We welcome you to our conversation with Mr Ruggero Zambelli and Mr Paolo Gamberini of Raffmetal, the Europe’s leading producer of aluminium alloys from recycling. Mr Zambelli serves as Quality Manager and Head of Alloys Development, and Mr Gamberni is Sales Responsible for Foundry Alloys from Recycling.

Sharing their outlook on the aluminium casting market, both Mr Zambelli and Mr Gamberini underline that lightweighting is a long-term strategic priority for the automotive sector, which continues to offer strong growth prospects to the aluminium casting market beyond 2026. While acknowledging near-term challenges, particularly the increasing outflow of aluminium scrap from Europe, they note that Raffmetal is working closely with government authorities to address these concerns. When asked about digitalisation and automation, they said those are the strong pillars behind Raffmetal’s operations, ensuring efficiency, quality and decision-making. For reducing energy intensity, they said they are undertaking process optimisation measures and structural decarbonisation initiatives.

To know more about Raffmetal, their views and opinions on the aluminium casting market, including challenges, keep reading the interview.

AL Circle: Can you tell us briefly about your products and services with a focus on aluminium casting solutions?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Raffmetal is the leading European producer of aluminium alloys from recycling and today, representing a global benchmark for aluminium casting solutions based on circular economy principles.

The company designs and supplies a wide range of primary and secondary aluminium alloys from recycling for HPDC and other foundry applications, serving international customers in the automotive, construction and consumer goods sectors. Thanks to deep metallurgical expertise and strong process control, Raffmetal is able to respond with precision and flexibility to the evolving technical and sustainability requirements of a complex industrial value chain.

With more than forty years of experience in the die casting sector, Raffmetal has progressively expanded its portfolio from conventional secondary alloys to advanced, application-specific solutions. A key milestone was the introduction of the SILVAL range in 2020: primary-quality aluminium alloys with high recycled content and performance comparable to primary alloys from bauxite. This portfolio enables customers to adopt more sustainable materials without compromising mechanical properties or process stability.

Our strong market reputation has grown over the years, thanks to the exceptional quality and performance levels achieved by our SILVAL recycled alloys, which are supplied directly to leading European automotive manufacturers.

All Raffmetal alloys are developed with a strong focus on environmental performance. They are EPD-certified, characterised by a low CO₂ footprint and fully aligned with circular material flows. By combining metallurgical innovation, traceable recycled inputs and industrial-scale efficiency, Raffmetal provides aluminium casting solutions that actively support Europe’s pathway toward climate neutrality while meeting the highest quality standards required by global OEMs and Tier-1 suppliers.

AL Circle: With lightweighting gaining urgency across automotive ICE, EVs, aerospace, consumer electronics and renewable energy, how do you assess the growth potential of the aluminium die casting market in 2026 and beyond?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Lightweighting is a long-term structural trend in the automotive sector, for both internal combustion engine (ICE) and electric vehicles, providing the aluminium casting market with solid growth potential beyond 2026.

Today, recycled HPDC aluminium alloys are also used in sectors such as aerospace, electronics and renewable energy, thanks to their high-performance levels - comparable to other manufacturing processes combined with clear advantages in terms of productivity and cost efficiency.

However, the sector is facing significant challenges that limit its full growth potential: high energy costs, the ongoing crisis in the automotive industry, and the large-scale export of aluminium scrap outside Europe - over 1.3 million tonnes per year, mainly to Asia. This situation threatens Europe’s industrial competitiveness and its “energy bank” embedded in recycled materials.

For this reason, Raffmetal, together with European Aluminium and other industry players, is in constant dialogue with European and national institutions to promote measures that safeguard the aluminium value chain and ensure the long-term sustainability of this strategic sector.

AL Circle: Digitalisation and automation are transforming every stage of aluminium manufacturing, including casting. How have smart technologies reshaped operational efficiency, quality control and decision-making at your facilities?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Digitalisation and automation have significantly reshaped the way our facilities operate, particularly in terms of efficiency, quality and decision-making. Advanced digital systems enable real-time monitoring of the entire production process through continuous data collection and analysis. This allows for immediate corrective actions in case of deviations, process optimisation, and constant control of energy consumption and environmental compliance.

Smart technologies also enhance quality control by improving process stability, traceability and consistency, supporting higher and more predictable metallurgical performance. At the same time, data-driven analytics strengthen decision-making, enabling faster and more informed choices based on objective production and performance indicators rather than ex-post analysis.

However, technological progress must go hand in hand with people development. Only highly skilled and well-trained personnel can fully unlock the value of digital tools. Data analysis and interpretation are therefore essential capabilities, enabling continuous improvement and ensuring that technology becomes a true driver of operational excellence and sustainability.

