Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseCharge

Shot report · Automotive Tier-2 foundry · Managing Director, Head of Foundry, Sustainability lead

Every shot carries its energy.
The housing leaves with its number.

A Tier-2 foundry casts EV motor housings and structural parts on fourteen cells of three makers and three vintages, fed by gas melting furnaces and electric holding furnaces. Customers now ask for a product carbon footprint per part. The plant knows its monthly bill and its monthly scrap; it does not know what one housing cost in kWh, which cell made it, or whether the X-ray that rejected it was looking at a melt problem or a die problem. This report shows the plant's own meters, cells and inspection stations on one read-only record, the six quantities the board asks for, and what changes when the shot itself is the unit of account. Every result is modelled from the inputs on sheet 7.

Melt-charge board · six quantities · today → modelledBasis: 9,000 t good cast a year · inputs C-01 to C-24

kWh per tonne good cast5,600→ 5,400Gas and electricity, melt to machined part. Today is the published die-casting average^S6.

Scrap after X-ray and machining6.0→ 5.0 %Each scrapped part is remelted; its energy is spent twice.

Melt loss3.0→ 2.7 %Metal to dross, by furnace and shift, from the charge scale.

kg CO2e per part7.41→ 7.12Gate-to-gate energy only; the ingot's 26.5 kg is shown beside it, never mixed in.

€ energy per part3.67→ 3.524.2 kg housing at 19.33 ct electricity, 6.75 ct gas^S5.

Cell OEEhelduntil 90 %Shown per cell once at least 90 % of its time is accounted for; not before.

The casting mark of this report: one shot is a biscuit, a runner, a gate, the part and its overflow wells. The plant pays for all of it, melts the biscuit and runner again, and sells the part. Three read points, all read-only, turn that shot into a record: the furnace meter, the cell's own shot counter and cycle signals, and the X-ray result. Nothing is written back to a furnace, a machine or a PLC. Pragmatos reads; people decide.

Who reads this

The Managing Director who signs the customer's carbon declaration, the Head of Foundry who owns scrap and melt loss, and the Sustainability lead who has to produce a defensible kg CO2e per part without a second data entry team.

What sits on one record

Furnace and holding-furnace supply meters, cell shot and cycle signals, die temperature units, the X-ray station's verdict per serial, charge-scale weights, and the plant's cost rates and emission factors, each with its source and date.

What it is not

Not a furnace controller, not a cell controller, not a setpoint. Pragmatos Live reads through a wizard-mapped point list with zero write paths. Decisions go through a named person; the record keeps who, what and why.

Archetype plant9,000 t good cast · 14 cells · 2 gas shaft furnaces · electric holding furnaces · X-ray and CT · trimming and machining

DeploymentOn premise in your plant, in your own cloud, or both: you choose.

Sheet 1 of 7 · Chargekg CO2e per part basis: metered gate-to-gate energy × dated factors Modelled

Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseMelt and hold

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Sheet 2 · The plant as it stands

Three makers, three vintages, two energy carriers

A die-casting plant grows one cell at a time. The newest cells speak a machine interface; the oldest give a shot-counter contact and nothing else. The furnaces came from a different supplier again. The question is not "which do we replace" but "how do we read all of them at once without a project per cell".

Stage	Equipment (maker lettered, vintage)	Count	Carrier	What is known today	How it is read with Pragmatos
Melting	Gas shaft furnaces, maker A, 2009 and 2016; electric crucible furnace for returns, maker B, 2021	3	Gas · electricity	Monthly gas bill; furnace hour meter read by hand	Supply meters on gas and electricity; charge scale read through its own interface
Holding	Electric resistance holding furnaces at each cell, maker B, 2011 to 2023	14	Electricity	Nothing per furnace; part of the hall feeder	One meter per holding furnace feeder; the base load becomes visible
Casting	Cold-chamber cells, maker C, 2019 to 2023, with machine interface	6	Electricity · hydraulics	Shot counter and cycle time on the machine screen	Existing interface, read-only: shot number, cycle phases, alarms
Casting	Cold-chamber cells, maker D, 2011 to 2015, no interface	5	Electricity · hydraulics	Shot counter on paper at shift end	Shot-counter contact and a cell supply meter; cycle from the contact timing
Casting	Cold-chamber cells, maker E, 2004 to 2008	3	Electricity · hydraulics	Shot counter on paper; energy unknown	Added sensor on the plunger stroke plus a supply meter; nothing changed on the machine
Die temp.	Oil and water temperature control units, one to three per cell	31	Electricity	Setpoint on the unit's display	Unit interface where present, feeder meter where not; read-only
Inspection	X-ray stations (2) and one CT for first-off and disputed parts	3	Electricity	Verdict per part in the station's own log	Verdict and serial read from the station log; linked to the shot that made the part
Finishing	Trimming presses and five-axis machining centres	11	Electricity · compressed air	Machining scrap counted per lot	Machine interface on the centres; press contacts; scrap note per serial
Site	Compressed air, cooling water, hall ventilation	–	Electricity	One site meter, one bill	Main meters plus the feeders above; the remainder is reported as unattributed, never spread

