The circular economy of zinc alloys

The eco-sustainable approach to zinc alloy die casting offers several distinctive benefits. Firstly, the process is based on the efficient use of resources, as zinc is an abundant material on Earth and can be recycled repeatedly without losing its mechanical properties. These characteristics make it possible to reduce the extraction of natural resources and to limit the environmental impact associated with the extraction itself. Furthermore, its ability to be melted down and reused repeatedly without ever losing its mechanical properties makes it an ideal product for the circular economy.

The circular economy is an economic system based on the reduction, reuse, recycling, and restoration of resources. Instead of considering products as objects to be used and discarded, the goal of the circular economy is to create a continuous cycle in which materials and resources retain their value for as long as possible over time.

The properties of zinc alloys obtained by die casting are perfectly suited to the needs of the circular economy since they can be remelted and reused repeatedly, returning to being a raw element ready for new processing. For this reason, it is correct to say that zinc is a material that is reused during its life cycle and not “consumed” as can happen with other materials, which, after each recycling and reuse, tend to lose part of their mechanical properties or chemicals arriving at an “exhaustion” of the material and turning into an unusable waste.

It is also recognized that metal recycling plays a key role in ensuring the availability of resources necessary to maintain and expand the technologies and infrastructure of the future.

The reduced environmental impact of zinc alloys

Zinc die-casting is a much more sustainable process, especially from the point of view of energy consumption, compared to other metal die-casting processes such as aluminum for example. This fact translates into lower greenhouse gas emissions (GHG – Greenhouse Gas) and a reduction in the overall carbon footprint (CF – Carbon Footprint). Furthermore, the die casting of zinc alloys requires less energy to reach the melting temperature than other metals, contributing to further energy savings.

The results of the life cycle assessments (LCA) of zinc alloy die-cast products confirm the low environmental impact. The Life Cycle Assessment (LCA) is, in fact, a methodology used to quantify the ecological effects of a product or service throughout its life cycle: from production to the end of its useful life in which it effectively becomes waste and is no longer usable. This methodology assesses environmental impacts regarding greenhouse gas emissions, energy consumption, water and natural resources use, waste generation, and other environmental factors.

CO2 emissions and other categories that stand in the way of CO2 neutrality. The CO2-neutral concept “avoid – reduce – compensate” can be followed, i.e.:

• Avoid emissions at the outset, both for material extraction and processing.
• Reduce emissions, where possible, during production processes by implementing measures to ensure greater energy efficiency and self-sufficiency.
• Offset the CO2 emitted through projects or certificates that can offset unavoidable emissions.

Conclusion

In conclusion, the eco-sustainable die casting of zinc alloys offers an advanced and responsible approach to production. Thanks to the combination of production efficiency, recyclable materials, and reduced environmental footprint, this technology is aimed at companies that want to achieve environmentally friendly results without compromising functionality. Zinc alloys can replace less sustainable materials by improving energy efficiency and dramatically reducing overall environmental impact.

Furthermore, in our article on the Automation of the die-casting production process, we explore the benefits in economic and, above all, environmental terms of a production process converted from manual to automated. By analyzing a specific case study, you will discover how the die-casting industry is adopting new advanced processes to achieve ever more ambitious quality and environmental sustainability objectives.

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Cost reduction strategies in zinc die casting

Cost reduction in zinc die casting can be implemented in different ways. In fact, zinc is a versatile metal that, if manufactured with the right technologies, allows saving not only in absolute terms, because it allows the die caster to save the time, energy and raw material that are required in the process, but also compared to other metals.

In the production of die-casts it is possible to implement cost reduction by:

•  Choosing zinc instead of other metals or other metal alloys
•  Optimizing the productive process
• Designing processes and components together with the customer through co-design methods

  When it comes to save during die casting process it is also important to choose the right die caster, if you want to learn more on the matter read How companies can save while selecting the die caster.

