Brembo Completes Foundry Expansion in Poland

Project doubles gray iron capacity for disc brake manufacturing


Brembo S.p.A. has started production at its expanded gray iron foundry in Dabrowa Gornicza, Poland. The project doubled the casting capacity of the original plant, which was established as a machining center in 2003. A 70,000-metric tons/year foundry was started up in 2006. The plan to double the foundry’s output was announced in 2008, and then delayed until last year.

Foundry Solutions & Design, Alpharetta, GA, handled project management engineering and provided installation support for the expansion project.

Brembo is an Italian manufacturer of high-performance disc brakes for cars, motorcycles, and commercial vehicles worldwide. It also produces clutches, seats, seat belts, and other components. In March 2010 it announced a five-year, $137-million plan to double the output of the foundry and expand disc machining at the site. The installation now covers 90,000-m 2, according to Brembo’s statement

The new operation reportedly was designed and built in accordance with environmental standards and energy efficiency, including waste-heat recovery for plant heating, advanced sand recycling, and “innovative” furnace particulate filtration.

Brembo further explained that its quality control systems include automated mold and flask inspection; shot blasting optimized according to product size and weight; and vision-based inspection of finished castings.

“It is my pleasure to open this new factory in Poland, which reinforces our presence in a country that is becoming the geographical center of the automotive industry in Europe,” stated Brembo president Alberto Bombassei at an inaugural event on October 14. “Our company celebrates its 50th anniversary this year with strong positive financial results. As part of our continuous effort to better serve our clients with an international footprint and a worldwide shop-floor presence, we continuously explore new potential investment opportunities, like this one which recognizes and values Poland's engineering, manufacturing and technical skills.”

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