Hams Hall, UK. BMW Group’s Hams Hall plant, located in the UK, has reached a major milestone: For exactly 25 years, the plant near Birmingham has produced highly efficient internal combustion engines for a variety of BMW Group vehicle models. More than 7.6 million engines have shipped from Hams Hall since 2001. The facility supplies numerous production sites worldwide with highly efficient petrol engines for the BMW, MINI and Rolls-Royce brands, including drive trains for plug-in hybrid models – making the plant an integral part of the BMW Group’s technology-open approach. Today, Plant Hams Hall produces three and four-cylinder petrol engines to high performance V8 engines, powering vehicles across both BMW and MINI. Separately, the V12 engine is produced at Plant Hams Hall exclusively for Rolls-Royce Motor Cars. Its assembly follows a distinct, bespoke production process, carried out by specially trained engineers and technicians, before final delivery to the Home of Rolls-Royce at Goodwood.

Plant Hams Hall – an integral part of the global production network

"This anniversary is a special milestone for our site," says Dirk Dreher, Head of the BMW Group's Hams Hall plant. "We are a competitive plant and there’s always been a real passion among our workforce to continually improve our manufacturing processes and site. Building on our strong foundation, we are looking forward to remaining a successful plant in the future."

“The Hams Hall plant is an integral part of our global production network,” explains Harald Gottsche, Head of Engine Production at BMW AG. “The site combines technological expertise with high flexibility. It reliably supplies our vehicle plants with efficient, powerful engines of premium quality. This includes the V12 engine – a masterpiece from Hams Hall!”

61% reduction in energy use per engine built since the start of full production

The British engine plant is systematically implementing the principles of the BMW iFACTORY. The strategic vision of the BMW iFACTORY focusses on sustainability, electrification, digitalisation and profitability. From the first concept of the plant to the present day, the Hams Hall team has made sustainability a key consideration. Since the first full year of production, the plant has made a 61% reduction in energy required per engine built, meaning the overall energy to operate the site has remained level even though there has been a considerable increase in production. The plant purchases 100% of its external electricity from renewable energy sources today. It has also worked to reduce its consumption of natural gas.

SpOTTO robotic dog scans and monitors manufacturing equipment

A four-legged autonomous robot named “SpOTTO” joined the Hams Hall team in 2024. The autonomous robotic dog scans the plant, supports maintenance and ensures production processes run smoothly. Equipped with visual, thermal and acoustic sensors, SpOTTO collects valuable data for the plant’s digital twin. It also serves as a watchdog, monitoring the maintenance of production facilities. SpOTTO was developed by Boston Dynamics under the product name “Spot”, an agile robot capable of climbing stairs and traversing rough terrain with ease. At Hams Hall, “Spot” was fondly renamed SpOTTO, paying tribute to the engine plant’s proud heritage: Gustav Otto, one of the founders of BMW, was the son of Nicolaus Otto, inventor of the four-stroke engine.

Fully connected digital twin: Big data on three levels

At the core of the Hams Hall plant’s digital transformation is the fully connected digital twin, which consists of three levels: On the first level, 3D representations of the entire plant are generated. The second level comprises a large data layer, continuously updated with all relevant information from the SpOTTO robotic dog, the plant’s manufacturing equipment and its IT systems. On the third level – the application level – dedicated programmes organise the collected data into comprehensible units. Using special apps, experts at Plant Hams Hall can leverage this information for tasks such as production planning and quality assurance.

A history of continuous growth

Over the past 25 years, BMW Group Plant Hams Hall has continuously evolved, establishing itself as a key pillar of the company’s production network. Relying on state-of-the-art manufacturing technologies, it provides drive trains for numerous BMW, MINI and Rolls-Royce models.

Selected historic milestones:

• 2001: Plant Hams Hall launches series production with new four-cylinder engines, using innovative Valvetronic technology in large-scale manufacturing for the first time.
• 2006: An additional engine family is introduced; Plant Hams Hall produces engines for the MINI brand for the first time.
• 2013: Plant Hams Hall becomes the exclusive manufacturer of the award-winning three-cylinder engine for the iconic BMW i8 plug-in hybrid sports car. The plant also integrates additional production lines for three- and four-cylinder petrol engines. At the same time, the processing hall for crankshafts, crankcases and cylinder heads is expanded.
• 2022: The plant takes over production of V8 and V12 engines. With this step the plant generates even greater business value for the company.
• 2026: Plant Hams Hall celebrates 25 years of production.

The BMW Group’s drive train production network

The BMW Group’s engine production network comprises several plants alongside Hams Hall: Its largest engine facility is in Steyr, Austria, where diesel and petrol engines, as well as sixth-generation electric motors, are developed and produced. The fifth generation of electric motors is produced in Dingolfing. Plant Munich handles mechanical production of V8 and V12 engine components, while Plant Landshut manufactures special engines. The Chinese joint venture BMW Brilliance builds engines for the local market in Shenyang. Collectively, these locations support the BMW Group's technology-open powertrain strategy.

