YKK AP Shikoku Plant Commences the Reconstruction of Its Aluminum Casting Facilities

YKK AP Inc. （Headquarters: Chiyoda-ku, Tokyo; President: Hidemitsu Hori）has launched its plan to reconstruct the aluminum casting facilities of its Shikoku Plant (Ayauta District, Kagawa Prefecture). This is an initiative toward the achievement of carbon neutrality by increasing the aluminum recycling rate*1 of the Shikoku Plant from the current 33% to 76% in FY2024 through the introduction of a dedicated recycling facility. The renewal of the aluminum melting and holding furnaces that had been progressing as part of Phase I construction was recently completed and operation of the facility commenced on September 30.

The renewal of the aluminum melting and holding furnaces, which constitutes Phase I construction, will reduce CO₂ emissions during the manufacturing process by 18% as compared to conventional emissions. In addition to strengthening quality and cost competitiveness through adoption of the latest technologies, efforts will be made to enhance safety during operation as well as in the case of accidents. The improvement of energy efficiency will reduce the environmental load. The investment amount for Phase I construction is approximately 900 million yen.

The construction of YKK AP’s first recycling furnace is planned for Phase II construction. Operation of the new recycling furnace will enable a great increase in the ratio of recycled aluminum scraps from the market that is used. The plan is to increase the aluminum recycling rate at the Shikoku Plant from the current 33%*2 to 76% in FY2024, which is the final year of the current mid-term plan, and to 100%*3 by FY2030.

Aluminum material procurement accounts for the greatest ratio of CO₂ emissions within the whole YKK AP supply chain. This is because a massive amount of electrical power is required to extract the metal from minerals. On the other hand, CO₂ emissions from aluminum casting using recycled aluminum are said to be only around 3% of making new aluminum. YKK AP already recycles nearly 100% of the scrap aluminum that arises internally from manufacturing processes. Introduction of a recycling furnace in Phase II construction will increase the ratio of the recycled aluminum scraps from the market that is used, or reduce the ratio of new aluminum that is used. This will greatly decrease CO₂ emissions.

The plan to reconstruct aluminum casting facilities through Phase I and Phase II construction will not only improve productivity and energy efficiency and reduce CO₂ emissions in the manufacturing process but will also contribute to the achievement of carbon neutrality by increasing the aluminum recycling rate.

[Outline of the Plan to Reconstruct Aluminum Casting Facilities at the Shikoku Plant]

[Outline of Shikoku Plant]

*1: Recycling rate through the use of recycled aluminum scraps from the market (recycled materials, such as aluminum scrap and other such materials collected from the market)

*2: FY2021 record

*3: In-house scrap aluminum and added metals are excluded from the denominator for calculating the recycling rate