From obligation to opportunity
Practical example of the reliable conversion of lead alloys
Increasing regulatory requirements surrounding the use of lead-containing materials are forcing many industrial companies to take action. This case study highlights how a manufacturer in the sanitary industry implemented a structured, technically sound, and economically viable transition to lead-free alloys—with clear processes, thorough testing, and collaborative coordination.
Background & problem
Company and industry
The company in question is an established player in the metalworking industry, specializing in the manufacture of complex components, particularly for water-carrying systems. The company operates in a highly regulated market environment that places the highest demands on material quality, product safety, and durability. With a diverse portfolio of piping systems, heating and cooling solutions, and infrastructure products, it supplies national and international OEMs, installers, and system providers.
Free consultation
We advise you without obligation
BEULCO is your partner for a lead-free future in your industry. A successful material transition can be achieved when it is implemented in a way that is legally compliant, technically sound, and economically viable—and that is exactly where we can support you.
Initial situation
In the wake of stricter European and national legislation, the company was forced to switch its product range from the materials it had previously used to lead-free alternatives. In particular, the German Drinking Water Ordinance (TrinkwV), which is based on the EU Drinking Water Directive 2020/2184, led to considerable pressure to adapt.
The key regulatory changes are as follows:
- The permissible lead limit in drinking water has been set nationally at 5 µg/l until 2023.
- Compliance with this limit will be mandatory from January 12, 2028: Products must not contain any lead-containing materials that exceed this value.
Goals
The main objective was to completely convert a defined range of products to a lead-free alloy without compromising the functionality and quality of the products. At the same time, the conversion had to be implemented in an economically viable manner. Other sub-goals included:
- Selecting a suitable lead-free alloy with comparable mechanical and chemical properties
- Ensuring machinability on existing machines
- Controlling and limiting potential additional costs
- Planning a staggered and process-reliable implementation
- Avoiding production downtime and scrap
- Taking inventory levels and certification processes into account
The 5 phases of the project
Phase 1
Analysis & initial consultation
Objective:
To create understanding of regulatory requirements, technical action needed, and economic impact.
Activities:
- Initial discussions with the customer to clarify requirements
- Assessment of regulatory relevance (e.g., REACH, EU Drinking Water Directive)
- Identification of possible alloy options
- Identification of affected items
- Initial technical consultation with materials specialists
- Internal assessment: Which machines, processes, and drawings are affected?
- Result:
Common understanding of the necessity, scope, and objectives of the changeover
Phase 2
Material selection & feasibility study
Objective:
Select the appropriate lead-free alloy based on technical and economic considerations.
Activities:
...
See the complete Case Study
Download now
Trinkwasserverordnung
Die neue Trinkwasserverordnung, die die europäische Trinkwasserrichtlinie in deutsches Recht umsetzt, stellt Inverkehrbringer von Produkten, die in Kontakt mit Trinkwasser kommen, vor erhebliche Herausforderungen. Mit der Herabsetzung des Bleigrenzwertes von 10 auf 5 Mikrogramm pro Liter, die spätestens zum 12. Januar 2028 einzuhalten ist, steigt der Druck auf die Hersteller und Anbieter dieser Produkte erheblich.
REACH
Die EU diskutiert aktuell, ob Blei auf Anhang 14 der REACH Verordnung aufgenommen werden soll, was ein Bleiverbot ab 2028 mit sich ziehen würde. Dies stellt Unternehmen in der EU vor erhebliche Herausforderungen. Dies betrifft sowohl produzierende Unternehmen als auch Unternehmen, die in die EU importieren.
Entwicklungspartner
Neben der hochqualitativen Beratung und Fertigung legen wir sehr viel Wert darauf, Sie von Beginn an in Ihrem Projekt zu begleiten - denn nur so können wir Expertise bündeln und daraus erfolgreiche Synergien entwickeln. Erfahren Sie mehr über unsere Kompetenzen, unseren Service und wie wir mit Ihnen gemeinsam Ihr Produkt zur Serienreife bringen.