Everllence SE: The transformation and future of the foundry in Augsburg
We meet Marco Nagler, foundry manager at Everllence in Augsburg, to discuss the name change and the future of the long-established foundry in the heart of the city.
The foundry looks back on more than 250 years of history – once as MAN, later as MAN Energy Solutions, and now under its new name, Everllence. For Marco Nagler, this step is far more than a mere formality:
“For us, this marks the beginning of a new era – an industrial icon is getting a new look.”
Everllence is bringing fresh impetus – stability at the site remains
There are several reasons behind the rebranding. On the one hand, the aim is to make the corporate strategy – with the guiding principle ‘ : Moving Big Things to Zero’ – more clearly visible. On the other hand, it is about creating a shared identity across all sites and consciously distancing the company from the traditional MAN image. “Many people still associate MAN with fossil-fuel technologies. With Everllence, we want to set a new direction,” explains Nagler.
The new name combines the terms ever and excellence – a fusion of tradition and technological excellence.
For the long-established foundry in Augsburg, however, this change does not represent a break with the past, as sustainability and resource conservation have long been hallmarks of the site. 97 per cent of the moulding sand is regenerated, predominantly green electricity is used, and the energy-intensive melting processes are controlled via a sophisticated load management system. Four induction crucible furnaces with capacities ranging from six to 23 tonnes form the heart of the operation. To avoid peak loads, the majority of the melting takes place at night.
The foundry is also well-staffed: around 300 employees and 15 apprentices work in Augsburg. Thanks to its in-house training workshop, the foundry is able to train five to six young hand moulders every year – an important contribution to tackling the shortage of skilled workers. In addition, Everllence focuses on training skilled workers from outside the industry. Digitalisation supports these processes, for example through the use of iPads in melting planning or QR codes for mould feedback. “The profession remains a craft – but with modern support,” says Nagler.
“Moving Big Things to Zero” – the foundry as part of the future strategy
True to the guiding principle Moving Big Things to Zero, Everllence supports key industries in reducing emissions that are difficult to avoid.
The company sees itself as a central component of a decarbonisation-focused strategy comprising five business areas:
- Green hydrogen via PEM electrolysis: Through its subsidiary Quest One, Everllence is involved in the global roll-out of hydrogen.
- Engines for climate-neutral fuels: Development of marine and power station engines, as well as retrofit solutions for new, alternative energy sources such as methanol for cruise ships.
- Retrofitting of existing engines, particularly for the use of so-called ‘future fuels’: e.g. in shipping, aviation and heavy industry.
- Carbon capture plants.
- Large-scale industrial heat pumps: Decarbonisation of heat supply for cities and industrial plants worldwide, complemented by CO₂ capture and storage technologies.
High-precision casting for complex components
The Augsburg-based foundry specialises in engine and retrofit components. “In this way, we are making our contribution to decarbonisation. Our foundry is closely linked to this strategy and forms an important part of it,” emphasises Nagler.
Everllence deliberately concentrates on complex, technically sophisticated castings and large-scale castings. Standard parts are left to others. Around 5,000 tonnes of customer castings are produced each year – roughly a quarter of the total production of 23,000 tonnes.
Additive manufacturing is not currently carried out in-house in Augsburg, but is handled through partnerships – such as with Fraunhofer Garching – and the purchase of additively manufactured cores, including for very large castings.
Investments are being channelled specifically into future-proofing the business. The first robot for post-casting finishing was installed several years ago – an area traditionally considered particularly strenuous. Today, a deburring robot for parts weighing up to three tonnes and a robotic shot blasting system are in operation. The next step is the automation of large-part processing.
“In doing so, we are not only changing the work itself, but also the job profiles. In future, we will be looking less for ‘cleaning labourers’ and more for plant and machine operators,” says Nagler.
Outlook and visibility
The company remains part of the Volkswagen Group. Everllence’s position is contractually secured until at least 2026. Nagler does not wish to speculate on possible changes to the Group’s structure: “We deliver our key performance indicators, we have full order books – that’s what counts.”
In its external image, Everllence focuses on quality rather than quantity. The company also intends to become more actively involved in trade associations and raise its profile through topic-specific presentations.
Nagler attaches particular importance to the close integration of design and foundry operations: “The demands placed on castings are constantly increasing – higher performance, lower weight, more complex integrations. It is becoming increasingly crucial that we foundry specialists are involved right from the early design phase.”
Conclusion
Nagler’s closing remarks are as clear as he is: Everllence is ideally positioned, as a site steeped in tradition, to continue playing a key role in the transformation of the industry in the future.
“With our castings, we are making a contribution that has an impact beyond the site itself. And we are demonstrating that a foundry can remain viable even in the heart of a city like Augsburg.”
About Everllence SE:
15,000 employees worldwide.
€4.3 billion turnover in 2024.
140 sites worldwide.