Makers are lettered because the archetype is the point, not the supplier. Counts and vintages are the archetype's inputs, not a customer's inventory.

What the customer asks

A kg CO2e figure per part, cradle-to-gate, on the supplier's letterhead. A European Tier-1 has asked its suppliers for a PCF since 2022^S9. Group reporting under CSRD wants the same number rolled up by site. From 2026 the definitive CBAM regime prices embedded emissions in imported aluminium^S4, so the ingot's footprint reaches the metal invoice.

What the plant knows

The site bill, the gas bill, the tonnes of ingot bought and the tonnes of good parts dispatched. From these a yearly kWh per tonne good cast can be calculated once a year. Scrap is counted per lot on the X-ray station and at machining; melt loss is estimated from metal purchases minus shipments.

What is missing

The kWh of one housing, by cell and by shift. The share of the bill that is holding furnaces idling through breaks and weekends. Whether a rejected part came from a melt that was held too long or a die that ran too cold. A declaration that a customer's auditor can trace back to meters, not to an allocation key in a spreadsheet.

Designed for the EU AI Act's human-oversight and logging requirements. Whether your use meets the Act is for you and your advisers to assess.

Sheet 2 of 7 · Melt shop and cellsArchetype inventory · counts are inputs Modelled

Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseInspect

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Sheet 3 · Reject tickets

Eight tickets the plant writes against itself

An X-ray station writes a ticket for every rejected part. These eight are the tickets a foundry's own numbers write against the business. Each one carries its public source; the archive copy sits in the evidence folder of this study.

Electricity is the cost, and it is three to four times the competitor's

German non-household electricity stands at 19.33 ct per kWh in the first half of 2025; only the largest consumers reach 13.38 ct^S5. The foundry association and the metalworkers' union jointly call electricity "three to four times as expensive" as abroad and ask for 6 ct^S8. The plant cannot set the price. It can know, per part, what it buys at that price.

S5 Federal Statistical Office, energy prices H1 2025 · S8 BDG and IG Metall position, 20 March 2026

Die casting sits at the heavy end: 5,600 kWh per tonne good cast

A 2011 foundry-industry survey puts die casting at around 5,600 kWh per tonne of good casting and about 2.5 t CO2 per tonne, against a foundry average of 2,000 kWh per tonne^S6. The yearly figure is one division. The figure per cell, per shift and per part is what moves it.

S6 Giesserei trade journal, energy study, 2011

Melting is the smaller half of the bill

A gas shaft furnace needs 580 to 900 kWh to melt one tonne of aluminium^S7. Against 5,600 kWh per good tonne, the rest is holding, hydraulics, die temperature units, compressed air and the remelting of biscuits, runners and scrap. Most of that load runs whether or not a shot is made.

S7 Foundry lexicon, shaft furnace entry

Porosity rejects carry all the energy twice

Porosity accounts for about 70 % of failures in high-pressure aluminium die casting^S10. A part rejected at X-ray or opened up at machining has already paid for its melt, its hold, its shot and its trim, and goes back into the furnace to pay again. At 6 % scrap, that is 137,000 housings a year on this archetype.

S10 Springer, HPDC porosity study, 2016

The customer's PCF request has a format and a deadline

A European Tier-1 asked its suppliers for a product carbon footprint from November 2022, cradle-to-gate, following the GHG Protocol product standard^S9. Each request costs the Sustainability lead about two days of spreadsheet work on this archetype, forty times a year, and the next one asks for the same part again with this year's factor.

