Global metal processing specialists Benteler in December announced the completion of a comprehensive modernisation of its casthouse at the Raufoss Industrial Park in Norway.

The expanded production facilities were officially opened at an inauguration ceremony attended by representatives from Benteler’s management team, employees, and partners from the industrial park and supply chain.

With this investment, the company is increasing the share of recycled aluminium used at its Norwegian site from around 30% to about 40%, with a target of 50% by 2030.

At the same time, the modernisation reduces CO2 emissions across the production process.

This reinforces Benteler’s commitment to more sustainable automotive production and supports original-equipment manufacturers (OEMs) in meeting their climate goals.

“The modernisation of our casthouse is a decisive step towards greater sustainability and innovation,” said Benteler Automotive Raufoss (BAR) plant manager Per Dale.

He added that the modernisation enables Benteler to meet its clients’ requirements for higher recycling quotas and lower CO2 emissions, while strengthening its position as a leading provider of sustainable automotive solutions, with BAR forming part of the Benteler Automotive Components division.

Driving Circularity

The modernisation is part of the company’s BAR Green project, launched in 2023, which focuses on aligning production with circular economy principles.

In addition to recycling production scrap from its own production processes, such as extrusion waste, Benteler is increasing its external and post-consumer scrap recycling – the latter referring to aluminium used in finished products.

This move significantly increases its share of recycled content and reduces carbon footprints of various products.

To enable these processes, the plant’s infrastructure and energy efficiency have been extensively upgraded.

Key measures include the construction of a new warehouse – meaning expanded storage capacity for external scrap and finished products – upgraded burner systems and the installation of a new dust filter.

Benteler also uses residual process energy to heat the floor of the new warehouse and dry raw materials. Meanwhile, surplus heat from the melting furnaces is fed into the industrial park’s district heating network.

The plant features an in-house casthouse, three extrusion presses, forming lines and “state-of-the-art finishing lines”.

Around 450 people are employed at the site, which supplies nearly all major European car manufacturers with premium aluminium components such as bumper systems and suspension parts.

“These products meet the strictest quality standards and now offer an even lower CO2 footprint,” concludes Dale.