Old meets new...

• Foundry explores new digital monitoring technology
• The new approach saves the company about 243 600 kWh of electricity per year

The German foundry Kemptener Eisengießerei has taken an important first step as it seeks to digitalise its manufacturing processes.

In principle, the workflows in a foundry have not changed in centuries. Today, as in the past, it is important to know the exact amount of cast iron needed for each mould (too little and the cast may fail; too much leads to waste). This is a very energy-intensive and often complex process. Accuracy is key; having to recast the alloy is costly and wasteful.

To better control these processes, Kemptener Eisengießerei introduced barcodes at each workstation where workers could retrieve data and monitor the composition of the alloy using smartphones.

Key results

With that information, they can ensure the right amount of raw material goes into each cast, which saves on materials and energy.

The company saves about 243 600 kWh of electricity and € 45 800 on energy costs each year, and it has reduced its carbon emissions by 85 000 kg.