S9 A Tier-1 supplier guideline on PCF, 2025 edition

The grid factor moves every year; a fixed factor is wrong by next year

The German grid factor is 363 g CO2 per kWh for 2024, after 386 in 2023 and 433 in 2022^S1. A declaration that bakes the factor into a formula has to be rebuilt each year. On the record the factor is an input with a date and a source, applied to the metered kWh of the part.

S1 Federal Environment Agency, grid emission factor, 2024 figure

The ingot is the footprint; the plant controls the gate-to-gate share

European primary aluminium carries 6.3 kg CO2 per kg; recycling needs about 5 % of the primary energy^S3. For a 4.2 kg housing that is 26.5 kg from the ingot against 7.4 kg from the plant's own energy. The two numbers belong on the same declaration, in separate lines, so the plant is judged on the line it owns.

S3 European Aluminium, environmental profile report 2024

CBAM is definitive from 2026 and aluminium is in scope

Since 1 January 2026 the carbon border adjustment mechanism applies under its definitive regime, with aluminium among the covered sectors^S4. Imported ingot arrives with a certificate cost attached to its embedded emissions. The buyer who can show its own gate-to-gate number per part, separately, keeps the conversation on what it controls.

S4 European Commission, CBAM, definitive regime page

Sources S1 to S10 are listed in full on sheet 7. Quotes in the evidence archive are verbatim; the figures on this sheet are the published figures, not the plant's. Cost rates, factors and share assumptions used in the model are marked C-xx on sheet 7 and can be replaced by the plant's own.

Sheet 3 of 7 · Reject ticketsEight pains · ten public sources · archive in _evidence Modelled

Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseShot

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Sheet 4 · One record from melt to machined part

The shot is the unit of account

Every read point below is a tap on something the plant already has. The record that results is one line per shot: which furnace charge, which holding furnace, which cell, which shot number, the cycle phases and their timing, the kWh the cell and its holding furnace drew during the cycle, the X-ray verdict for the serial, and the machining outcome. Each module touches that line once.

LoomConnects each read point: furnace and holding-furnace supply meters, the newer cells through the interface they already have, the older cells through a shot-counter contact, an added plunger sensor and a cell meter. The wizard runs identify, discover, map, point list, install, approve; the point list is what the plant signs. Loom is software; it reads and never writes.Output: the signed point list, one per cell and furnace.

Pragmatos LiveShows the hall as it runs: power now from the main meters, energy today, load by area, and for each meter the readings the electrician trusts. Every number carries its basis, for instance "parts-weighted across 10 of 14 cells", and a data-quality line when a meter has gaps.Output: the Live hall screen and the meter detail shown below.

Pulse · AnalyseBuilds the metering concept to DIN EN 17267, allocates kWh to furnace charges, cells and shots, and reports what it cannot allocate as "unattributed" rather than spreading it. Computes kWh per tonne good cast, kWh and € per part, melt loss per charge, and the energy baseline and performance indicators of ISO 50006 for the ISO 50001 review. OEE per cell to ISO 22400-2 is withheld while more than 10 % of a cell's time is unaccounted for.Output: energy per part by cell, the loss tree, the yearly EnPI against its baseline.

OrbisPuts a proposal in front of a person with the evidence beside it: which holding furnaces to put on weekend standby, which 15-minute window carries the peak and what load in it can wait, which melt charge the porosity rejects cluster on. Confidence is stated as coverage, never as a promise.Output: a proposal with its evidence, waiting for a decision.

FlowTurns an approved disposition into the action record: a quality lot hold with per-part genealogy back to the charge and the shot, a scrap note carrying the serial, and the cost rate applied with its source. Flow keys each record to the works order and the part number the plant already uses.Output: the lot hold, the scrap note, the cost line.

DecisionsKeeps the record that a customer's auditor reads: every proposal, who approved it and when, two-person sign-off where the plant requires it, in an append-only chain. Exports per part, per cell, per period or per company; the works council has its own read-only view.Output: the declaration export per part and period, sheet 6.

The human
step

Nothing acts on its own. Orbis proposes, a named person in the foundry approves or declines, Flow records the action, Decisions keeps the chain. A holding furnace goes on standby because the shift leader says so at 21:40 on Friday, and the record shows that she did, with the load curve that made the case. The furnace is operated the way it is today, by hand, from its own panel.

Live hall screen: power now 122 kW from 3 main meters, energy today 5,657 kWh, power factor 0.94, and the load-by-area chart — **Pragmatos Live, hall screen.** Power now from the main meters, energy today, power factor and load by area. In the foundry the areas are melt shop, holding, cells and finishing. Product screen, 1:1 crop.

