Aluminium footprint: primary, recycled and the European mix

Aluminium is a material where the generic figure misleads. Two identical profiles can have very different footprints depending on where the metal comes from.

What is the difference between primary and recycled?

• Primary: obtained from ore. It requires a lot of electricity, and its footprint depends on the source of that electricity.
• Recycled: existing aluminium is remelted. It needs much less energy.
• Mix: a combination of both. A regional average describes the usual mix, not the metal you buy.

What else counts?

After the origin of the metal come extrusion or machining, the scrap generated and transport. Process scrap is usually remelted, but it has to be counted carefully.

What to ask your supplier

1. The origin of the metal and the recycled percentage.
2. Extrusion or machining process data, if available.
3. Inbound transport.

With that primary data, the calculation gains precision. If you do not have it, the most conservative factor is applied and noted.

And CBAM?

Aluminium is one of the goods covered by the carbon border adjustment mechanism, which affects whoever imports into the EU. A part’s footprint does not replace the declaration it requires, but organising origin and process data makes it easier to respond. More in the glossary: CBAM. And for sector detail, the aluminium page.

How do you question your supplier?

A good starting point is to ask for three specific things in writing: the origin of the metal (primary, recycled or blend, and in what proportion), the process (extrusion, rolling, machining) and the energy of each stage if known. If they cannot give you one of them, a conservative factor is applied and noted, and the figure improves when the supplier provides it.

What mistakes come up again and again?

• Using the regional average as if it were your metal. It describes the usual blend, not the ingot you bought.
• Not separating process scrap. It must be counted properly: it is remelted, but remelting has its own cost.
• Forgetting machining. It can weigh heavily on parts with a lot of material loss.
• Mixing the footprint of the metal with that of the part. Customers usually ask for the latter.

How does the figure improve over time?

1. Start with what you haveDrawing, weight and alloy; metal origin if known.
2. Apply physical factorsWith the most conservative factor where data is missing.
3. Ask the supplier for dataMetal origin, recycled percentage and energy.
4. RecalculateEach primary data point replaces an assumption.

What can you do this week?

Review your latest aluminium orders and check whether delivery notes or material data sheets state the origin and recycled content. Often the data exists but sits in a document nobody has crossed with the calculation. If it is not stated, ask your supplier to include it in upcoming shipments.

Then choose a representative profile or part and run a first calculation. You will see how much of the result comes from the metal and how much from your process, and that tells you whether it is worth working more with the metal supplier or with your own processing. It is a decision that cannot be made with a regional average.

How does Xain do it?

Xain calculates the footprint of the part from the technical documentation with physical factors and recognised databases, and aluminium is one of the sectors included in the LRQA verification. The process tree separates the metal from the processing, so your supplier’s data goes in where it belongs. For sector detail, see the aluminium page or write to us.