useful tool for monitoring and communicating their environmental footprint with verifiable and scientifically based data.

Research, Development, and Technological Innovation

The tool is the result of a collaboration between Assofond, the Scuola Superiore Sant'Anna of Pisa, and Tecno S.r.l. Its development was funded by the European Union through the PNRR, as part of the GRINS and BRIEF projects.

The contribution of approximately fifteen associated foundries was crucial, providing data and technical input during the testing phase, enabling the system to be fine-tuned to meet the needs of companies. Thanks to this synergy, the tool now allows companies to independently conduct initial environmental accounting, answering the question of how to calculate the carbon footprint of die casting in a structured and reliable manner.

Operation and Scientific Methodology

The tool is a web platform structured into seven modules that track the different phases of the production cycle: melting, forming, casting, shakeout, finishing, inspection, and heat treatment.

The system analyzes input flows, such as energy and materials, and output flows, such as waste and emissions, converting them into environmental impacts according to the European Commission's Product Environmental Footprint (PEF) methodology. This scientifically recognized methodology allows for the precise quantification of the environmental footprint of aluminum castings throughout the entire production process.

A notable aspect is the flexibility of the module dedicated to the melting phase, which can be duplicated to individually manage the different alloys processed, thus allowing for a detailed and differentiated analysis based on specific metal compositions.

Calculation Results and Their Use

Upon completion, the tool generates results in tabular and graphical formats. These outputs can be downloaded in a summary report, a valuable tool for:

• Responding promptly to customer and supply chain requests;
• Supporting the preparation of the Sustainability Report with verifiable data;
• Engaging with institutional and financial stakeholders, demonstrating a scientific approach to sustainability.

The ability to accurately calculate the environmental footprint of aluminum castings is increasingly required by clients, particularly in the automotive and aerospace sectors, where companies are required to report emissions throughout the entire supply chain.

Source: In Fonderia – Il magazine dell’industria fusoria italiana