Optimizing Motorcycle Manufacturing Sustainability through the Integration of Waste Heat Recovery and Metal Scrap Recycling: A Process Engineering Approach

The automotive industry manufacturing has experienced rapid growth 2–3 times by 2050, with motorcycles constituting around 30% of vehicles worldwide, but this increase in production has significantly heightened the demand for raw materials and energy. A major challenge arises in managing material waste and waste heat generated during the manufacturing process. This research aims to develop a framework that optimizes the synergy between material waste recycling and waste heat recovery to enhance the sustainability of the motorcycle industry, reduce waste, and lower energy consumption. The design leverages waste heat from the melting process to preheat raw materials, raising temperatures from around 50 °C to 350 °C before melting, thereby reducing additional energy needs, lowering emissions, and decreasing operational costs. Utilizing waste heat for preheating not only mitigates environmental impact and thermal load but also significantly improves energy efficiency, ultimately resulting in cost savings and optimized resource use. Utilizing waste heat directly for preheating raw materials has effectively lowered energy consumption by as much as 30%. This approach not only improves operational efficiency but also decreases production costs and minimizes environmental impact, offering a more sustainable solution for the manufacturing sector.