Advantages of zinc: chemical and physical qualities and characteristics, melting temperature, circular economy

Zinc alloys usually employed in the die casting process have some properties that make them competitive if compared to other metals. These are chemical-physical properties that allow the reduction of costs related to productive processes and to the subsequent stages, such as, for example, those of disposal and recycling. Let’s analyze these characteristics in detail.

Chemical-physical qualities and properties

In the die casting process different zinc alloys are employed. The most common of those alloys are Alloy 2, 3 and 5, and they are chosen for the production of different components depending on their chemical-physical properties. In fact, according to the percentage and the relative values of the metals that are contained in them, the alloys have different characteristics that make them more or less appropriate to realize different typologies of products. For example, if the component is a safety product the alloy that guarantees the greatest resistance to wear, corrosion and pressure, yield strength and dimensional accuracy is to be chosen. In case of a technical component, for which it is often important to achieve details and thin ribs, the Zamak to be preferred will be the most fluid because it will be capable of spilling over the mold in the most uniform way. In this way it will be possible to obtain thin walls thickness that is essential to guarantee the functionality of products. Finally, for aesthetical products Zamak alloys able to ensure the best surface quality and the best performance if subject to subsequent processing and finishing, are to be preferred. Therefore it is very important to know the chemical-physical characteristics of the different zinc alloys in order to choose the most suitable for the production of a specific component. Only in this way, in fact, it is possible to make a winning choice and obtain, with reduced scrap rates, quality die casts that need a reduced number of finishing and further processing.

If you want to discover more about different zinc alloys and how to take advantage of their specific characteristics read the articles The best zinc alloys for hot chamber die casting and Zamak molding in hot chamber die casting: chemical composition.
To deepen your knowledge about the advantages of zinc in comparison to other metals read The importance of zinc die casting in automotive industry and Coating, plating and other kind of surface treatments.

Melting temperature

One chemical-physical property that has a great impact in terms of cost reduction is the melting temperature of Zamak. The melting point of Zamak, in fact, is low and this allows hot chamber die casting. Differently from aluminum, which has a higher melting point and that is cold chamber die cast, Zamak allows energy saving provided by the different technological process used to melt the material. There are further advantages related to time that are connected to hot chamber die casting: hot chamber die casting is a faster process than cold chamber die casting and, as a consequence, it has an increased productivity. Another saving factor related to melting temperature is that the mold, subjected to lower temperatures, is affected by less wear and, for this reason, has a longer lifetime, with beneficial effects especially in large scale production.

Circular economy

In this brief review of the qualities of zinc in comparison to other metals one last property has to be mentioned: recyclability. Zinc, in fact, fits in circular economy processes and therefore meets the recent trends toward environmental sustainability. Zinc recyclability is not only an advantage for the final consumer, who can recycle products and appliances, but it is also an important factor of cost reduction for the die caster. In fact, if the agreements with customer allows it, zinc can be re-melted and, in controlled percentages, it can be reintroduced in the productive process with evident consequences in terms of reduction of scrap rate and of optimization of the productive processes.

If you wish to learn more about the possibility of recycling Zamak click here.
If you look for insights on zinc circular economy we suggest you to read Zinc life cycle: how it contributes to circular economy.

Productive process optimization

In regards to cost reduction in die casting not only the properties of zinc are important but also the productive process with which the metal is manufactured. Die casting techniques and machineries have to be up to date with technological development in order to be efficient, for this reason constant research and innovation are necessary. It is also important to have effective supply chain and logistic managment, if you want to learn more click here.

For a general overview about these topics we suggest you to read the article Production process improvement in the die casting industry. If you wanto to deepen your knowledge on the  analysis necessary to optimize the productive process read the article How die casting companies can help you save time and budget.

Automation and cycle time

An important step to achieve cost reduction is, for example, the introduction of automation in the productive process. In fact, automation makes the system more efficient by diminishing the percentage of scrap and allowing the operators to deal with activities with a greater added value.

