Raffmetal featured on AL Circle: energy efficiency, innovation and circularity driving the future of aluminium melting

Raffmetal, Europe’s leading producer of recycled aluminium alloys, is featured in the Interviews section of the international magazine AL Circle with an in-depth discussion on aluminium casting market perspectives and the company’s industrial strategy.

In the interview, Ruggero Zambelli, Quality Manager & Head of Alloys Development, and Paolo Gamberini, Sales Responsible Foundry Alloys from Recycling, outline an evolving sector landscape shaped by growth opportunities, structural challenges and the increasing centrality of sustainability.

Lightweighting and growth of the aluminium casting market

According to Raffmetal, lightweighting represents a long-term structural trend, particularly relevant for the automotive sector—both internal combustion engine and electric vehicles—and is expected to sustain demand for casting alloys well beyond 2026. At the same time, applications in aerospace, electronics and renewable energy are expanding the use of recycled HPDC alloys, thanks to their high performance and industrial competitiveness.

Digitalisation and automation as operational enablers

Technological evolution has significantly transformed Raffmetal’s facilities. Advanced digital systems allow continuous process monitoring, performance optimisation and precise control of energy consumption and environmental parameters. Automation and data analytics also enhance process stability, quality and traceability, supporting faster, evidence-based decision-making.

Reducing energy intensity and advancing decarbonisation

Aluminium melting is inherently energy intensive, making energy intensity reduction a strategic priority for Raffmetal. The company adopts an integrated approach combining maximised recycled content, advanced scrap selection technologies and a substantial share of self-generated renewable energy, currently covering around 40% of electricity consumption. This is complemented by heat recovery solutions and the production of the SILVAL range entirely using green electricity.

An industrial journey rooted in innovation and sustainability

Over recent decades, Raffmetal has consolidated a development path characterised by technological innovation and investments aimed at circularity and efficiency. Key milestones include early implementation of salt slag recovery systems, continuous casting, EPD certification across the entire product range, installation of 11 MW of photovoltaic capacity and the commissioning of a steam turbine for energy recovery.

Value chain collaboration and advanced metallurgical quality

Collaboration with customers and OEMs enables the development of alloys with very high recycled content—often up to 100%—without performance compromises. At the same time, advancements in sorting, treatment and refining technologies make it possible to achieve scrap-based alloys with quality levels comparable to primary solutions.

Industry challenges and institutional dialogue

The interview also highlights several critical issues affecting the European aluminium sector, including high energy costs, uncertainty in the automotive market and significant scrap exports outside Europe. In this context, Raffmetal continues its dialogue with institutions and stakeholders to promote measures safeguarding the value chain and ensuring the availability of secondary raw materials.

New application frontiers

Looking ahead, the company is working on the development of high-performance recycled alloys for large and giga-castings without heat treatment, a solution expected to deliver both energy savings and improved production efficiency.

Participation in international events such as Euroguss further confirms Raffmetal’s role as a key player in the global aluminium landscape, fostering networking, technological exchange and close monitoring of market developments.

Full interview available at: https://www.alcircle.com/interview/detail/117355/al-circle-x-raffmetal-reducing-energy-intensity-is-a-key-priority-for-us-given-the-inherently-energy-intensive-nature-of-aluminium-melting