Harnessing CO₂ Reduction Potentials Along The Value Chain

Co-engineering for Greater Sustainability

In recent years, many German companies have closely examined their own processes to identify opportunities for reducing CO₂ emissions, taken responsibility, and implemented numerous measures.

Yet in some places – metaphorically speaking – the “last light bulb has been replaced.” The situation is similar for the joining technology experts at Arnold Umformtechnik. Added to this is the fact that, as a component supplier, they have a direct influence on only a small single-digit percentage of CO₂ emissions within the entire value chain. They are dependent on steel suppliers, and as long as steel is not produced sustainably, this naturally accounts for the largest share of emissions in the overall process. However, medium-sized companies have virtually no influence over further developments in the field of green steel. Because sustainability has always been a key concern for the joining experts – the first factory in an existing mill already used hydropower to drive the machines—the company is on the lookout for further savings opportunities within its sphere of influence. One starting point was found among their customers, most of whom are in the automotive industry. Through co-engineering services, the joining experts support their customers in reducing CO₂ emissions.

Cold forming saves material and energy
This becomes clear with a simple example: the production of fasteners and multifunctional parts via cold forming instead of machining. This is interesting because cold forming removes almost no raw material (e.g., steel), meaning that virtually only the volume ultimately contained in the fastener is required. Although the steel removed during machining is reused—meaning no material is wasted—the energy and logistics required for reprocessing the chips are not negligible. Depending on the complexity of the parts, cold forming can reduce CO₂ emissions by up to 45 percent. At the same time, cold-formed fasteners offer tolerances that differ only slightly from those of machined parts. This is where co-engineering comes into play. If the mating part for the fastener is designed accordingly during development, cold-formed fasteners can create connections that are just as secure and durable as those made with conventional solutions.

Michael Pult, Director of Marketing & Sustainability at ARNOLD, explains: “This type of cooperation naturally requires mutual trust. Since we have been working with many of our customers for decades and are listed as a preferred supplier by many automakers, we have earned this trust in many places.” Co-engineering opens up further opportunities for cost savings. If you bring in a fastening technology expert right from the start of the development process, they can use their calculation and simulation tools to identify applications where, for example, an M8 screw can be replaced with an M7 screw. Sound trivial? Given the volume of screws used and the energy footprint of currently produced steel, this is anything but negligible.