Green light for one of the most ambitious decarbonization projects in the German foundry industry – a state-of-the-art electric melting plant replaces the cupola furnace
The official launch of a groundbreaking large-scale project was marked by the signing of a contract between Phil Limbach from the management of the Beinbauer Group and ABP CEO Till Schreiter, as well as a joint site visit by the project teams from Beinbauer Casting and ABP Induction. The Schwerte foundry site will undergo a fundamental technological transformation in the coming months: The existing cupola furnace will be replaced by a modern, electrically powered induction melting plant – a step that could reduce CO₂ emissions by up to 90 percent in the future.
A spirit of optimism in Schwerte
For Beinbauer Casting, the project represents more than just technological modernization. The new electric melting plant opens up opportunities for more sustainable production, meeting new customer requirements, and long-term growth at the German site: “Despite the current economic challenges for energy-intensive industries, we are consciously investing in modern, sustainable technology – for the benefit of the environment, our employees, and the long-term future of the Schwerte site,” explains Phil Limbach from the Beinbauer Group’s management team.
This investment by the Beinbauer Group is therefore a strategic decision aimed at climate protection and long-term competitiveness. Increasing demands along the supply chain and growing interest among OEMs in low-carbon components have recently increased the pressure for transformation. At the same time, the foundry is located in the middle of the city – another reason to significantly reduce emissions and pollution.
“The order placed by Beinbauer Casting GmbH with ABP Systems GmbH is a strong commitment to Germany as a business location and underscores the metallurgical industry’s determination to press ahead with decarbonization in Germany despite adverse conditions,” emphasizes Till Schreiter, CEO of ABP Induction Systems GmbH. “Both companies share a long history of trust-based cooperation and cultural similarities. ABP would like to express its gratitude for the trust placed in our employees and our technological expertise, and we look forward to successfully completing this project together.
Engineering based on real operating data
Beinbauer had already commissioned ABP to conduct a comprehensive engineering study in 2021. The goal was to develop a viable concept that took into account both the structural conditions and ongoing production operations. Using ABP’s own simulation software, the ABP Meltshop Designer, numerous variants were simulated and tailored to the customer’s specific requirements.
“Special attention was paid to maximizing the flexibility of the future melting operation,” explains Alexander Keller, Head of System Sales at ABP Induction. “Fluctuating sales volumes, the reuse of scrap and charging areas, and energy efficiency played a key role in this.” The integration of existing storage furnaces was also examined in order to optimize investment costs in a targeted manner. The new electric smelting plant is designed to adapt optimally to changing production volumes. This creates an extremely flexible, future-proof system for Beinbauer,” explains Alexander Keller, who has been involved in the project from the outset.
Latest generation induction melting technology
The new smelting plant will have a capacity of 25 tons of molten iron per hour. For reasons of operational safety and flexibility, the design is based on two independent melting systems, which together consist of three crucible furnaces from the ABP IFM 7 series. The modern extraction hoods meet the strictest requirements of the TA Luft (Technical Instructions on Air Quality Control) and at the same time ensure optimized occupational safety and environmental protection. Power is supplied by two powerful MF converters, each with a capacity of 8,000 kW. The plant technology is supplemented by the Prodapt Enterprise digital control software, which enables long-term storage of all relevant operating and production data—a crucial component for process stability, auditability, and efficiency.
A cooling concept as a technical milestone
Special attention is paid to the newly developed cooling and heat recovery concept, which perfectly complements modern electric melting technology. Instead of the previous cooling tower solution, which required high maintenance, water consumption, and conditioning, air/water coolers with speed-controlled, highly efficient fans will be used in the future.
Each of the two furnace systems will also be equipped with a regulated additional water/water heat exchanger that can store up to 2,000 kW of waste heat. Performance-dependent single-pipe control achieves a return temperature of almost 80°C – an exceptionally high value that eliminates the need for an additional heat pump. At the same time, equipping all pump stations with frequency converters significantly reduces energy consumption.
The recooling of existing systems – including ABP storage and casting furnaces as well as the hydraulic station of the molding plant – will also be integrated into the new concept. The coolers installed on the hall roof will also comply with all noise limits, ensuring low-emission operation in the middle of the city.
The next steps
Construction and installation work is scheduled to be completed by the end of 2026, with production set to start in early 2027 – when liquid iron will flow from the new electric arc furnace in Schwerte for the first time. With this project, Beinbauer Casting and ABP Induction are sending a clear message: transformation is possible when technology, courage, and partnership come together.
Info box: The roadmap to CO2-friendly production
- Construction work at Beinbauer Casting is expected to be completed by mid-September 2026.
- Delivery of plant components from the end of September 2026
- Completion of installation work by early December 2026
- Start of commissioning of the plants from the end of November 2026
- End of “cold commissioning” of the furnace systems by December 23, 2026
- Refractory lining and sintering of the crucible furnaces at the beginning of the new year 2027
- The date for the first liquid iron from the two furnace systems is planned for calendar week 3/27.
- Full production will start at the new smelting plant at the end of January 2027.
About the Beinbauer Group
With over 100 years of experience, the Beinbauer Group combines proven tradition with state-of-the-art manufacturing technology. With five locations, the group is one of Europe’s leading providers of casting and machining solutions.
The full range of services extends from mechanical processing and coatings to the logistics of cast and forged parts. From raw material procurement to just-in-time delivery, the Beinbauer Group develops customized solutions for high-quality components – both in large and small series.
Quality and sustainability are at the heart of everything we do: with certifications according to IATF 16949, ISO 50001, ISO 45001, ISO 14001, and TISAX, the company meets the highest standards and takes responsibility for the environment and safety. Strict quality controls and continuous improvement processes ensure first-class results.
For further information about the Beinbauer Group: www.beinbauer-group.de
About ABP Induction
ABP Induction is a leading provider of induction melting and heating equipment, aftermarket services and digitalization solutions for the global foundry, forging and steel industries. ABP has sales, production and customer service locations in the USA, Germany, Sweden, Mexico, Thailand, India, China and South Africa. Further information about ABP Induction can be found at www.abpinduction.com.
Press contact
ABP Induction Systems GmbH
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Email: press.de@abpinduction.com