BMW Opened A New Plant In China
|   Monday, August 08, 2016
BMW Brilliance Automotive (BBA) has opened a new engine plant which includes a light metal foundry in Shenyang, China.
BBA is a long-term joint venture between the BMW Group and Brilliance China Automotive Holdings Ltd. A total of about 2,000 employees will work long term at the BBA engine factory.

Both the engine plant and foundry for light metals incorporate the latest standards of production and will be a supplier of parts for automobile factories Dadong and Tiexi from BMW Brilliance.
Production capacity, which currently can be up to 300,000 units per year, is linked to the production volume of the two automobile plants.
In 2015 car production reached over 287,000 local units. BBA has financed the necessary investment from its own funds, so that no one called on the capital of the joint venture's partners.

The latest generation BMW TwinPower Turbo petrol engines with three and four cylinders are characterized by very high efficiency, low emissions and represent the latest development in the range of BMW's EfficientDynamics engines.

The use of a high percentage of aluminum significantly reduced the weight of the drivetrain. Thermal management and acoustic particularities were also improved. The centerpiece of the engine range is the -award winning TwinPower Turbo technology that latest generation combines variable load control with direct injection.

The foundry sets new standards for sustainable production and has an annual capacity of up to 15,000 tons of aluminum. It is modeled after the partner plant in Landshut (Germany), whose extensive experience has been integrated into production processes.

For the first time in China, inorganic binders are used and lead to a reduction of 98 percent of the emissions of combustion residues, in comparison with organic molding processes commonly used in the industry. In addition, 90 percent of the sand used for molding can be recycled in order to reduce the waste to a minimum. In 2009, the BMW Group became the first which used exclusively this environmentally friendly cutting-edge technology in series production of metal molding.

The necessary aluminum for molding will continue to be delivered in solid form and then liquefied at about 760 degrees in the on-site smelter. The metal waste products, separated from raw metal casting during cleaning are melted in the blast furnaces and foundry, after that those residues are reused.

The innovative spray arc (LDS) was also introduced for the production of cast aluminum crankcase: the cylindrical face of all crankcases is coated with a very thin layer of iron particles in a liquid form spray. The result is a lower weight and reduced friction in the engine, leading to lower fuel consumption.

Another advantage of the standardized production system is stable and uniform production processes that increase the level of quality. Meanwhile, the modular production which does not depend on location is very flexible: the standardized systems and processes allow the company to react quickly to market changes and customer demands.

In addition to thermal engines, the new engine plant will produce high-voltage batteries for future plug-in hybrid models. As in the case of assembling engines, this project will involve close collaboration between BBA and BMW Group to ensure knowledge transfer from Germany in terms of high voltage output batteries.
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