Gerd Roeders is reluctantly preparing for the temporary
shutdown of his German aluminium foundry to survive Europe's growing gas
crunch. He hopes by moving the 200-year-old plant to three weeks of 24-hour
shifts followed by a one-week shutdown, he can maintain output while cutting
his gas consumption.
His bill has already more than doubled this year from
last, he said, fearing it will triple or even quadruple in 2023.
The plan will save the cost of gas needed to fire up the
ovens every morning, Roeders calculates, even if it means paying staff at
family-owned G.A. Roeders more to work night shifts.
Survival
for G.A. Roeders GmbH and Germany's 600 other foundries, most of which are
small-to-medium enterprises with less than 250 staff, will mean cost cuts and
tough talks with customers.
"We're laying out our prices to customers and telling
them they have to pay more," 59-year-old Roeders told Reuters as workers
prepared the plant for the first week of rest. "We can't deliver parts if
we invest and don't earn anything back."
G.A. Roeders, with plants in Germany and the Czech Republic
employing around 500 people, produces more than1,000 parts. It serves auto
makers like Volkswagen and Continental, airline manufacturers and medical
technology firms, yielding annual revenues of 60 million euros.
While contracts for foundries generally include a clause
that allows them to charge more when the cost of metal increases no such clause
exists for energy.
Roeders said he has always sought to be frugal on energy -
the business' second-largest expenditure after staff - a habit he learnt from
his father who would turn off office computers at night and switch off the
lights during lunch breaks. But the firm is now facing unprecedented rises.
The
price of the front-month Dutch TTF gas contract, the benchmark for Europe, has
almost tripled since the start of the year due to the slowdown of Russian gas
deliveries through Nord Stream 1 and a tight global market.
And while the firm still has a 30,000-litre oil tank on
site, which has not been used for years, to use it again would feel like a
backward step, Roeders said.
Germany's energy regulator is pleading for businesses,
government and consumers to reduce their gas intake and has asked the biggest
firms to submit emergency plans to cut usage further in the winter.
Yet chief executives of German carmakers including Mercedes-Benz and
Volkswagen have warned in recent weeks that maintaining output levels
under emergency plans will only work if their suppliers can continue to deliver
parts.
Producers of the aluminium, steel and glass essential to
making cars rely even more heavily on natural gas than the automakers
themselves, prompting fears of a ripple effect across their global client base
if they are forced to halt production.
German manufacturers of car components sell to more than
3,000 direct customers in the United States, Europe and Japan with their
products reaching over 100,000 second-tier customers, supply chain analytics
firm Interos estimates.
The energy crisis is the latest in a string of upheavals,
from carbon emissions curbs and supply chain bottlenecks to stricter due
diligence laws, which small businesses say they will struggle to overcome
without more support.
"Converting to electricity-driven units requires massive
renovation and is at best conceivable in the medium term," a spokesperson
for the German Association of Foundries said.
"No
technology other than firing up machines with gas is currently available,"
the spokesperson added.
Together with an alliance of other aluminium makers and a
university, G.A. Roeders has received government funding to design a prototype
smelting oven which could operate on a mix of 30%-40% hydrogen and 60%-70% gas.
The aim is to eventually run exclusively on hydrogen.
Interest in the project has multiplied since Russia's
invasion of Ukraine, Roeders said, but there are still many hurdles before it
can become operational - from scaling up the technology to setting up a
hydrogen charging network.
"To
industrialize something like this usually takes at least five years," he
said. "We'll have to dress up warm; we won't have a hydrogen oven
yet."