Meter detail tiles: power 93.1 kW, power factor 0.94, apparent power 99.1 kVA, reactive power 33.8 kvar, meter reading 1,291,874 kWh, voltages, current, frequency, THD — **Pragmatos Live, one supply meter.** The readings a holding-furnace feeder meter gives: power, power factor, apparent and reactive power, the meter reading itself, voltages, current, frequency and harmonic distortion. Product screen, 1:1 crop.

Sheet 4 of 7 · One recordSix modules · one line per shot · read-only edge Modelled

Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseSolidify

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Sheet 5 · What the readings show

5,600 kWh per tonne good cast, stage by stage

The published die-casting average is the archetype's starting point^S6. Split by stage from the plant's meters, two things stand out: holding furnaces and cell base load run through every break, and every rejected part drags its whole stack back to the furnace. The modelled bar below applies the four energy levers of sheet 7; the € and PCF-effort levers do not move kWh and are not in it.

Quantity	Before: yearly, from bills	With: per shot, from the record
kWh / t good cast	One number a year, bill divided by tonnes dispatched.	Per cell, per shift, per charge; stage split from meters; unattributed share stated.
Scrap	Per lot, on paper, cause guessed at the morning meeting.	Per serial with the shot's phase times, holding time of the melt and die temperature beside the verdict.
Melt loss	Purchases minus shipments, once a quarter.	Per furnace and charge from the charge scale, against holding time.
kg CO2e / part	Two days per request, fixed factor, allocation key in a spreadsheet.	Metered kWh of the part × the dated factor; ingot share on its own line; export per part and period.
€ energy / part	Unknown; quoted from a plant average.	Per part family and cell, with the tariff and its source on the line.
Cell OEE	From the shot counter on paper.	Per cell, shown only once 90 % of time is accounted for; the rest reported as unknown.

Beyond the readings: the record itself

What the Sustainability lead sends the customer is not a number but a provenance: which meters, which allocation rule, which factor with its date, which shots, signed by whom. Decisions exports it per part, per cell, per period or per company. The customer's auditor reads the same record the shift leader approved from.

Product screen heading: Digital Product Passport, auditor-facing provenance, exportable, with Resolve, Export JSON and Print buttons

Decisions, provenance export. Heading and toolbar of the product screen, 1:1 crop. The table below it is the per-part record.

What else the one record carries

Part history per serial. Charge, holding furnace, cell, shot, phase times, X-ray verdict, machining outcome: the genealogy a field return needs, years later.

Digital nameplate. Each cell, furnace and meter carries its asset data in the Asset Administration Shell form (IEC 63278), so the customer's or the auditor's tools read it without a phone call.

Retention. Records kept for the life of the part plus one year, up to fifteen years, matching what the Tier-1 contracts ask for.

ISO 50001. The energy baseline and performance indicators of sheet 4 are the management-review input; the metering concept to DIN EN 17267 is the document the certifier asks for first.

Capability gaps, named. No die-casting machine or furnace interface is in the product today; the read path is a contact, an added sensor and a meter until there is one. No emission-factor field per energy carrier and no PCF export per part exist as product screens yet; both are modelled here from the per-part energy figure and are open questions for the product team. Charge-scale and X-ray readings reach the record only where those systems expose a log.

Sheet 5 of 7 · What the readings showChart to scale from zero · stage split C-24 Modelled

Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseEject

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Sheet 6 · Rollout and the declaration lines

Rolled out like a shot: slow, fast, intensify, hold

The rollout follows the plunger. A slow first phase while the melt shop meters go on and the point lists are signed; a fast phase through the fourteen cells; intensification while Pulse settles the allocation and the first PCF export is checked against last year's spreadsheet; then hold, the operating rhythm. No cell stops for any of it: every tap is a meter, a contact or a read-only interface.