Moreover, the acquisition of automation is closely related to the capability of updating and implementing the productive machineries. Thanks to the purchase of new machineries activities that used to be manual become automatic with a resulting diminishing in lead time, cycle time and scrap rate and a noticeable increase in productivity. Cycle time, in particular, is very important in relation to cost reduction strategies: in fact diminishing cycle time means increasing OEE, the productive performance index of a plant, and, consequently, the production. In the specific field of hot chamber die casting the reduction of cycle time represents a further saving opportunity because, in a reduced cycle time, the thermal power that the melted material provides to the mold is increased with a resulting decrease of cold fronts and related defects.

If you want to learn more about automation and its importance for the production process read How automation helps improving the production process; if you want to discover more about cycle time and its optimization we suggest you to read How die casting cycle time optimization can help to reduce costs.

Simulation

Another strategy to optimize the productive process is to use simulation software that allow designers to forecast what is going to happen during the die casting process. Simulation is a useful instrument to prevent problems, errors and defects during the production of the die casts and it is, moreover, a fundamental aid during design, prototyping and testing phases.

You can find a study about the advantages of simulation in zinc die casting clicking here.

Quality certifications

A guarantee of optimization of the productive process and of the subsequent cost reduction is the achievement of quality certifications. Smeta 4 Pillars, for example, is a certification of qualitative standards, environmental management, company integrity, health and safety with a noticeable impact in terms of cost reduction. In fact, Smeta 4 Pillars through the sharing of standardized approaches improves and aligns the productive process safeguarding brand reputation and guaranteeing an ethical supply chain.

Co-design

Co-design consists in a series of activities aimed at increasing the value of the product and at improving it in terms of quality and efficiency. Often these activities do not result in an increase in production costs but, on the contrary, they result in a decrease in costs. Through co-design, if already implemented during designing phase, it is possible to agree with the customer on weight reduction, elimination of secondary operations, optimization of the mold and a number of other actions that directly lead to a noticeable cost reduction. Obtaining a drawing that is already optimized for mass production allows the customer to have a final product that is in line with expectations and with less risks and scraps. As a further assurance of cost reduction, already during co-design phase, it is possible to undertake a VA/VE value analysis and to optimize the process through the DFM. VA/VE value analysis is a method of problem solving that allows the effective identification of unnecessary costs making it possible to reduce them. DFM, Design for Manufacturability, is a feasibility study in which the design of the product is evaluated and in which adjustments, special treatments and structural modifications are proposed in order to make the optimization of the production possible.

For a deeper insight on co-design we suggest you to read the article Product design for die casting, if you want to deepen your knowledge on VA/VE read The zinc die caster impact on production costs reduction. 

The methods to implement cost reduction in zinc die casting and to optimize processes and products do not end here. However, by reading this article you should have had evidence of some important benefits of cost reduction.

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Zinc is not only a metal used for die casting: first of all it is a natural occurring element that is essential for life and it is considered a “Life Saving Commodity” by the United Nations. Zinc indeed plays a fundamental role for our planet: it is vital for the natural development of biological processes of every living thing, such as cell division, protein synthesis, immune system and growth. It is therefore an essential element for life.

Furthermore zinc is highly recyclable, when it reaches the end of its life cycle it can indeed be recycled without losing any physical property, thus representing a new source of raw material. Approximatively 45% of available zinc at the end of life cycle is recovered and recycled; in Europe and in the United States this percentage reaches even 50%.

It is exactly this characteristic that is a key element for sustainability and development of a circular economy.

Zinc contributes to circular economy

Circular economy is an economic model based on waste reduction and on the development of a circular life cycle, at the end of which a product is no more considered a waste for disposal but is instead a new source of raw material. Zinc fits perfectly in this model: zinc life cycle indeed starts from mining, goes through refining process in order to be used in the modern society and ends with recycling stage at the end of its useful life. During this cycle zinc contributes in different ways to the well-being of our planet:

• It is highly recyclable, thus reducing need for new raw material and exploitation of natural resources

• It protects steel used for infrastructures and transport from corrosion extending the life cycle of steel products

• When used for coating steel it contributes to the reduction in CO₂ emissions

The countless areas of use of zinc and its excellent physical properties therefore confirm the great importance that zinc life cycle has for our planet. Here in Bruschi we are proud to use a highly sustainable material, essential for life and for the protection of the riches of our Earth.

