Redefining Efficiency and Sustainability: FRECH ZPF Sets New Standards in Aluminum Processing

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Foundry Corporate News Topic Pressure Die Casting

27. March 2025

With a clear focus on energy efficiency and innovative process recycling, FRECH ZPF GmbH is driving the future of aluminum processing forward.

Pressemitteilung | Reading time: min | Bildquelle: FRECH

Since the acquisition of ZPF GmbH from Siegelsbach in January 2022, FRECH ZPF has established itself as a key player in thermal process technology. The founding of the new company, headquartered in Schorndorf, marked a significant step in expanding the corporate portfolio and opening new markets within the foundry industry.

The roots of today’s FRECH ZPF date back to 1993, when the former ZPF Therm Maschinenbau GmbH was founded. Since then, the company has become a specialist in holding and melting furnaces in the large-scale segment, with melting capacities of up to 20 tons. With over 800 installed systems worldwide, FRECH ZPF is among the leading suppliers in the aluminum foundry industry. Its diverse product portfolio includes melting, holding, and alloying furnaces, as well as state-of-the-art chip/wheel recycling systems and customized special equipment. The company’s innovation strategy is clearly defined: energy efficiency, CO2 neutrality, and sustainable process recycling are at the core of its technological advancements.

Live Innovation at GIFA 2023: Premiere of a Highly Efficient Melting Unit

At the world-leading GIFA 2023 trade fair in Düsseldorf, FRECH ZPF unveiled a groundbreaking prototype for aluminum process recycling (Image 1). This innovative melting unit sets new industry standards with a capacity of up to 12 tons of liquid aluminum and an impressive melting rate of 0.7–1.2 tons per hour.

The core of the system is an advanced burner control technology combined with optimized temperature management. This enables highly energy-efficient processing of aluminum chips from process recycling and allows for a flexible mix of different secondary materials such as wheels, scrap, or shredded material.

A significant milestone: thanks to newly developed preheated burner air technology and a specialized insulation structure, energy consumption has been significantly reduced. Whereas previous systems required approximately 800 kWh per ton of aluminum, consumption has now dropped below 600 kWh—a savings of up to 25%. Additionally, the system’s passive exhaust gas purification ensures compliance with TA-Luft regulations without the need for additional filter systems.

With this innovative approach, FRECH ZPF not only reinforces its leadership in the development of sustainable technologies but also makes a decisive contribution to the "Green Foundry" of the future. The combination of energy efficiency, emission reduction, and intelligent recycling sets new benchmarks for the aluminum industry, demonstrating how sustainability and economic efficiency can go hand in hand.