Declaration lines · € a year · bars to scale from zero · 1 px = €500Modelled

Total €585,178 a year, 7.4 % of a €7,874,190 energy bill. At half the levers €292,589; at double €1,170,356. The weakest line is R-04: the peak tariff component has no public source and the kW it moves is an assumption. Lines do not overlap: R-02 counts energy per good tonne, R-03 metal, R-05 idle hours, R-01 a share of the remaining electricity.

kWh / t good cast5,600 → 5,399R-01, R-02, R-03, R-05 applied

kg CO2e / part, gate to gate7.41 → 7.12metered kWh × dated factors S1, S2

€ energy / part3.67 → 3.52at 19.33 ct and 6.75 ct, S5

Scrap6.0 → 5.0%23,996 fewer housings remelted

Melt loss3.0 → 2.7%55 t of metal a year stays metal

PCF answer2 d → 2 hper request, from the export, C-20/21

Energy cost per part plant roll-up: plant cost per part 2.485 kWh measured, parts-weighted across 3 of 5 machines, unattributed note, per-machine table with not-measured rows — **Pulse, energy per part roll-up.** The € energy per part line above comes from a screen like this: the plant figure with its basis ("parts-weighted across 3 of 5 machines"), the unattributed remainder named and never spread, machines without a meter listed as not measured. In the foundry the rows are cells. Product screen, 1:1 crop.

Sheet 6 of 7 · Rollout and declaration linesSix lines · total €585,178 a year · inputs on sheet 7 Modelled

Pragmatos · Crius Software · Industry archetype CS-10Aluminium high-pressure die casting · EV housings and structural parts

Cycle phaseTrim

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Sheet 7 · Calculation sheet

Every number comes from this sheet

Put your own figures in the C column and the R column follows. Rows marked plant are what the foundry knows; rows marked ASSUMED have no public source and are the first to replace.

Id	Input	Value	Source
Plant
C-01	Good cast dispatched a year	9,000 t	plant
C-02	Casting yield, net part ÷ shot weight	0.55	plant
C-03	Scrap after X-ray and machining	6.0 %	plant
C-04	Melt loss, share of metal melted	3.0 %	plant
C-11	Net part mass, housing	4.2 kg	plant
C-16	Casting cells	14	plant
C-17	Planned hours per cell a year	6,000 h	plant
Energy and factors
C-05	Energy per tonne good cast, all carriers	5,600 kWh/t	S6
C-06	of which gas, melting	1,650 kWh/t	ASSUMED
C-07	Electricity, non-household, H1 2025	19.33 ct/kWh	S5
C-08	Natural gas, non-household, H1 2025	6.75 ct/kWh	S5
C-09	Grid factor 2024	0.363 kg/kWh	S1
C-10	Natural gas factor, Hi	0.20 kg/kWh	S2
C-23	Melt and hold one tonne of returns	1,000 kWh/t	S7 band + hold
C-24	Stage split of C-05 (sheet 5 chart)	6 stages	ASSUMED
Cost rates and levers
C-12	Conversion cost of a scrapped part beyond energy	€4.00	ASSUMED
C-13	Metal lost to dross, net of recovery	€2,000 /t	ASSUMED
C-14	15-minute peak	6,500 kW	ASSUMED
C-15	Peak price	€120 /kW·a	ASSUMED
C-18	Idle draw of a cell with its DTC units	95 kW	ASSUMED
C-19	PCF requests a year	40	ASSUMED
C-20	Effort per request, today	2.0 d	ASSUMED
C-21	Effort per request, from the export	0.25 d	ASSUMED
C-22	Day rate, engineer	€450	ASSUMED
L	Levers: base load −3 % · scrap → 5.0 % · melt loss → 2.7 % · peak −3 % · OEE +2 pts	five	ASSUMED

Id	Derived and results	Value	How
Derived
D-1	Parts a year	2,142,857	C-01 ÷ C-11
D-2	Electricity per tonne	3,950 kWh/t	C-05 − C-06
D-3	Energy bill	€7,874,190	C-01 × (D-2 × C-07 + C-06 × C-08)
D-4	kWh per part · € per part	23.5 · €3.67	C-05 × C-11; el × C-07 + gas × C-08
D-5	kg CO2e per part, gate to gate	7.41	16.6 × C-09 + 6.9 × C-10
D-6	Ingot embodied, shown not counted	26.5 kg/part	C-11 × 6.3 (S3)
D-7	Scrapped parts a year, today	136,778	D-1 ÷ (1−C-03) × C-03
D-8	Metal melted a year · melt loss	17,947 t · 538 t	C-01 ÷ C-02 ÷ (1−C-03) ÷ (1−C-04)
Results, € a year
R-01	Base load, 3 % of electricity	206,154	C-01 × D-2 × 3 % × C-07; 118.5 kWh/t
R-02	Scrap 6.0 → 5.0 %	178,871	energy C-05 × (1 − 0.94/0.95) = 58.9 kWh/t → 82,886; conversion 23,996 parts × C-12 = 95,985
R-03	Melt loss 3.0 → 2.7 %	114,402	D-8 at both rates: 55.3 t × (C-13 + C-23 × C-08)
R-04	Peak −3 %	23,400	C-14 × 3 % = 195 kW × C-15
R-05	OEE +2 points, idle draw	30,851	C-16 × C-17 × 2 % × C-18 = 159.6 MWh × C-07; 17.7 kWh/t
R-06	PCF effort	31,500	C-19 × (C-20 − C-21) = 70 d × C-22
Σ	Total, 7.4 % of D-3	585,178	half 292,589 · double 1,170,356
Δ	kWh/t · kg CO2e/part · €/part	5,399 · 7.12 · 3.52	energy lines applied to D-4, D-5
S	Sensitivity, electricity at 13.38 ct	bill €5,758,965	S5 band above 150 GWh; R-01, R-02, R-05 scale with it

