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SinterCast and the Environment

SinterCast contributes to the environment directly and indirectly. In the foundry, the improved efficiency of the SinterCast-CGI technology reduces energy consumption; reduces CO2 emissions; and reduces the demand for raw materials. On the road, CGI enables the use of more efficient downsized engines, improving fuel economy and reducing CO2 emissions. Scroll down to learn more about how the SinterCast technology contributes to the environment: in the foundry; in passenger vehicles; in commercial vehicles; in clean diesel engines; and in life cycle analyses compared to aluminium engines and electric vehicles.

Foundry Efficiency

In the foundry, the improved efficiency of the CGI casting process provides energy savings and reduced CO2 emissions. More than 90% of the raw materials used to produce CGI come from recycled sources.

Foundry Efficiency: Process Control and Tracking Technologies.

Foundry Efficiency: Process Control and Tracking Technologies.

The Audi 3.0 litre V6 engine with a CGI cylinder block is 15 kg lighter than  the Mercedes 3.0 litre V6 based on an aluminium cylinder block.

The Audi 3.0 litre V6 engine with a CGI cylinder block is 15 kg lighter than the Mercedes 3.0 litre V6 based on an aluminium cylinder block.

Right First Time

    • Improved process control reduces energy consumption and CO2 emissions.
    • Reduced scrap rates mean fewer castings need to be re-melted and re-cast.
    • The energy needed to melt cast iron: ~10,000 MJ / tonne.
    • Annual energy demand for a foundry producing one million Engine Equivalents per year, with a mould yield of 65%: 800 million MJ.
    • Every 1% of scrap reduction, 1% of weight reduction or 1% of improved mould yield saves 8 MJ – approximately 400 tonnes of CO2 for every one million Equivalents.
    • SinterCast contributes to the environment by improving process efficiency, helping foundries to be right-first-time.

Weight Reduction

    • The increased strength and stiffness of CGI allows engine engineers to reduce 10-20% weight compared to conventional grey iron designs.
    • Less weight means less metal melted, less energy consumed and less CO2 emissions from the foundry.
    • 15% weight reduction provides an annual savings of 7,500 tonnes of castings, and approximately 10,000 tonnes of liquid iron for every one million Engine Equivalents.
    • The reduced liquid metal demand corresponds to a saving of approximately 100 million MJ of electricity and 500 tonnes of CO2 per year.
    • SinterCast contributes to the environment by enabling the reliable high-volume production of CGI; and enabling weight reduction of critical components such as cylinder blocks and heads.

Vehicle Efficiency

On the road, CGI enables the use of more efficient downsized engines, providing higher fuel economy and lower CO2 emissions.

The Ford F-150 offers six engine options. The two SinterCast-CGI engines are the most fuel efficient engine options in the world's most popular vehicle.

The Ford F-150 offers six engine options. The two SinterCast-CGI engines are the most fuel efficient engine options in the world's most popular vehicle.

Engine downsizing and power-up with SinterCast-CGI can save 100 kg in heavy duty engines, providing 250 kg of CO₂ savings per year, per vehicle.

Engine downsizing and power-up with SinterCast-CGI can save 100 kg in heavy duty engines, providing 250 kg of CO₂ savings per year, per vehicle.

Passenger Vehicles

    • The higher strength and stiffness of CGI allows engineers to reduce weight while increasing combustion pressure, resulting in more power per litre.
    • Smaller CGI engines can replace larger engines while providing similar performance.
    • CGI downsizing can provide weight reduction of approximately 25 kg in a passenger vehicle.
    • Every 100 kg of weight reduction provides a fuel saving of approximately 0.2 litres for every 100 km driven.
    • 25 kg weight saving corresponds to approximately 100 litres of saved fuel over the 200,000 km lifetime of a vehicle, providing a reduction of approximately 250 kg of CO2 per vehicle.
    • SinterCast-CGI diesel engines provide 20~30% improved fuel economy and 20~30% less CO2 compared to the nearest available petrol engine option.

Commercial Vehicles

    • Weight reduction in commercial vehicles enables increased payloads, educed vehicle-miles and improved fuel economy.
    • Every 100 kg of weight reduction improves fuel economy by approximately 0.1%.
    • For a typical 12L engine, with fuel consumption of 40 litres per 100 km, SinterCast-CGI can reduce weight by approximately 100 kg.
    • Weight reduction of 100 kg can yield fuel savings of approximately 0.04 litres for every 100 km.
    • For annual mileage of 250,000 km, 100 kg of weight saving in a fleet of 100 trucks corresponds to a fuel saving of approximately 10,000 litres of diesel fuel per year – a reduction of more than 25 tonnes of CO2 per year for the fleet.

SinterCast and the Environment: Full-size Pick-up Trucks

In passenger vehicle and commercial vehicle engines, the properties of Compacted Graphite Iron enable engineers to reduce weight and increase performance, resulting in improved fuel efficiency and reduced CO2 emissions.

The Ford F-150 – America’s best-selling vehicle – offered five engine options in 2020. Two of the five engine options were based on SinterCast-CGI cylinder blocks: the 2.7 litre V6 Ecoboost® petrol engine and the 3.0 litre V6 Power Stroke® diesel. The two SinterCast-CGI engines are the most fuel-efficient among the five engine options.


Source: US Department of Energy Website

    • The SinterCast-CGI 2.7 litre V6 petrol engine is the base engine for the high-volume, mid-level Lariat model. The 3.5 litre V6 and the 5.0 litre V8 are the base engines on the higher-spec King Ranch, Platinum and Limited trim levels.
    • Assuming 300,000 vehicles per year and the US average driving distance of 21,500 km per year, the SinterCast-CGI petrol engine provides savings of approxiamtely 110 million litres per year compared to the 3.5 litre engine, or approximately 155 million litres per year compared to the 5.0 litre engine.
    • These fuel savings correspond to a reduction of approximately 265,000 tonnes of CO2 per year compared to the 3.5 litre engine, or approximately 370,000 tonnes per year of CO2 compared to the 5.0 litre engine.
    • The Ford, Ram and GM full-size pick ups were the top-three best-selling vehicles in America again in 2020. With combined sales of almost two million units, these three pick ups outsold the combined volume of the next six vehicles.
    • The Diesel Technology Forum in the US calculates that, if every full-size pick up in the US was equipped with a modern diesel engine, the US could save approximately 1.9 billion litres of fuel and 4.5 million tonnes of CO2 per year. This is equivalent to 15% of the US car market switching to battery-electric vehicles. In 2020, battery-electric vehicles accounted for approximately 1.5% of US passenger vehicle sales. Diesel accounted for approximately 4.5% of 2020 US passenger vehicle sales.

SinterCast contributes to the environment by enabling improved fuel efficiency and reduced
CO2 emissions in high volume passenger vehicles and commercial vehicles