In our plant in Rottweil, Germany, two production lines for MONOTHERM^® steel pistons were fitted with a closed fully automated system for chip disposal and emulsion recirculation. This allowed us to significantly reduce coolant consumption and cooling costs. In addition, a new heat exchanger with external air cooling decreased the energy consumption required to cool the emulsion.

Reduced energy consumption at MAHLE, inc., Morristown, USA
In the MAHLE plant in Morristown, USA, gas consumption was dramatically reduced, costs were saved, and a substantial environmental benefit was achieved by periodically shutting off an industrial boiler heated by natural gas. The boiler supplied hot water to the cafeteria, shower rooms, and washrooms and heated the heat exchangers for hot air blowers. By installing four electric boilers for the supply of hot water and a smaller, lower-consumption water pump for the hot air blower for use in the summer, the natural gas boiler could be shut off for almost five months from March to October 2006, subject to weather conditions. The result: a saving of 198,240 cubic meters of natural gas and a cost saving of around USD 57,000. In addition, the total pollution emissions were reduced by more than 256 kilograms.

Recycling rate for batteries increased to 64%
Within a period of two and a half years, the battery recycling rate at MAHLE, Inc., Morristown, USA, was increased from 24% to 64%. The proportion by weight of recycled alkali batteries grew by almost 79% during this period.

Modern waste water technology for China
The rapid growth in the Chinese market places a special obligation on MAHLE to protect the environment. By constructing a modern waste water treatment plant with the latest filter technology and neutralization at our plant in Yingkou, we made an important contribution to water pollution control and the establishment of improved environmental standards in China.