Brooklyn, N.Y. – September 18, 2023 – MINI USA is marking Climate Week NYC, the largest annual climate event of its kind, with its North American debut of the new all-MINI Countryman Electric, which makes its first appearance in the U.S. following the World Premiere earlier this month at IAA Mobility in Munich.  Expected to arrive on U.S. shores for consumers in the fall of 2024, this evolution for the largest model in the MINI family is another step in the brand’s journey toward fully electrified mobility and sustainable design.

The new electric Countryman makes it first presence on American shores at a special panel called Driving Forward: The Transforming of Future Mobility hosted by URBAN-X, the leading urban technology startup platform by MINI, at Newlab in the Brooklyn Navy Yard.  URBAN-X, which recently welcomed its 13^th cohort of early-stage startups, is committed to fostering more sustainable, livable, and resilient cities by nurturing startups that offer impactful climate technology solutions.

 “The all-new MINI Countryman Electric is a significant step as MINI moves to becoming a more sustainable and fully electrified brand by 2030.” said Mike Peyton, President of MINI Business Innovations LLC, and Vice President of MINI of the Americas “Sustainability is also a key mission of URBAN-X, our start-up accelerator focused on climate tech innovations that help make city life better.  That’s why it’s a perfect fit to showcase our next new electric MINI at URBAN-X on the occasion of Climate Week NYC.”

A bold new addition to the MINI family, the all-new MINI Countryman Electric boasts a revolutionized digital ecosystem, greater utility, electric power output that keeps the “fun to drive” spirit going, and a design that is forward-thinking but unmistakably MINI.  At the event the New MINI Countryman Electric’s North American debut takes place alongside the appearance of the new BMW CE-04 battery electric scooter and the BMW iX5 Hydrogen prototype that showcases the company‘s development of hydrogen technology for future series production.

The panel at URBAN-X also features Alexander Bilgeri, BMW Group Vice President of Corporate Communications for Human Resources, Production, Purchasing and Sustainability, as the session explores the transforming future of mobility with several start-ups and innovators. As part of the panel Bilgeri is presenting the BMW Group sustainability strategy and the company‘s plans to meet its decarbonization targets by 2050.

About MINI in the US

MINI is an independent brand of the BMW Group. In the United States, MINI USA operates as a business unit of BMW of North America, LLC, located in Woodcliff Lake, New Jersey and includes the marketing and sales organizations for the MINI brand. The authorized MINI USA dealer organization is represented by a network of 104 MINI full passenger car sales and service dealers located throughout the US.  MINI USA began selling vehicles in the U.S. in 2002 with the introduction of the MINI Cooper and MINI Cooper S Hardtops. Since then, the MINI brand in the U.S. has grown to encompass a model range of five unique vehicles.

Journalist notes: Media information about MINI and its range new products to come is available to journalists on-line at MINIUSANEWS.com.

About URBAN-X
URBAN-X is the platform for founders reimagining city life. Built by MINI in 2016, URBAN-X partners with startups to build bold technology solutions for a sustainable planet. Breaking from traditional startup program molds, URBAN-X provides Pre-Seed and Seed-Stage entrepreneurs with individualized and tailored support that accelerates growth and builds successful businesses for the next generation of climate- and city-focused innovators. Core to its platform, URBAN-X offers world-class engineering and design resources, industry-leading investment capital from our venture partner JVP, a global network of investors, policymakers, corporate strategies and end-customers, and premier educational content for a global network of founders. Find URBAN-X on Twitter & Instagram at @urbanxtech and on Facebook at facebook.com/urbanxtech.

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• Zipse: “We are committed to a clear course to achieve the 1.5 degree target”
• 50% reduction in global CO2 use-phase emissions by 2030
• Over 40% reduction in CO2 emissions during life cycle
• Ten million all-electric vehicles within ten years
• Secondary first: Up to 50% use of secondary material planned – initiatives to develop the market are required
• Cooperation with BASF and ALBA on plastic recycling
• Resource scarcity and social responsibility: BMW Group focussed on circular economy for sustainable materials
• RE:BMW – circular economy at the IAA Mobility in Munich

Munich. The BMW Group is increasing the pace of its efforts to combat climate change. Looking ahead to the introduction of the Neue Klasse, the company is further strengthening its self-defined objectives, announced in summer last year, to significantly reduce CO2 emissions, whilst also committing itself to a clear course that supports the 1.5 degree target for the limitation of global warming. The Neue Klasse will also see the BMW Group hugely increase its use of secondary materials with a firm focus on the principles of the circular economy, whilst also promoting better framework conditions for establishing a market for secondary materials.

