With a multi-million investment, the Siempelkamp foundry is setting new standards in this energy-intensive sector
The medium-sized company is gearing up for the future with a strategic investment package: the technology leader is making targeted investments in digitalisation, automation and a unique energy architecture – to boost competitiveness, efficiency and sustainability in a market environment characterised by global economic tensions.
Innovation meets corporate responsibility
Siempelkamp Giesserei is tackling the challenging economic climate in the sector with a clear commitment to growth through innovation. As the European market leader in hand-mould casting, the company is bucking the industry trend and pursuing a comprehensive investment strategy that encompasses all stages of the value chain, from melting to quality assurance.
The focus is on the further development and expansion of digital and automated processes – combined with a resource-efficient energy supply based on North Rhine-Westphalia’s largest industrial battery. The company’s management is consciously embracing the regulatory challenge of decarbonisation and is continuously optimising its own production processes – to the benefit of its customers.
The aim is not only to strengthen competitiveness and tap into new market potential, but also to actively secure the future of the site and its jobs.
Mission: Holistic transformation of the foundry
A key element of the investment drive is the newly created Smart Moulding Hub. This state-of-the-art production area combines digital control, intelligent logistics and flexible production processes – and will enable the Siempelkamp foundry to manufacture even smaller components weighing from one tonne upwards cost-effectively in future. At the same time, the foundry’s overall output and productivity are set to rise significantly – a decisive advantage in an increasingly challenging market environment characterised by fluctuating demands and high levels of complexity in international competition.
Another technological milestone is the investment in the largest industrial mould milling machine. In the new Automatic Rapid Moulding process, sand moulds are milled fully automatically and with precise contours directly into modules – without the need for any prior model creation. This technology opens up new possibilities for efficient single-unit and small-batch production, e.g. of prototypes or complex geometries. At the same time, the process is particularly resource-efficient and represents a genuine alternative to the emission-intensive lost-foam process – superior in ecological, economic and technological terms, as well as safer in every respect.
In parallel, the ‘Digital Foundry Centre’ is being established as part of the ‘ ’ – a platform on which all process data is linked via neural networks: from furnace control and quality assurance to post-processing. For the first time, this creates a holistic digital twin of the entire foundry, taking efficiency, process reliability and quality to a new level.
Objective: Sustainable production of CO ₂-neutral castings
A key element of the investment strategy is the development of a highly complex in-house energy architecture, the centrepiece of which is the largest industrial battery in North Rhine-Westphalia. This innovative storage solution makes it possible, for the first time, to combine flexibility and energy efficiency with the maximum use of renewable energy. Siempelkamp Giesserei is thus setting new standards in energy-intensive industry – with the clear aim of being able to offer customers CO CO ₂-neutral castings in the near future. The intelligent storage solution not only stabilises peak loads and relieves pressure on the electricity grid, but also forms the basis for resilient and climate-friendly production.
“We are making these investments as a proactive response to political uncertainties and a lack of solutions,” explains Dirk Howe, Managing Director of Siempelkamp Giesserei. “We are fed up with being at the mercy of energy policy. Instead, we stand for creativity and entrepreneurship. With smart ideas, digital excellence and German engineering, we are providing a bold, forward-looking response – and, with CO₂-neutral castings, we are creating a sustainable footprint and genuine added value for our customers.”
Furthermore, Siempelkamp Giesserei has invested in an innovative sand recycling plant, which significantly reduces resource consumption in production. The proportion of reused moulding sand is significantly increased, whilst the demand for valuable fresh sand is drastically reduced. This not only alleviates pressure on natural raw material sources but also significantly reduces heavy goods vehicle traffic: up to 850 lorry journeys per year can be avoided – a measurable contribution to climate protection and quality of life in the region.
Technological standard: digital high-tech processes as the basis for innovation
The Siempelkamp foundry relies on automated, digitally supported processes throughout the entire production process. At the heart of quality assurance is the world’s largest robot-assisted measuring cell , which fully automatically measures components several metres long and weighing several tonnes and compares them with 3D design data – precisely, efficiently and reproducibly. This takes industrial component testing to a new level of quality.
’s sample analysis has also been fully automated and equipped with state-of-the-art analytical technology to ensure maximum process reliability. The system is complemented by innovative moulding material testing technology, which continuously monitors and documents material quality using optical-digital methods.
Siempelkamp Giesserei thus combines digital technologies with a high degree of technical precision – and creates the conditions for improved product quality, closer process monitoring and more efficient production processes.
“Our investments not only bring greater efficiency – they are an expression of our commitment to technological leadership,” says Dr Georg Geier, Managing Director of Siempelkamp Giesserei. “We combine sustainability with Industry 4.0 to remain internationally competitive. Our mission as a medium-sized enterprise: to move into the future with economic, environmental and social strength – in attack mode.”
People shape the future
Just as consistently as Siempelkamp Giesserei invests in technology and sustainability, it also invests in its employees. In times of a skills shortage, the company specifically focuses on training and further education as a strategic factor for success.
At the heart of this skills development strategy is the innovative partial qualification as a foundry mechanic, which is aimed at employees and new colleagues – particularly those without formal training, those from outside the industry, or those with qualifications not recognised abroad. 30 employees have already successfully completed this course – the next project is set to start later this year.
Furthermore, the foundry places great emphasis on transparent communication, active participation and a culturally rich working environment in which personal responsibility, trust and team spirit are fostered. For the company, one thing is certain: Innovation comes from people – and from a culture that inspires.
The future of industrial production – secured through our own efforts
With its consistent investment strategy, the Siempelkamp foundry demonstrates what sustainable industrial production looks like today: digitally connected, efficient, resilient and environmentally responsible. The company not only sets technological standards – it is also an entrepreneurial role model for personal responsibility, commitment to its local community and sustainable growth ‘Made in Germany’.
About Siempelkamp
The Siempelkamp foundry in Krefeld specialises in the production of large hand-moulded castings weighing up to 320 tonnes made from ductile iron and, with a casting volume of over 60,,000 tonnes per year and a workforce of 400, it is one of the largest hand-moulding foundries in the world. Its comprehensive and customer-focused range of services includes the supply of structural components for many innovative machinery manufacturers in the energy sector, the raw materials industry, press engineering, steel production, the automotive sector and many other areas of manufacturing.
Siempelkamp is a globally active group of companies with business divisions in mechanical and plant engineering, casting technology, and engineering and service. Worldwide, nearly 3,000 employees ensure that the Siempelkamp Group remains a world leader with its technologies.