Beneath the hum of progress, from car engines to wind turbines, lies the massive and often-overlooked world of foundries, which produced a staggering 52.6 million metric tons of castings in 2022, signaling a resilient industry forging ahead post-pandemic.
Key Takeaways
- In 2022, global foundry casting production totaled 52.6 million metric tons, marking a 2.5% increase from 2021.
- China's foundry industry produced 30.5 million metric tons of castings in 2022, accounting for 58% of global output.
- India's casting production reached 11.2 million metric tons in 2022, up 5.8% year-over-year.
- Global grey iron casting production was 28.4 million tons in 2022.
- Ductile iron castings worldwide totaled 15.2 million tons in 2022, growing 3.1%.
- Steel castings production globally hit 8.9 million tons in 2022.
- Global foundry market size was valued at USD 146.5 billion in 2022.
- The foundry market is projected to grow at a CAGR of 5.2% from 2023 to 2030.
- Automotive sector accounted for 42% of global foundry demand in 2022.
- Global employment in foundries was 2.8 million direct jobs in 2022.
- China employed 1.2 million workers in its foundry sector in 2022.
- US foundry industry had 188,000 employees in 2022.
- Foundry energy consumption averaged 650 kWh per ton of casting globally in 2022.
- CO2 emissions from global foundries totaled 180 million tons in 2022.
- 35% of European foundries adopted electric melting by 2022, reducing emissions by 20%.
Global foundry production grew to 52.6 million tons in 2022, led by China and India.
Employment
- Global employment in foundries was 2.8 million direct jobs in 2022.
- China employed 1.2 million workers in its foundry sector in 2022.
- US foundry industry had 188,000 employees in 2022.
- India’s foundries employed 5 million people, including informal sector, in 2022.
- Germany had 85,000 foundry workers in 2022.
- Average annual wage in US foundries was USD 58,000 in 2022.
- Foundry labor productivity in Europe improved 2.1% to 9.2 tons per employee in 2022.
- Japan’s foundry workforce declined to 120,000 in 2022 due to aging population.
- Brazil employed 45,000 in organized foundries in 2022.
- Female participation in global foundries was 25% in 2022.
- Skilled labor shortage affected 62% of US foundries in 2022 survey.
- Training investments in foundry workforce reached USD 1.2 billion globally in 2022.
- Turnover rate in foundries averaged 18% in 2022.
- Automation reduced manual labor by 15% in advanced foundries by 2022.
- Number of active foundries in US was 1,200 in 2022.
- Apprenticeships in German foundries trained 4,500 youth in 2022.
Employment Interpretation
While the global foundry industry pours the literal foundation of modern life for 2.8 million workers, its future hinges on balancing China's massive scale, America's high wages and skill gaps, Europe's efficiency push, Japan's demographic drain, and a universal need to better mold its own human capital.
Global Production
- In 2022, global foundry casting production totaled 52.6 million metric tons, marking a 2.5% increase from 2021.
- China's foundry industry produced 30.5 million metric tons of castings in 2022, accounting for 58% of global output.
- India's casting production reached 11.2 million metric tons in 2022, up 5.8% year-over-year.
- The United States produced 9.8 million metric tons of castings in 2022, representing a stable output compared to pre-pandemic levels.
- Japan's foundry sector output was 4.7 million metric tons in 2022, down 1.2% from 2021 due to supply chain issues.
- Germany manufactured 2.1 million metric tons of castings in 2022, focusing on high-value automotive components.
- In 2021, global production was 51.3 million metric tons, with Asia contributing 78% of the total.
- Brazil's foundry output stood at 2.9 million metric tons in 2022, driven by agricultural machinery demand.
- Russia's casting production was 5.8 million metric tons in 2022, heavily reliant on iron castings.
- South Korea produced 1.9 million metric tons in 2022, emphasizing steel castings for shipbuilding.
- In 2020, global foundry production dipped to 47.8 million metric tons due to COVID-19 disruptions.
- Italy's output was 1.1 million metric tons in 2022, specializing in aluminum and magnesium alloys.
- France produced 0.8 million metric tons in 2022, with growth in aerospace castings.
- Turkey's foundry industry achieved 2.4 million metric tons in 2022, up 4%.
- Mexico output reached 0.7 million metric tons in 2022, boosted by automotive exports.
- In 2019, global production was 50.1 million tons, with grey iron at 27.5 million tons.
- Iran's foundry output was 1.6 million tons in 2022.
- Spain produced 0.6 million tons of castings in 2022.
Global Production Interpretation
While China firmly anchors the global foundry industry with over half its tonnage, the rest of the world is a story of India's impressive climb, America's steady recovery, and other nations quietly carving out their high-value or hyper-specialized niches.
Market Economics
- Global foundry market size was valued at USD 146.5 billion in 2022.
- The foundry market is projected to grow at a CAGR of 5.2% from 2023 to 2030.
- Automotive sector accounted for 42% of global foundry demand in 2022.
- Machinery and equipment segment held 28% market share in foundries in 2022.
- Asia-Pacific region dominated with 65% of global foundry market revenue in 2022.
- US foundry market revenue reached USD 35.4 billion in 2022.
- Average foundry revenue per ton of casting was USD 2,780 globally in 2022.
