ProGRess – Configuration of energy and resource efficient process chains using the example of aluminium die casting

Every year more than 400,300 tons of final goods are produced through aluminium die casting processes in Germany. Thus the aluminium die casting process chain is responsible (foundry-internal) for emissions of about 1 mio. tons of CO2-equivalents. Hence there is a high demand to improve the efficiency of energy and resource consumption in the aluminium die casting process chain. The measurement and optimization of energy and material flows in single processes as well as the mapping and improvement of reciprocal interdependencies between the single processes builds the basis for analysis and assessment of technical as well as organizational activities in order to increase the level of energy and ressource utilisation in aluminium die casting. Within the project ProGRess the level of energy and resource utilisation is optimized for the whole die casting supply chain as well as for single process steps regarding economical as well as ecological criteria. Thereby the goal of the ProGRess-project is an increase in the level of energy efficiency of about 15 %. To support this goal a catalogue of measures and simulation models will be developed to identify possible fields of action, to assess ecological and economical impacts of these measures and to establish a tool for integrative decision support for the whole process chain in aluminium die casting – including the design of single process steps as well as the management of the whole supply chain.


Keywords: Production management, sustainable manufacturing, simulation, aluminium die casting, energy and material flow management


06/2009 – 08/2012


German Federal Ministry of Education and Research (BMBF)
Supported by Project Management Agency Karlsruhe (PTKA)



  last changed 06.05.2019
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