We meet Marco Nagler, foundry manager at Everllence in Augsburg, to talk about the name change and the future of the traditional foundry in the heart of the city.
The foundry looks back on more than 250 years of history – first as MAN, then as MAN Energy Solutions, and now under a new name, Everllence. For Marco Nagler, this step is much more than a formality:
“For us, this is the beginning of a new era – an industry icon is getting a new look.”
Everllence Provides New Impetus – Stability at the Site Remains
There are several reasons for the renaming. On the one hand, the company's strategy is to be made clearer with the motto “Moving Big Things to Zero.” On the other hand, the aim is to create a common identity across all locations and to consciously distance itself from the traditional MAN image.
“Many people still associate MAN with fossil fuels. With Everllence, we want to set a new course,” explains Nagler.
The new name combines the terms “ever” and “excellence” – a combination of tradition and technological ambition.
For the traditional foundry in Augsburg, however, the change does not mean a break with the past, as sustainability and resource conservation have long been hallmarks of the site. 97 % of the molding sand is regenerated, green electricity is used predominantly, and the energy-intensive melting processes are controlled by a sophisticated load management system. Four induction crucible furnaces with capacities ranging from six to 23 tons form the heart of the plant. To avoid peak loads, most of the melting is carried out at night.
The foundry also has a solid workforce: around 300 employees and 15 trainees work in Augsburg. With its own training workshop, it is able to train five to six young hand molders every year – an important contribution to countering the shortage of skilled workers. Everllence also focuses on training skilled workers from other industries. Digitalization supports these processes, for example through iPads in melt planning or QR codes for mold feedback. “The profession remains a craft – but with modern support,” says Nagler.
“Moving Big Things to Zero” – The Foundry as Part of the Strategy for the Future
True to its motto – Moving Big Things to Zero – Everllence supports key industries in reducing hard-to-avoid emissions.
The company sees itself as a central component of a decarbonization strategy with five business areas:
- Green hydrogen through PEM electrolysis: Through its subsidiary Quest One, Everllence is involved in the global hydrogen rollout.
- Engines for climate-neutral fuels: Development of ship and power plant engines as well as retrofit solutions for new, alternative energy carriers such as methanol for cruise ships.
- Retrofit of existing engines, for the use of so-called future fuels: E.g., in shipping, aviation, and heavy industry.
- Carbon capture plants.
- Large-scale industrial heat pumps: Decarbonization of heat supply for cities and industrial plants worldwide, complemented by technologies for CO₂ capture and storage.
Demanding Casting for Complex Components
The Augsburg foundry focuses on engine and retrofit components. "This is how we are contributing to decarbonization. Our foundry is closely linked to this strategy and is an important part of it," emphasizes Nagler.
Everllence deliberately focuses on complex, technically demanding castings and large castings. Standard parts are left to others. Around 5,000 tons of customer castings are produced each year – about a quarter of the total production of 23,000 tons.
Additive manufacturing is not currently carried out in Augsburg itself, but through collaborations – for example, with Fraunhofer Garching – and the purchase of additively manufactured cores, including for very large castings.
Investments are being made specifically in future viability. The first robot for post-casting processing was installed several years ago – an area that is traditionally considered particularly demanding. Today, a cleaning robot for parts weighing up to three tons and a robotic blasting system are in operation. The next step is to automate the machining of large parts.
“This will not only change the work itself, but also the job profiles. In the future, we will be looking less for ‘cleaners’ and more for plant and machine operators,” says Nagler.
Outlook and Visibility
The company will remain part of the Volkswagen Group. Everllence's position is contractually secured until at least 2026. Nagler does not want to speculate about possible changes in the group structure: “We deliver our key figures, we have full order books – that's what counts.” In its external communications, Everllence focuses on quality rather than quantity.
The company also wants to become more involved in trade associations and raise its profile through topic-specific presentations. Nagler attaches particular importance to the close integration of design and foundry:
“The demands on castings are constantly increasing – more performance, less weight, more complex integrations. It is becoming increasingly important that we foundrymen are involved in the early design phase.”
Conclusion
Nagler's closing words are as clear as he is: Everllence is ideally positioned to continue playing a key role in the transformation of the industry as a traditional location.
“With our castings, we are making a contribution that extends beyond the location. And we are showing that a foundry can also be future-proof in the heart of a city like Augsburg.”
About Everllence SE:
15,000 employees worldwide.
€4.3 billion turnover in 2024.
140 locations worldwide.
