How Die Casting Can Help Reduce Environmental Impact

In an age where sustainability is at the top of the agenda for business around the world, the vast majority are seeking new ways to minimise their carbon footprint and reduce waste. The die casting industry is no exception, and companies like MRT Castings are at the forefront of adopting environmentally friendly practices.

Manufacturing has historically been perceived as a ‘dirty’ industry, with factories considered to be a source of pollution and intensive use of finite resources. However, thanks to the sheer amount of innovation in the sector, this perception is starting to change. When done right, die casting – in particular - can contribute significantly to reducing environmental impact.

Here’s 7 reasons why…

1. Material Efficiency.

Die casting is a near-net-shape manufacturing process, which involves injecting molten metal into precision moulds, allowing for high levels of material efficiency. Unlike other manufacturing processes that generate substantial waste, die casting has high material yield. This means that a large percentage of the material used ends up in the final product, reducing the overall consumption of raw materials.

By returning 100% of the dross from the melting process, and swarf from machining, to our material suppliers for reprocessing, MRT provide an excellent example of how material use can be made exceptionally efficient. We even return casting trimmings to our in-house melt, to ensure material waste is at the absolute minimum.

2. Energy Efficiency.

Modern die casting machines are designed to operate efficiently, with a focus on minimising energy consumption. The use of computer-controlled systems and advanced technologies ensures that energy is used optimally during the casting process. Additionally, the ability to recycle and reuse metal alloys further contributes to energy savings.

At MRT, all our processes are engineered to be as efficient as possible. For example, our standard process is to use high efficiency melting during the casting process, with recuperative gas burners fitted to all furnaces.

3. Recycling Opportunities.

One of the key advantages of die casting is the ability to recycle metal alloys. MRT principally uses secondary aluminium alloys. These are produced from recycled material, reprocessed from previous uses. Not only is our raw material recycled, but our products are infinitely recyclable too. This not only reduces the demand for virgin materials but also lowers energy consumption associated with mining and refining metals.

We even use fully recyclable packing materials when we ship our products to you.

4. Extended Product Lifespan.

Die-cast components are known for their durability and high structural integrity. Products manufactured through die casting are less prone to wear and tear, leading to longer lifespans. This means fewer replacements and less waste, ultimately reducing the environmental impact of a product over its lifetime.

5. Lightweighting.

Die casting allows for the production of lightweight yet robust components. This is particularly important in industries like automotive and aerospace, where reducing weight can lead to significant fuel savings and emissions reductions. By using lightweight materials and optimising component design, die casting contributes to overall energy efficiency and lower emissions.

6. Local Sourcing.

The UK die casting industry offers a domestic sourcing option for manufacturers. This reduces the need for long-distance transportation of components, which can result in lower carbon emissions and a smaller environmental footprint.

At MRT, we reduce our reliance on external transportation by keeping the majority of our processes in-house.

In cases where outsourcing becomes necessary, we make a concerted effort to engage a select group of local subcontractors and suppliers. Additionally, we employ our own efficient delivery fleet for transporting goods.

When it comes to international deliveries, our strategy involves consolidating shipments with national carriers to optimise efficiency. When feasible, we even provide returnable packaging options to our customers based in the UK.

7. Regulatory Compliance.

Die casting companies in the UK adhere to strict environmental regulations and standards. By partnering with such companies, OEMs can ensure that their products are produced in an environmentally responsible manner, helping them meet their own sustainability goals and regulatory requirements.

In the case of MRT Castings, our own Environmental Management Systems have earned certification to BS EN ISO 14001:2015, showcasing our dedication to overseeing and enhancing our environmental performance.

This certification also enables us to…

  • Uncover cost-saving opportunities, particularly in the management of resources, waste, and energy. These savings can then be passed on to our customers.
  • Enhance efficiency and diminish environmental impact, throughout the entire life cycle of our products.
  • Measure, track, and exert control over the continual environmental consequences of our operations, empowering us to continually enhance our strategy.

By choosing die casting for their manufacturing needs, businesses can contribute to a greener, more sustainable future while still enjoying the benefits of high-quality, precision-engineered components.

Embracing eco-friendly manufacturing is a journey that demands time, effort, and unwavering commitment.

At MRT Castings, we are wholeheartedly committed to enhancing sustainability by:

  • Establishing clear objectives and targets.
  • Conducting annual reviews of our sustainability policy and its efficacy.
  • Collaborating with our employees, customers, suppliers, neighbours, and other stakeholders to tackle environmental challenges that impact our company.

Ready to discuss a casting idea?

MRT Castings are experts with over 75 years’ experience in the manufacture of high-quality aluminium die castings, across a wide range of applications and industries.

Simply get in touch today and we’ll be happy to assist with your next project.

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