The ecological transition in the automotive industry also depends on the choice of materials. Green aluminum is a real game-changer for cutting emissions without sacrificing quality, and Profall has made it a design priority.
Green aluminum is quickly becoming a key factor in the sustainable transformation of the European automotive industry. As electric vehicles become more widespread, the focus has shifted beyond tailpipe emissions to the entire vehicle lifecycle—especially the production phase.
Aluminum is one of the most commonly used materials in electric vehicles, particularly for the frame, battery housing, and other structural components. But not all aluminum is created equal. To truly tackle the climate challenge, it’s essential to use green aluminum—recycled or produced with renewable energy and low-impact processes.
Learn more about green aluminum with Profall:
Traditional aluminum production is extremely energy-intensive: it takes about ten times the annual electricity consumption of a typical European household to produce just one ton. That’s because aluminum is extracted from bauxite, which involves a high-energy electrolytic process.
Green aluminum, on the other hand, is produced through:
Thanks to the growing share of renewable energy in the European grid, the EU now has a real opportunity to become a hub for green aluminum production, with a much smaller climate impact compared to other regions in the world.
A recent study by Transport & Environment clearly highlights the potential of green aluminum. If the European automotive industry were to use only green aluminum by 2040, annual CO₂ emissions could be cut by an amount equivalent to those produced by 900,000 gasoline or diesel cars.
And the cost? Just €25 more per vehicle. A small investment, considering the major environmental and strategic benefits.
That’s why the study proposes binding targets: 60% green aluminum by 2035, 85% by 2040.
Ambitious but achievable goals, ones that could drive the entire industry toward a clean-tech European economy.
In this rapidly evolving landscape, Profall stands out as a strategic partner for companies looking to innovate while staying committed to environmental sustainability.
Sustainability and reliability are two of our core values. For years, Profall has been adopting low-impact practices, offering sustainable aluminum profiles made from recycled materials and produced with cutting-edge technology. Our highly flexible production capabilities allow us to handle both large-scale and small-batch orders (starting at 300 kg), meeting the specific needs of the automotive and energy sectors.
With advanced technical expertise and a highly specialized production process, Profall manufactures both standard and custom aluminum profiles, even in shapes and tolerances that few others can achieve. This unique capability enables us to meet complex design requirements with precision, delivering reliable, sustainable, and cutting-edge solutions.
Green aluminum isn’t just environmentally strategic, it’s also a key industrial asset. Europe currently imports more than half of the primary aluminum it consumes, and the number of smelters has halved over the past decade. Promoting local green aluminum production based on renewables and recycling means revitalizing the European supply chain, creating jobs, and reducing dependency on foreign sources.
At Profall, we believe green aluminum isn’t just a sustainable solution, it’s a strategic vision for the future of industry. Every profile we create is the result of a finely engineered process, designed to bring your concept to life in a way that’s reliable, practical, and sustainable.
Whether you're an operations manager in the automotive sector or a technical director in the energy field, Profall is the right partner to face the challenge of ecological transition with. Get in touch to find out how we can develop custom green aluminum solutions together—without compromising on quality or performance.
Let's shape the future of aluminum, one profile at a time.
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