1. Solar Energy

Since April 2024, ALCAR Leichtmetallräder Produktion GmbH, based in Neuenrade, Germany, has been using sustainable electricity from the photovoltaic system of its neighbor, the company Bültmann, for the production of its aluminum wheels for the AEZ, DOTZ, and DEZENT brands.

With over 1,100 PV modules and an installed capacity of 783 kWp, covering an area of 3,429 square meters, the company not only reduces its dependence on fossil fuels but also avoids over 300,000 kilograms of CO2 emissions annually. This input provides ALCAR with around 800,000 kWh of solar power each year. This is a significant step towards more responsible resource management and minimizing environmental impact.

This partnership reaffirms the commitment of both companies to sustainable development and demonstrates how innovative ideas and good neighborly relations can lead to real change. At ALCAR, we are dedicated to responsible actions and protecting our environment by prioritizing sustainability in all areas of our production and logistics.

2. Conversion from gas-fired riser heating to efficient thermal insulation

 ALCAR Produktion has undertaken a comprehensive conversion of its heating systems, switching from a traditional gas-fired riser heating system to a state-of-the-art thermal insulation. This measure offers several advantages:

• Reduction of CO2 Emissions: By eliminating gas-based heating and implementing efficient thermal insulation technologies, CO2 emissions are significantly reduced. This plays a crucial role in achieving the company's climate goals.
• Cost Efficiency: In the long term, these energy-efficient systems lead to substantial cost savings by optimizing energy consumption and minimizing the need for fossil fuels.
• Improved Energy Efficiency: The new thermal insulation ensures even and sustainable heat distribution, resulting in higher energy efficiency and an improved indoor climate.

3. Sophisticated Peak Load Management
Additionally, ALCAR Produktion employs a sophisticated peak load management system to control energy consumption in a cost-efficient manner. This system allows for the reduction of energy load during peak times, thereby significantly lowering energy costs. Through careful planning and management of energy consumption, a balanced and sustainable use of resources is ensured.

4. Utilizing Innovative Heat Recovery Technologies
In certain production areas, ALCAR Produktion has already implemented innovative technologies that capture and convert heat generated during production into heating energy. This approach is particularly advantageous as it allows for the effective and sustainable use of the otherwise wasted "by-product" of heat. This not only contributes to energy savings but also promotes a more environmentally friendly operation.

5. Optimizing Operational Logistics with Electric Cargo Bikes
In addition to energy efficiency measures, ALCAR Produktion has also taken innovative steps in operational logistics. A central aspect of this strategy is the use of electric cargo bikes for logistics between maintenance and production.

• Environmentally Friendly Logistics: Electric cargo bikes are emission-free, contributing to further reductions in CO2 emissions. This is a significant step towards greener and more sustainable operations.
• Increased Efficiency: The use of electric cargo bikes allows for flexible and rapid delivery of materials and tools within the facility. This leads to better coordination between departments and reduces downtime.
• Sustainable Mobility: Promoting electromobility within the operation not only supports emission reductions but also signifies a commitment to innovation and environmental awareness.

Although Switzerland had the lowest CO2 emissions in Europe in 2023, with 53 grams per produced kWh of electricity—on par with France and the Scandinavian countries — ALCAR took the opportunity presented by the roof renewal of its production halls to install a photovoltaic system. This step reaffirms the company’s commitment to sustainability and environmental protection.

As part of this project, 3,500 PV modules with an impressive total capacity of 1,200 kWp were installed. This system was commissioned in the fall of 2020 and has since significantly contributed to the energy supply of the production facility. Thanks to this photovoltaic system, approximately 20% of the annual electricity demand for steel wheel production in Switzerland is covered by renewable, CO2-free sources. This not only represents a significant reduction in CO2 emissions by around 50 tons per year but also marks an important step towards more environmentally friendly production.

With this project, ALCAR demonstrates that economic efficiency and ecological responsibility can go hand in hand. By harnessing solar energy, the company helps to conserve natural resources and reduce environmental impact without compromising production quality and efficiency. This initiative serves as a model for other companies in the industry, showing that sustainable practices are not only feasible but also economically beneficial.

Energy Management in our office and warehouse locations:
At our office and warehouse sites, we are transitioning our lighting to modern LED technology. This shift not only significantly reduces energy consumption but also extends the lifespan of our lighting systems, thereby lowering maintenance costs.

We are also increasingly adopting sustainable drive technologies. Most of our pallet trucks and forklifts have been converted to environmentally friendly battery-powered drives. This measure helps to reduce CO2 emissions and supports our efforts to create a greener and more efficient working environment.