A novel process can repurpose steel and aluminum sheet metal scraps from production without having to melt them down. An algorithm is used to match material properties with requirements.
According to Beneva, approximately 50% of the sheet metal used in car body manufacturing ends up as scrap. Typically, this scrap is sent for recycling and, in the case of steel, is remelted. With the Saturnin® process, the company is taking a different approach: Suitable production offcuts are processed and used directly as raw material for new components. According to the company, this results in a CO₂ footprint that is up to 99% lower than that of newly produced steel—less than 0.1 kg CO₂e/kg of steel.
Material properties are preserved
The process recycles production waste generated primarily during the punching and stamping of sheet metal. Since the material is not melted down, the properties of the material originally produced at the steel mill are preserved. In addition to steel sheets for automotive body manufacturing, aluminum sheets can also be reused in this way.
For users, Beneva cites not only reduced CO₂ emissions but also lower material costs compared to conventionally produced new steel as a benefit. However, a prerequisite for reusing the material is that its properties and dimensions meet the requirements of the application.
The process is based on a proprietary algorithm. It analyzes the available material data and determines which applications are suitable for each production stage. Factors taken into account in this assessment include, among others, steel grade, sheet thickness, surface coating, and dimensions. In addition, the system takes logistical conditions and production requirements into account.
Based on this data, the algorithm identifies potential new applications for the material. Beneva then handles the entire process—from collection and sorting through reprocessing and forming to quality assurance, traceability, and delivery of the sheets to the customer. This sets the concept apart from material recycling: Instead of melting down production scrap to produce new steel, sheet metal sections that are sufficiently large and suitable are to be fed directly into further production.
Jiří Böhm, Founder
Jakub Šrot, CEO and Co-Founder
Maria Kamenskaya, Quality Manager
Jan Ludvík, Sales Manager
© Beneva
Open and Closed Material Cycles
According to Beneva, several European industrial companies are already using Saturnin®. Users and partners come from the automotive industry, the automotive supply industry, and other sectors such as the furniture industry.
One example of its application is the collaboration with Škoda Auto. Production stages from the automaker’s plants are used to manufacture various components within its supply chain. The process can accommodate both closed and open material cycles.
In a closed-loop system, the reusable material remains within the supply chain. In an open approach, however, it can also be transferred between different companies, brands, or corporate groups. For example, production offcuts from Skoda Auto are also used outside the company’s own supply chain. Conversely, suitable material from external sources can enter the automaker’s supply chain as raw material.
The reused material is expected to meet the same quality standards as newly produced steel. To this end, Beneva has established a multi-stage inspection process. Each scrap metal shipment is sampled and analyzed in an accredited laboratory.
During the remanufacturing process, each part also undergoes an inline inspection. During this process, dimensional and geometric tolerances are checked. A scan on both sides is used to detect surface defects. Each panel produced in this way is also assigned a unique identification number. This ensures that the material can be traced throughout the entire process.
First site in the Czech Republic in series production
The first Saturnin® center in the Czech Republic is complete and operational. The company plans to establish further locations based on the same concept. Beneva aims to expand capacity in line with regional demand and bring reprocessing closer to customers.
The company aims to expand the industrial reuse of steel production waste on an international scale. For the metalworking industry, direct reuse is intended to serve as an alternative to remelting, particularly in cases where the geometry, material properties, surface condition, and quality requirements allow for the reuse of the steel sheets.
Web:
www.beneva.cz/en/