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Breyden: Sustainable Production of Brake Discs

Committed to resource efficiency and recycling
Brake discs are in production.

In manufacturing, environmental sustainability is increasingly important. As the industry evolves, individual castings like brake discs are coming under the spotlight for their environmental impact due to energy-intensive production processes. Breyden addresses this issue by using recycled materials in its casting process, which reduces the consumption of raw materials and lowers energy usage, fostering more sustainable production.

European market leader in car brake discs
The automotive supplier annually produces 15 million brake discs for passenger cars. For manufacturing, Breyden uses both industrial scrap and recycled materials from its own production, thus offering a safety relevant and sustainably produced product. The German company has committed itself to the goals of sustainability and resource efficiency. Each brake disc manufactured in the plant is 100% recyclable.

Less scrap – more quality
The automated quality assurance is conducted with a ZEISS ScanBox during production. If it detects deviations, it transmits the generated measuring data to production in real time to allow for adjusting process parameters. Marcel Nickel, Optical Metrology Specialist at Breyden, is very pleased with the system: “[…] the inspection during production shows us that our process is stable and that we generate almost no scrap.”

Optical 3D measuring machine ZEISS ScanBox 4105 RC with monitor and a connected automated enclosure.

Automated loading and measurement of parts

ZEISS ScanBox 4105 RC is an optical 3D measuring machine with a motorized sliding door. Parts up to 500 mm in size can be loaded into the ZEISS ScanBox 4105 RC with a robot or an individually configured feeding system and placed on the rotation table module. The elimination of manual, individual placement significantly reduces the time required, ensuring a higher throughput in quality assurance. The autonomous operation increases machine utilization, speeds up measurement cycle times, and allows personnel to be deployed more efficiently.

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Engineer inspecting industrial metal framework

More on this topic: Giant precision

Large-scale castings are becoming more important across various industries, driven by the need for efficiency and cost-effectiveness in manufacturing. Handtmann, Europe’s largest light-metal foundry, is leading the transition to gigacasting by casting complete structural parts and battery trays for electric vehicles in one piece. Learn more about quality assurance for XXL casting parts!

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