AL Circle: Aluminium casting is an energy-intensive process, with electricity consumption averaging around 2.3 kWh per kg of cast product. What concrete measures are you implementing to reduce energy intensity and improve overall process efficiencies with a view on more sustainable solutions?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Reducing energy intensity is a key priority for us, given the inherently energy-intensive nature of aluminium melting. Our approach is based on both process optimisation measures and structural decarbonisation initiatives.

First, we maximise the use of recycled materials, reaching up to 100% recycled content in our alloys through continuous technical dialogue with our customers. This significantly reduces energy demand compared to primary aluminium production. At the same time, we invest in state-of-the-art scrap selection and treatment technologies, enabling us to identify and process the most suitable input material for each specific alloy, improving melting efficiency and reducing material losses.

From an energy supply perspective, approximately 40% of our electricity consumption is covered by self-generated renewable energy, produced through photovoltaic systems and a steam turbine. In addition, our SILVAL range of primary alloys from recycling is manufactured entirely using green electricity. We also place strong emphasis on energy recovery. Waste heat from the melting process is recovered and converted into usable energy to power our internal dross and melting-residue recycling facilities, further enhancing overall process efficiency and reducing the environmental footprint of our operations.

AL Circle: Could you highlight some of the key milestones and technological or operational achievements your company has accomplished in aluminium casting over the past few years?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: In recent years, our development in aluminium melting has been driven by a combination of technological innovation, operational efficiency and sustainability leadership.

We were pioneers from an early stage, becoming the first company in our sector to install a continuous casting line in 1994, and as early as 1989 we had implemented an internal salt slag recovery system, closing material loops well ahead of regulatory requirements. This circular approach has been progressively strengthened through further investments, such as the installation of an oxygen pipeline in 2013 to reduce road transport and related emissions, and a heat recovery plant in 2014 to improve overall energy efficiency.

More recently, sustainability and decarbonisation have marked key milestones. In 2022, we became the first aluminium refiner to obtain Environmental Product Declarations (EPDs) across our entire product range. In 2023, we installed 11 MW of photovoltaic systems on the rooftops of our plants, followed in 2024 by the commissioning of a steam turbine to further enhance on-site energy efficiency. In 2025, we completed the transition to 100% green electricity for the production of our SILVAL primary alloys from recylcing through the purchase of Guarantees of Origin.

These achievements are supported by a robust ESG and governance framework, including ISO 9001, ISO 14001, ISO 50001, ISO 45001, IATF 16949, TISAX, ISO 14064, EPD certification and a fully implemented Organisational Model 231. Together, these milestones reflect a consistent, long-term strategy focused on innovation, circularity and industrial excellence in aluminium melting.

AL Circle: As sustainability becomes a central pillar of the aluminium value chain, collaboration is emerging as a powerful enabler. Could you share one or two instances where strategic partnerships have delivered tangible sustainability outcomes?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Collaboration is a key enabler of sustainability along the aluminium value chain. A concrete example is our continuous and structured cooperation with customers and OEMs to maximise the recycled content of the aluminium alloys used in their components.

Through early technical dialogue and joint development, we tailor alloy compositions to specific applications, enabling the use of very high—often up to 100%—recycled content without compromising quality or performance. This has allowed our customers to significantly reduce the CO₂ footprint of their products while supporting a truly circular aluminium model.

AL Circle: Which end-user industries do you expect to be the primary demand drivers for aluminium casting products in 2026 and the years ahead, and why?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Looking ahead to 2026 and beyond, we expect demand for aluminium casting products to be driven primarily by sectors most influenced by European regulatory frameworks and industrial transition policies. New EU measures—ranging from sustainability and climate packages to targeted support for the automotive industry and energy-efficient buildings—will significantly shape market dynamics across Member States.

Automotive will remain a key driver with strong opportunities for both transformation and diversification linked to electrification, lightweighting, and emissions reduction. At the same time, the construction sector, supported by regulations on energy efficiency and decarbonisation, is set to increase the use of aluminium components. In parallel, green technologies, such as renewable energy systems and energy infrastructure, will further boost demand, reinforcing aluminium’s role as a strategic and sustainable material for Europe’s industrial future.

AL Circle: There is a growing shift towards secondary aluminium casting for sustainability, but it brings certain challenges related to impurities, metal cleanliness and compositional control. How are modern cast houses and foundries strengthening their capabilities to manage these complexities while ensuring consistent quality?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: The performance of aluminium alloys today is the result of remarkable technological progress in the management and control of metallurgical quality. Through advanced analysis and refining systems, it is possible to precisely monitor trace impurities and ensure an increasingly high level of metal cleanliness, effectively removing non-metallic inclusions such as oxides, spinels and refractory residues.

Producing alloys from scrap is no longer a limitation but a significant technological opportunity. Thanks to innovative sorting, treatment and purification processes, we are now able to transform heterogeneous raw materials into high-performance alloys that are fully comparable—and in many cases equivalent—to primary bauxite-based alloys.

