CASTWELL – the pathway to net zero in foundries

About CASTWELL

CASTWELL is a collaborative system demonstrator that supports the transition of the Swedish foundry industry toward net-zero emissions, circular resource use, and sustainable production. The project brings together foundries, material suppliers, researchers, and industry partners to develop and demonstrate solutions that reduce climate impact and strengthen industrial competitiveness.

Why the project is needed

Metal casting is a key process for components used in the transport, energy, construction, and manufacturing sectors. The processes are energy-intensive and generate CO₂ emissions as well as material wastes. CASTWELL addresses these challenges by reducing climate impact, optimizing resource efficiency, and strengthening the long-term competitiveness of Swedish industry.

Innovative solutions for sustainable foundries

The project demonstrates practical solutions that can be implemented in real production:

• production of cast iron with a lower climate footprint
• circular use and recycling of foundry sand
• reuse of refractory materials
• bio-based binders with low emissions

These solutions reduce emissions, minimize waste, and enable circular material flows.

System analysis and step-by-step monitoring

CASTWELL includes a system analysis that evaluates environmental impact, resource efficiency, and economic feasibility. Using life cycle assessments (LCA) and techno-economic analyses, the project assesses how the solutions affect climate emissions, material flows, and cost efficiency across the entire value chain

The project applies a stepwise stage-gate process in which results are reviewed at defined checkpoints. Technical progress, environmental benefits, business models, and risks are continuously evaluated, enabling adjustments and prioritization of the solutions with the greatest impact.

The continuous follow-up strengthens the project’s long-term impact and ensures that the solutions are both environmentally sustainable and economically viable to implement at large scale.