Towards a climate-neutral metal processing industry
Accelerating the decarbonisation of Europe's forging and casting industries through innovative in-line heat treatment technologies
“GREENLINE – Green Electrified Ultrafast In-Line Heat Treatment for Net-Zero Forging and Casting” project consortium is targeting forges and foundries for which it is competitively advantageous to adopt net-zero in-line heat treatment the broadest possible.
With that purpose, the GREENLINE research team is focused on developing and validating a solution that exchanges energy intensive off-line heat treatments in forging and casting components with net-zero ultrashort in-line heat treatments, by combining ultra-fast thermal conditioning technology and energy storage of the waste heat with net-zero heat treatment furnaces.
Part-by-part heat treatment performed immediately after the forging or casting operation, commonly referred to as in-line heat treatment, has been demonstrated to be the most effective net-zero approach for heat treatment in forges and foundries. Compared with conventional off-line heat treatment, this approach offers significant advantages in terms of energy efficiency, reduced processing time, and shorter lead times.
Nevertheless, European forging and foundry companies face two main difficulties to apply in-line heat treatments:
- Their factory layouts were not designed for this type of process and regular heat treatment equipment do not fit the available space in the existing facilities.
- Technical specifications and downstream operations for most forged/cast products come from the off-line heat treatments. The adoption of in-line heat treatments leads to changes in supply specifications that can affect machining operations afterwards.
To overcome current scenario, GREENLINE Project is targeted at developing a modular net-zero in-line furnace system to maximize flexibility while keeping standard engineering, with different space-usage alternatives using available lay-out spaces at ground level and in height. These innovative technology will combine ultra-fast thermal conditioning technology and energy storage of the waste heat with net-zero heat treatment furnaces.
- Deploy a flexible turn-key concept adaptable to the existing space restricted space layouts (no greenfield required).
- Develop skills on how to adjust energy intensive processes to take advantage of the waste and residual heat.
- Combine ultra-fast thermal conditioning technology with net-zero heat treatment furnaces and energy storage for allowing in-line heat treatment.
- Design a modular net-zero in-line furnace system to maximize flexibility while keeping standard engineering, with different space-usage alternatives using available lay-out spaces at ground level and in height.
- Asses the operational energy needs according to:
- the new energy scenario required to perform the heat treatment in comparison with the current SoA.
- the new energy scenario required to condition the cooling fluid for the ultra-fast thermal conditioning stage.
- the cost scenario (CAPEX and OPEX) for the deployment of the new net-zero technology.
- the GHG avoidance achieved.
The adoption of net-zero solutions —including ultra-fast in-line heat treatment, modular electric furnaces, thermal energy recovery systems, and optimised quenching cycles — is not only a regulatory and climate-driven necessity but also a strategic lever to sustain competitiveness. Expected benefits include lower energy costs, reduced distortions and rework, shorter production cycles, and enhanced product quality, positioning Europe favorably within the global forging and casting markets.
The project will generate impact across the next principal areas:
Technological Innovation and Industrial Deployment
GREENLINE consortium will develop and demonstrate a fully electrified in-line heat treatment system, integrating ultra-fast thermal conditioning, modular furnace design, and waste heat recovery. By combining these innovations, the system achieves operational flexibility compatible with existing forging and casting lines, enabling rapid deployment without major infrastructure modifications.
The new technology at TRL 6–7 will be validated in an operational environment. That way, industrial end-users benefit from a system that preserves material quality, optimises throughput, and reduces process variability, creating a blueprint for scalable deployment across Europe’s energy-intensive manufacturing sites.
Energy Efficiency and Carbon Reduction
The in-line electrified heat treatment system is designed to substantially reduce energy consumption and CO₂ emissions compared to conventional gas-fired or salt-bath processes. By using electricity from renewable sources and recovering residual heat from forging and casting operations, the project targets 30–40% lower energy use per batch and up to 2,500 tons reduction in CO₂ emissions annually. These improvements directly contribute to the EU’s climate goals and reduce operational costs for manufacturers. In addition, by shortening heat treatment cycle times by 80%, the technology increases throughput while simultaneously reducing energy intensity, demonstrating that environmental sustainability and industrial efficiency can go hand in hand.
Strategic Alignment and Ecosystem Collaboration
The project strengthens Europe’s industrial leadership by fostering direct collaboration between technology developers and industrial end-users, bridging the gap between innovation and deployment. This collaboration ensures rapid adoption of net-zero technologies, aligned with the EU’s strategic objectives under the Green Deal, Fit for 55, and Net-Zero Industry Act. By integrating clean energy solutions into energy-intensive sectors like forging and casting, the project accelerates the green and digital transition, supporting the industrial roadmaps of Processes4Planet and Made in Europe. Furthermore, it creates a framework for knowledge transfer, training, and workforce upskilling, ensuring that technological benefits translate into sustainable industrial competitiveness across Europe.
AZTERLAN Metallurgy Research Centre (Spain)
Project leader
CIE LEGAZPI
(Spain)
Fundación CIE
(Spain)
Industrie Ofen Bau IOB Industrie-Ofen-Bau GmbH (Germany)
Betsaide
(Spain)
Tecnodelta
(Italy)
RWTH Aachen University (Germany)
Sidenor Aceros Especiales (Spain)
Sidenor I+D
(Spain)
EEIP - Energy Efficiency in Industrial Processes
(Belgium)
AGH University of Science and Technology
(Poland)
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GREENLINE is funded by the European Union under the Horizon Europe programme as a HORIZON Innovation Action (Project No. 101294375), under the HORIZON-CL4-2025-01 call and the topic HORIZON-CL4-INDUSTRY-2025-01-TWIN-TRANSITION-34, supporting the twin green and digital transition of Europe’s energy-intensive industries.