Ljunghäll Södra Vi
At Ljunghäll, Helios Innovations installed a CONTESS for local treatment of emulsion concentrate from their existing evaporator as well as emulsions from foundry operations. The solution reduces the amount of liquid hazardous waste, reduces the need for external transport and enables return of treated water to existing treatment processes.
Södra Vi, Sweden
Ljunghäll in Södra Vi is Sweden's largest aluminum die-casting foundry and currently handles over 14,000 tons of emulsions and contaminated water in two traditional evaporators. From these evaporators, approximately 500 tons of concentrate with high water content is produced and sent away as waste. In addition to the concentrate, Ljunghäll needed to send away untreated emulsion as waste several times each month because the traditional evaporators often had problems cleaning all the water. The large volumes of liquid waste resulted in extensive transportation, high handling costs, and significant environmental impact. Ljunghäll needed a more sustainable and local solution to reduce the amount of liquid hazardous waste from the facility.
During 2026, a fully automated unit was installed with the capacity to treat 1,500 m³ of process water per year on-site at Ljunghäll. Through low-temperature evaporation, water is separated from the emulsion concentrate and the emulsions are concentrated to a significantly smaller residual volume. The purified water is then returned to Ljunghäll's existing treatment plant with ultrafiltration and carbon filter before it is discharged to the municipality's treatment plant. The fully automated solution enables stable and continuous operation while significantly reducing the amount of liquid waste from the site. Since the solution was installed in February 2026, Ljunghäll has been able to reduce the amount of emulsions and emulsion concentrate leaving the site as waste by approximately 80%.
1,500 m³
process water treated per year
≤90%
volume reduction
2026
production start
What we achieved
Significantly reduced waste flows
Through local treatment, Ljunghäll can reduce the amount of liquid hazardous waste from the facility by up to 1,500 m³ per year.
Reduced transports and lower environmental impact
The need for external transports is reduced, which contributes to lower climate impact and more resource-efficient waste management.
Stable and automated operation
The fully automated unit enables continuous operation with high reliability.
A more sustainable flow for industrial emulsions
By moving the treatment of emulsions closer to production, Ljunghäll has taken an important step towards more sustainable and circular management of industrial process water.
The project demonstrates how the foundry industry can reduce both transportation dependency and the amount of liquid hazardous waste through local and automated treatment technology.
The collaboration between Helios Innovations and Ljunghäll continues while creating opportunities for further optimization and future reuse of treated water in production.
Contact us
Get in touch for more information about how we can help you reduce the amount of liquid waste and your CO₂ emissions.