This technical report by Massimo Plavsic outlines a comprehensive framework for improving energy efficiency and sustainability within high-pressure die casting (HPDC) foundries. It identifies the melting process as the primary source of consumption and provides a detailed roadmap for reducing energy use by up to 40% through heat recovery, equipment upgrades, and renewable energy integration. Using a real-world case study from Italy’s industrial heartland, the text demonstrates that strategic investments in servo-hydraulics, induction furnaces, and photovoltaic systems can yield significant financial savings and a rapid return on investment. The document emphasizes that transitioning to decarbonized production is no longer just an environmental goal but a critical competitive advantage for suppliers in the automotive sector. Ultimately, the report ...