Raffmetal’s SILVAL alloys are clear evidence of this qualitative leap: recycled aluminium is not an alternative, but a technologically advanced solution capable of combining outstanding performance, industrial reliability and environmental sustainability.

AL Circle: Given the risks associated with extreme heat, high-pressure equipment and heavy materials, injury-related downtime remains a concern in die casting operations. How has technology helped improve workplace safety, and which innovations have played a decisive role in reducing downtime?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: It is important to clarify that high-pressure die casting is not part of Raffmetal’s production activities: the recycled aluminium alloys we produce are supplied to customers operating in the casting and die casting sectors, but we do not directly manage high-pressure processes.

Nevertheless, safety remains an absolute priority within our facilities, where we operate melting furnaces and complex industrial plants. The adoption of real-time monitoring systems, automation of the most critical phases, and the use of advanced sensors has reduced operators’ exposure to risks and improved overall process control.

Technology, continuous training and structured procedures are the key elements that enable us to prevent injuries and minimise potential downtime.

AL Circle: What are your most successful markets right now? What are some challenges that you are facing in your established markets for aluminium?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Our most successful markets are those where demand for high-quality, low-carbon aluminium alloys is strongest, particularly in automotive, building and selected industrial applications across Europe. Customers in these segments increasingly value recycled content, traceability and consistent performance, which aligns well with our positioning as a leading producer of recycled aluminium alloys.

However, the entire European aluminium sector is currently facing a very challenging context.

Three structural issues are having a significant impact on established markets:

 1. Persistently high energy costs;

2. The ongoing crisis and uncertainty in the automotive sector; and

3. The large-scale export of aluminium scrap.

First, persistently high energy costs represent a major burden for energy-intensive industries, directly affecting fixed costs and reducing operating margins. This situation makes European production less competitive compared to regions with lower energy prices.

Second, the crisis and uncertainty in the automotive sector—our main end market—have a direct impact on aluminium demand. The energy transition and new climate neutrality regulations require a profound transformation of production processes, while increasing competition from Chinese manufacturers, who are also relocating assembly operations to Europe, threatens the entire European value chain.

Finally, the large-scale exports of aluminium scrap outside Europe are over 1.3 million tonnes annually - mainly to Asia - represent a serious loss. This scrap, which constitutes a valuable embedded “energy bank” and a low-energy green resource, is shipped to countries that actively incentivise recycling through state subsidies. This phenomenon weakens Europe’s industrial base and deprives it of a fundamental raw material for a circular economy.

To address these challenges, protective and safeguarding measures at European level are urgently needed. Raffmetal, together with other associated companies and European Aluminium, is in constant dialogue with European and Italian institutions to identify tools and policies that can ensure the resilience and long-term survival of the aluminium value chain in Europe.

 In particular, we propose concrete actions:

1. Stop indiscriminate scrap exports: It is essential to introduce an erga omnes export duty on aluminium scrap to non-European countries. This would ensure that this embedded energy resource remains available within Europe in sufficient quantities, supporting our industry with recycled, low-impact materials.

2. Review the impact of CBAM and ETS: Although based on shared and valid principles, the current structure of the Carbon Border Adjustment Mechanism (CBAM) and the progressive phase-out of free allowances under the Emissions Trading System (ETS) risk increasing import costs and undermining the competitiveness of European products, thereby encouraging delocalisation. These mechanisms must be recalibrated to support, rather than penalise, European industry.

3. Revitalise the European automotive sector: We must promote technological neutrality that supports innovation and competitiveness. It is crucial to ensure that vehicles and components registered in Europe contain at least 80% European content. This would protect the value chain, stimulate domestic production and employment, and counteract delocalisation and unfair competition.

AL Circle: What are some of the new markets you are targeting for expansion in the near future?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Thanks to the continuous development and growing use of large castings and giga-castings by major automotive manufacturers, our next challenge is to improve and develop high-performance recycled aluminium alloys that achieve excellent castability without the need for heat treatment.

This approach offers clear advantages in terms of reduced energy costs and, above all, the elimination of lengthy and costly straightening operations required to correct distortions occurring after heat treatment.

AL Circle: As one of the biggest events on casting, and one of the first major events in 2026, how was Euroguss for you? Are you participating in any other similarly big events this year?

RUGGERO ZAMBELLI & PAOLO GAMBERINI: Euroguss is one of the most important events for Raffmetal and for the entire aluminium casting value chain. Each edition provides a valuable opportunity to meet new potential partners in person and to strengthen long-standing relationships with customers and industry stakeholders. It is also a key platform for networking, identifying emerging market trends, and gaining deeper insights into the industrial and geopolitical dynamics that influence our sector.

As one of the first major industry events of the year, Euroguss sets the tone for the months ahead. In addition to this event, we regularly participate in other leading international trade fairs and sector-focused events throughout the year, as they play a strategic role in supporting customer dialogue, promoting innovation, and reinforcing our positioning within the global aluminium industry.