The future of the steel industry lies in the circular economy. While many companies are still looking for ways to increase recycling rates and reduce CO₂ emissions, Breitenfeld Edelstahl AG is already taking a consistent approach:
With a recycling rate of 95%, innovative processes for processing secondary raw materials and a clear zero-waste strategy, the company shows how sustainability, efficiency and independence can go hand in hand in steel production.
Secondary raw materials are materials that are not disposed of after their original use, but are fed back into the production cycle. At Breitenfeld, this primarily concerns refractory materials that line furnaces and ladles.
Dr. Martin Stückelschweiger, Head of Refractories, Infrastructure and Secondary Raw Materials, explains:
"Large quantities of refractory material used to be dumped. Today, we collect and sort these materials during the process - they don't become waste in the first place."
Every year, Breitenfeld produces around 5,000 to 6,000 tons of secondary raw materials that can be directly reintegrated into the cycle. This increases the company's recycling rate to a total of 95%.
The secondary raw materials are processed in several steps:
A decisive difference to the past: just a few years ago, Breitenfeld was sending up to 28,000 tons of material to landfill every year. Today it is 0 tons.
Andreas Schirnhofer, Sustainability Manager at Breitenfeld, adds:
"The circular economy is a cornerstone of our sustainability strategy. By using secondary raw materials, we not only reduce waste, but also conserve primary raw materials and reduce CO₂ emissions along the entire value chain."
A milestone in this process is the decision to dismantle the existing landfill site. Initial tests have shown that the materials stored there can be successfully processed and marketed.
"We will purchase a modern sorting plant that will enable us to separate waste streams efficiently and at the same time recover valuable materials from the landfill. This not only creates new jobs, but also underlines our goal of working completely in the spirit of zero waste," explains Stückelschweiger.
Breitenfeld is thus sending out a strong signal for the region: instead of leaving valuable raw materials lying fallow, they will be used systematically in future.
The benefits of secondary raw materials go far beyond conserving resources. The production of virgin refractory material such as magnesia or fused corundum is extremely energy and CO₂-intensive. One tonne of refractory material generates up to 2 tons of CO₂ on average.
This value can be massively reduced by using recyclates. At the same time, long transportation routes are eliminated, as many primary raw materials would have to be imported from Asia. Breitenfeld therefore not only reduces emissions, but also strengthens regional value creation.
Even though secondary raw materials are being used more and more, the quality of the products remains high. The processed materials are subject to the same quality management systems as the stainless steel itself:
This ensures that the high requirements of customers from demanding sectors such as aviation, energy and mechanical engineering are met.
The biggest challenge with secondary raw materials is their complex composition. Slag caking or mixtures of different fractions require complex separation processes. Breitenfeld relies on a combination of mechanical sorting and manual inspection - an approach that delivers precise results.
At the same time, the demand for secondary raw materials in Europe is constantly increasing. This is because the EU prescribes ambitious recycling quotas, while primary raw materials are becoming scarcer and more expensive. For Breitenfeld, this presents a clear opportunity: the company is positioning itself as a pioneer in the sustainable use of raw materials and gaining a competitive advantage.
Implementing the zero-waste strategy is not just a question of technology, but also of corporate culture. "Order, cleanliness and the awareness of our employees are crucial," emphasizes Schirnhofer.
Through training, internal communication and certifications such as EMAS, sustainability is actively practiced at Breitenfeld - and the commitment of the workforce makes a tangible contribution to success.
The goal for the coming years has been clearly formulated:
"Our vision is zero waste - no fraction as waste. Everything that is still considered waste today will be used as a recyclable material tomorrow," summarizes Stückelschweiger.
With its clear focus on secondary raw materials, Breitenfeld Edelstahl proves that sustainable steel production is more than just a buzzword. It is a living reality - with tangible results for the environment, the economy and the region.
From consistent processing to the dismantling of the landfill and investment in new sorting technology, Breitenfeld shows how a medium-sized company can be a role model for an entire industry: stable, independent and future-oriented.