Smart Casting – the New Casting Technology Using Water Cooling

With more sustainable water cooling in the low-pressure casting process, RONAL Smart Casting (RSC) has brought RONAL GROUP into a new era of casting.

COMPRESSED AIR IS NOT SUSTAINABLE

RONAL GROUP previously used compressed air to cool casting molds in the low-pressure casting process. Some 50 m³ of compressed air per die-cast (casting mold) is required for the production of one wheel. This compressed air can only be used once and consumes a great deal of electricity when it is produced. This cooling of the die-casts alone accounts for about 70% of a plant's total electricity requirements. The use of compressed air is therefore not only expensive, it is also not exactly sustainable. Although RONAL GROUP already uses 50% green electricity, electricity consumption accounts for 121000 tons of the company’s CO₂ emissions.

COOL WATER FOR LIGHT WHEELS

In RONAL Smart Casting (RSC), water cooling in addition to air cooling is used. The water used in the process can be recycled and used again and again after cooling. One kilogram of CO₂ emissions per wheel is saved simply by halving the compressed air consumption at RSC. RSC also achieves greater material strength, enabling wall thicknesses to be reduced and ensuring that the finished wheels are lighter.

a man standing behind a Ronal Smart Casting machine

STILL WATER ON STAGE

Water cooling is more efficient than conventional cooling using compressed air. It facilitates higher cooling capacity in the die-cast, which means that the heat is dissipated more quickly. It is also much quieter, thereby improving the working conditions on the casting platform. However, the use of water also calls for higher demands in terms of safety at work and precise handling.

One kilogram of CO₂ emissions per wheel is saved simply by halving the compressed air consumption at RSC.

A NEW ERA FOR RONAL GROUP

With the acceptance of the proof of concept by the Executive Board in September 2021, RONAL GROUP is embarking on a new era of casting. “This is a milestone for the future of RONAL GROUP,” confirms Dietmar Süß, EVP Group Operations. “By using this technology, we are contributing to the reduction of our carbon footprint and taking a big step toward technology leadership.” The first new casting machines are being deployed in Teruel, Spain. As part of the “Plant Setup” program, however, as many of the Group's casting machines as possible are to be converted to water cooling in the years ahead.