Weakest metric: R-04. The peak tariff component and the kW that can wait have no public source. Second weakest: R-06, an effort figure, not a meter reading. Not counted: ingot embodied carbon (D-6), scrap-metal recovery value, any claim on porosity cause. Non-overlap: R-02 lowers energy per good tonne, R-03 metal mass, R-05 idle hours, R-01 a share of what is left; R-04 and R-06 are tariff and effort.

S1 Umweltbundesamt, spezifische Treibhausgas-Emissionen des deutschen Strommix 1990–2024 (Climate Change 2025): 363 g CO2/kWh 2024; 386 in 2023; 433 in 2022.

S2 Umweltbundesamt, CO2-Emissionsfaktoren für fossile Brennstoffe, 2022: natural gas 202.022 g CO2 per kWh (Hi), rounded here to 0.20 kg.

S3 European Aluminium, Environmental Profile Report 2024: 6.3 kg CO2e per kg European primary aluminium, cradle to gate; recycling at about 5 % of the primary energy.

S4 European Commission, Carbon Border Adjustment Mechanism: definitive regime from 1 January 2026; aluminium is covered.

S5 Statistisches Bundesamt, Erdgas- und Strompreise für Nicht-Haushalte, 1. Halbjahr 2025: electricity 19.33 ct/kWh average; 13.38 ct above 150,000 MWh; gas 6.75 ct/kWh.

S6 Giesserei trade journal, 2011, die-casting energy study: about 5,600 kWh and 2,500 kg CO2 per tonne good cast for the die-casting route; about 2,000 kWh per tonne as the foundry average.

S7 Giesserei-Lexikon, Schachtofen: 580 to 900 kWh per tonne for melting aluminium in a gas-fired shaft furnace.

S8 BDG and IG Metall joint position, 20 March 2026: German industrial electricity three to four times the price in competing regions; a target of 6 ct/kWh.

S9 A Tier-1 supplier guideline on product carbon footprints, 2025 edition: PCF requested from suppliers since November 2022, cradle to gate.

S10 Springer, International Journal of Metalcasting, 2016, high-pressure die casting defect study: porosity accounts for about 70 % of failures.

All ten are archived with their retrieval date in the study's evidence folder. No customer, vendor or OEM is named on these sheets; the plant on sheet 2 is an archetype composed from the public record.

Sheet 7 of 7 · Calculation sheetC-01 to C-24 · R-01 to R-06 · S1 to S10 Modelled

Every shot carries its energy.The housing leaves with its number.

Who reads this

What sits on one record

What it is not

Three makers, three vintages, two energy carriers

What the customer asks

What the plant knows

What is missing

Eight tickets the plant writes against itself

Electricity is the cost, and it is three to four times the competitor's

Die casting sits at the heavy end: 5,600 kWh per tonne good cast

Melting is the smaller half of the bill

Porosity rejects carry all the energy twice

The customer's PCF request has a format and a deadline

The grid factor moves every year; a fixed factor is wrong by next year

The ingot is the footprint; the plant controls the gate-to-gate share

CBAM is definitive from 2026 and aluminium is in scope

The shot is the unit of account

5,600 kWh per tonne good cast, stage by stage

Beyond the readings: the record itself

What else the one record carries

Rolled out like a shot: slow, fast, intensify, hold

Every number comes from this sheet

Every shot carries its energy.
The housing leaves with its number.