- China's foundry market was valued at USD 85 billion in 2022.
- Foundry exports from India totaled USD 4.2 billion in FY2022.
- European foundry market turnover was EUR 45 billion in 2022.
- Investment in new foundry equipment globally reached USD 12.5 billion in 2022.
- Price of grey iron castings averaged USD 1,200 per ton in 2022.
- Aluminum casting prices rose 8% to USD 3,200 per ton in 2022.
- Foundry industry M&A deals numbered 45 globally in 2022, valued at USD 2.8 billion.
- Digital foundry solutions market within industry grew to USD 4.1 billion in 2022.
- Foundry market in Europe valued at USD 40 billion in 2022.
- Scrap metal prices impacted foundry margins by 15% in 2022.
Market Economics Interpretation
The global foundry industry, a staggering $146.5 billion behemoth in 2022, is fueled largely by our insatiable demand for cars and machinery, with Asia-Pacific firmly holding the steering wheel while China and the U.S. race neck-and-neck in this high-stakes metal-casting marathon.
Material Types
- Global grey iron casting production was 28.4 million tons in 2022.
- Ductile iron castings worldwide totaled 15.2 million tons in 2022, growing 3.1%.
- Steel castings production globally hit 8.9 million tons in 2022.
- Aluminum castings amounted to 6.7 million tons in 2022, driven by automotive lightweighting.
- Copper alloy castings reached 1.2 million tons globally in 2022.
- Magnesium castings production was 0.15 million tons in 2022, mainly for electronics.
- In 2021, grey iron dominated with 27.9 million tons out of 51.3 million total castings.
- China's steel castings output was 5.4 million tons in 2022.
- US aluminum castings production was 2.1 million tons in 2022.
- Europe's ductile iron production totaled 3.8 million tons in 2022.
- Sand casting method accounted for 85% of global foundry production in 2022.
- Die casting represented 10% of aluminum castings globally in 2022.
- Investment casting output was 0.9 million tons worldwide in 2022.
- Zinc alloy castings production reached 0.8 million tons in 2022.
- Steel castings in India totaled 1.8 million tons in 2022.
- Global malleable iron production was 0.9 million tons in 2022.
- Permanent mold casting share was 5% of total production in 2022.
Material Types Interpretation
Despite being the old workhorse of the industry, grey iron still comfortably out-muscles its flashier competitors, proving that when it comes to global casting, heavy and reliable still carries the most weight.
Sustainability
- Foundry energy consumption averaged 650 kWh per ton of casting globally in 2022.
- CO2 emissions from global foundries totaled 180 million tons in 2022.
- 35% of European foundries adopted electric melting by 2022, reducing emissions by 20%.
- Water usage in foundries averaged 0.8 cubic meters per ton in 2022.
- Recycling rate of scrap metal in foundries reached 92% globally in 2022.
- US foundries reduced energy intensity by 25% since 2000, to 550 kWh/ton in 2022.
- China’s foundries emitted 120 million tons CO2 in 2022 from melting processes.
- 48% of foundries invested in green tech in 2022, per global survey.
- Dust emissions controlled to under 10 mg/Nm3 in 70% of modern foundries in 2022.
- Renewable energy use in foundries increased to 12% of total in 2022.
- Waste generation per ton of casting dropped to 110 kg in 2022.
- Low-carbon steel castings production grew 15% to 2.1 million tons in 2022.
- Foundry industry biodiversity impact mitigated in 40% of sites by 2022.
- SOx emissions from foundries reduced 30% since 2015 to 2022.
- Hydrogen pilot projects in 5% of foundries for melting in 2022.
Sustainability Interpretation
While the foundry industry's old image as a grimy, coal-choked behemoth still lingers in our minds, the data reveals a much more hopeful and industrious reality: in 2022, the sector began greening its rough-hewn edges by slashing dust and emissions, recycling nearly all its metal scrap, and cautiously but earnestly investing in a future powered by hydrogen, renewables, and an awful lot of electricity.
Technology
- In 2022, 3D printing adoption in foundries rose to 22% for patterns.
- AI optimization used in 35% of advanced foundries for defect prediction in 2022.
- Simulation software employed in 78% of US foundries for casting design in 2022.
- Robotic automation handled 45% of finishing tasks in top foundries in 2022.
- Induction furnaces comprised 60% of melting capacity in Europe by 2022.
- Digital twins implemented in 18% of global foundries for process monitoring in 2022.
- Additive manufacturing for sand molds grew 28% in volume in 2022.
- IoT sensors deployed in 52% of foundries for real-time data in 2022.
- Machine learning reduced scrap rates by 12% average in adopting foundries 2022.
- Vacuum-assisted casting processes used in 25% of steel foundries in 2022.
- CNC machining integration reached 65% in post-casting operations by 2022.
- Blockchain for supply chain traceability piloted in 8% of foundries in 2022.
- AR/VR training modules adopted by 15% of foundries in 2022.
Technology Interpretation
While foundries are still getting their hands dirty, over half have now wired themselves with IoT sensors and three-quarters lean on digital simulations, quietly building a smarter industrial backbone that already uses robots for nearly half the finishing work and AI to catch its own mistakes.
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