New service model almost completely replaces new sand.
FSP has successfully commissioned the world's first plant for the cost-saving and environmentally friendly regeneration of foundry waste sand. The company recently began supplying 100 tons of regenerated sand per week to the foundry of a well-known automobile manufacturer in the region. On October 24, Rita Schwarzelühr-Sutter, Parliamentary State Secretary at the Federal Ministry for the Environment, Climate Protection, Nature Conservation, and Nuclear Safety, will officially inaugurate the plant. The opening also marks the launch of FSP's new service model, which significantly reduces costs for foundries and conserves the precious resource of sand.
The patented wet process makes it possible to recycle up to 90 percent of the used sand and return it to the production process as regenerated material. This almost completely replaces new sand and creates a closed material cycle: used sand is delivered or collected, regenerated in the new plant, and then returned to the foundries as a high-quality raw material.
60,000 tons of sand regeneration per year – many advantages
The new wet regeneration plant complements a mechanical-thermal plant that is already in the planning stage. Together, the two processes can process up to 60,000 tons of used foundry sand per year and save significant amounts of CO₂ – a key contribution to resource conservation and climate protection.
FSP's new service model saves foundries the investment in expensive plant technology and the operation of their own regeneration plants. It also drastically reduces the costs of purchasing new sand and disposal. There are further advantages for the environment: regeneration at FSP saves landfill space and avoids the transport of sand over long distances.
A milestone for the circular economy
Not only with its service model, but also with its own plant, FSP is setting new standards for resource conservation and sustainable working in the circular economy: The new plant is equipped with a combined heat and power system, which makes it largely energy self-sufficient and enables CO₂-neutral operation. FSP technology thus combines economic efficiency with ecological responsibility – a prime example of the circular economy in action.
Stefan Zimmermann, Managing Director of FSP GmbH, sees the project as a milestone for the circular economy in the foundry industry: Previously, new sand had to be purchased for each individual core and the used sand had to be disposed of at great expense after casting. Now, the regenerated sand runs in a continuous cycle and is reused repeatedly in core production and the casting process.
About FSP GmbH
FSP GmbH Foundry Sand Processing, founded in Stuttgart in 2022, develops and distributes systems and solutions for the regeneration and processing of bulk materials. The company builds on the decades of experience of its founders in the recycling of raw materials and the mechanical-thermal or wet regeneration of used foundry sand.
The founding partners are Heinrich Feeß GmbH & Co. KG in Kirchheim/Teck and DEANTEC GmbH in Kirchhundem. Feeß, which was awarded the German Federal Environmental Prize in 2016, contributes its expertise in recycling mineral waste, while DEANTEC brings its experience with its unique, patented wet regeneration and drying process—a plant technology that uses largely renewable energies for the processing of used sand.