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As the Journal of Industrial Engineering International reports, customers are more and more calling for environment-friendly products and this demand puts pressure on the whole supply chain, because it involves manufacturers, suppliers, retailers and customers. The latter are asking for a greener supply chain that promotes environmental protection and, at the same time, are also developing a well-defined purchasing behavior, which avoids unsustainable products and services. Businesses are therefore studying new methods in order to reach green supply chain management (GSCM), the integration of environmental issues and supply chain that results in reducing manufacturers’ impact on environment while enhancing an organization’s performance.

White goods recycling system

As far as white goods are concerned, emphasis is placed on their recycling cycle: manufacturers must therefore focus on materials. According to AHAM, the Association of Home Appliance Manufacturers, household appliances are increasingly being recycled: they are overtaken only by automotive industry as a source of recycled materials. The growing interest towards recycling has allowed to achieve significant results in the household appliances industry, also thanks to the United States Environmental Protection Agency, specifically with the Responsible Appliance Disposal (RAD) program, which in 2017 has recycled almost 70 million pounds of ferrous metals, 4 million pounds of nonferrous metals, 17 pounds of plastic and 3 million pounds of glass. As data highlight, consumers are increasingly aware of the importance of recycling and are more and more adopting a responsible and sustainable purchasing behavior: white goods industry is therefore continuously renovating and appliances’ manufacturers must face new challenges that environmental consciousness generates, developing products with recyclable materials through sustainable processes.

Metals recycling

White goods are characterized by a long life cycle, normally 10 to 18 years, and when they are no more usable they provide a consistent amount of recycled materials, specifically metals. As stated by The Global Metal Waste and Recycling Market report, the most recycled metals are iron, steel, aluminum, copper, lead and zinc; in addition to that, the report indicates the leading recycling industries, which are building, automotive, shipbuilding and consumer appliances. Metals are among the main materials that undergo a recycling process: they are perfectly suitable for recycling, indeed metals are valuable, can be easily transported thanks to their density and, furthermore, they present properties that allow them to be recycled repeatedly. In the U.S. metal recyclers manage thereabouts 120 million tons of recycled metal every year, with the metal recycling industry having registered nearly $27 billion in 2018.

Zinc recyclability

White goods are complex machines composed of several elements and different materials, among which zinc represents an intelligent and recyclable choice. As a matter of fact, zinc has exceptional metallurgical and chemical properties that remain unchanged also after recycling process, making zinc a suitable material for a wide range of modern products, such as white goods and small appliances.

To calculate zinc recycling rates experts rely on two main methods: the End of Life (EoL) recycling rate and the Recycled Content. Usually EoL is preferred because it measures the quantity of available zinc recovered at the end of product life and recycled, whereas the Recycled Content approach considers the amount of recycled material in a given product. Recent analyses report that around 45% of zinc at the end of life is estimated to be recovered and recycled; in developed regions, such as Europe and North America, this percentage reaches 50%.

Typical Recycling Rate Indices

What is more, zinc not only is itself recyclable, but also contains numerous substances that are recyclable: this quality certifies zinc as Cradle-to-Cradle (C2C), a concept inspired by nature that promotes circular economy. According to this approach a product is designed already considering future reuse and, at the end of its life, it is seen as a new source instead of waste: materials and elements that compose the product are thus recovered and again inserted into the processing cycle.

Zinc benefits in white goods manufacturing

Taking into consideration customers’ request for quality products manufactured with sustainable practices, zinc constitutes an ideal material for white goods components. Indeed, zinc presents high recycling rates and excellent aesthetical quality, combining two of the most demanded characteristics by end-users. Highlighting zinc properties can therefore be an efficient promoting strategy, thus meeting customers’ expectations, providing environmental-friendly solutions and improving selling rates.

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