BMW Cutting CO2 Emissions from Aluminum Wheel Casting

The BMW Group claims that working on sustainability it will use cast aluminum wheels produced with so-called for its BMW and MINI brands from 2024 onwards. The transition applies, in particular, to the energy-intensive electrolysis used in producing aluminum and to the wheel-casting process. Agreements have been reached with all BMW Group wheel suppliers. Up until now, wheels have accounted for  ~5% of supply chain CO₂ emissions. Transitioning to more sustainable production that relies on green power will reduce these emissions by more than half. The BMW Group procures ~10 million light-alloy wheels per year; 95% of these are made from cast aluminum.

There is not a globally agreed methodology, approved audits or accounting principles or common terminology in the increasing use of sustainability by large manufacturers. The German auto industry is currently under heavy criticism for its lobbying the German government to not impose sanctions on the use of Russian or other fossil fuels, saying it can’t be done. There isn’t even an agreed way to spell or say aluminium in English.

Through independent audits, the BMW Group claims it can ensure conscious and sustainable use of aluminum by its contracted producers, saving up to 500,000 tons of CO2 per year. “Green power is one of the biggest levers for reducing CO₂ emissions in our supply chain. We have already signed more than 400 contracts with our suppliers, including suppliers of wheels and aluminum, requiring them to use green power,” said Joachim Post, member of the Board of Management of BMW AG responsible for Purchasing and Supplier Network.

Since 2021, the BMW Group has sourced aluminum from the United Arab Emirates manufactured exclusively using electricity obtained from solar power. The aluminum produced in Dubai is processed in the light metal foundry at BMW Group Plant Landshut, where it is used to manufacture body and drive train components. The 43,000 tons of solar aluminium sourced in this way supply almost half the annual requirements of the Landshut light metal foundry.

Aluminum has suitable recycling properties. This makes it easier to melt down old wheels as part of the so-called circular economy. This eliminates the need for energy-intensive electrolysis to produce the primary raw material. The secondary raw material must also meet the BMW Group’s premium requirements for quality, design, safety and mechanical properties.