To achieve a further reduction in CO2 emissions, the focus is on the utilisation phase of vehicles, which account for 70% of the BMW Group’s CO2 footprint. By 2030, the CO2 emissions per vehicle and kilometre driven will be at least halved from 2019 levels. The commitment of all manufacturers when it comes to combatting climate change can best be compared when looking at the entire life cycle of a vehicle, including production and upstream supply chain. Here, the BMW Group is planning a reduction of CO2 emission per vehicle of at least 40%.

“How companies are dealing with CO2 emissions has become a major factor when it comes to judging corporate action. The decisive factor in the fight against global warming is how strongly we can improve the carbon footprint of vehicles over their entire life span. This is why we are setting ourselves transparent and ambitious goals for the substantial reduction of CO2 emissions; these are validated by the Science Based Targets Initiative and will deliver an effective and measurable contribution,” said Oliver Zipse, Chairman of the Board of Management of BMW AG, in Munich on Thursday. “With the Neue Klasse we are significantly sharpening our commitment and also committing ourselves to a clear course for achieving the 1.5 degree target.”

The BMW Group is the first German carmaker to join the Business Ambition for 1.5°C of the Science Based Targets Initiative and is committed to the goal of full climate neutrality over the entire value-added chain by 2050 at the latest. This means that the company is also part of the international Race to Zero Initiative. The company is convinced that this can be achieved using innovation, rather than any overall ban on individual technologies.

The most powerful driver on this path to climate neutrality is electric mobility, with the BMW Group’s Neue Klasse set to provide significant further momentum to the market. During the next ten years or so, the company will be putting around ten million all-electric vehicles on the road. As early as 2030, at least half of global BMW Group sales will be all-electric vehicles, with the MINI brand offering exclusively all-electric vehicles from 2030.

The BMW Group continues to comply with the stringent criteria of the Science Based Targets Initiative, when it comes to measuring the reduction of worldwide CO2 emissions of the company’s vehicles whilst they are being driven on the roads. For example, emissions from the production of fuel or electricity are included in the calculation and consumption is based on the WLTP cycle plus ten percent. With its current product and electrification strategy, the company is on track to meet the EU fleet target for 2030.

Beyond green electricity: Stronger focus on use of resources in future

BMW Group is clear that simply increasing the number of electric vehicles on the road does not automatically lead to climate-friendly mobility. The company understands that it is also crucial to reduce the use of primary material and the related environmentally harmful exploitation of resources and their often CO2-intensive processing – especially when it comes to car manufacturing, one of the most resource-intensive industries.

“2017 was the first time the world’s population consumed more than 100 billion tons of resources within a single year - a trend which we in the automotive industry must also counteract,” Zipse demanded. “This is a strategic issue, concerning not only ecological but also economic sustainability; the current development of commodity prices demonstrates the impact an industry that is dependent on limited resources must expect.”

With the number of battery-powered vehicles growing, there is increasing demand for many commodities such as cobalt, nickel and aluminium, which are required for the vehicles’ high-voltage batteries. However there is great potential for the reuse of materials in the sense of a circular economy and together with specialist partners, the BMW Group has already demonstrated that it’s technological feasible to achieve a recycling efficiency of over 90 percent.

The amount of secondary nickel used for the high-voltage battery in the BMW iX is already as high as 50 percent, with the battery housing containing up to 30 percent secondary aluminium. The BMW Group aims to improve these figures even further for future product generations.

In addition to the increasingly scare availability of primary materials and resulting commodity price increases, there are many sustainability reasons to use more secondary materials and move towards a circular economy.

The supply of secondary materials is considerably less CO2-intensive than is the case with primary materials and can significantly improve the CO2 footprint, especially within the supply chain. In the case of secondary aluminium, the CO2 saving compared with primary material constitutes a factor of approximately 4 to 6, whilst steel and thermoplastics lie between around 2 and 5.

The extraction of resources for primary materials – particularly through mining – has a significant impact on the basic regenerative capacity of ecosystems. This impact can be greatly reduced by increasing the use of secondary materials.

The mining and trading of conflict materials carries the possible risk of associated infringements of environmental and social standards. The BMW Group has established numerous measures to counteract this risk, including membership of the Responsible Minerals Initiative. However, the most efficient strategy for avoiding risks is to minimise the mining of such primary materials.

‘ Secondary First’: Crucial vehicle materials with high secondary content

As part of its holistic approach to sustainability, the BMW Group aims to increase significantly the percentage of secondary materials in its vehicles. On average, current vehicles are manufactured using almost 30 percent recycled and reusable materials. With the ‘ Secondary First’ approach, BMW Group plans to successively raise this figure to 50 percent.

Of course it’s crucial that the quality, safety and reliability of the materials comply with the same high standards as those existing for primary materials – and so it’s essential that the market availability of such high-quality materials increases considerably. In order to achieve this, cross-industry approaches and political initiatives are necessary.

Based on the four principles Re:think, Re:duce, Re:use, Re:cycle, the BMW Group is boosting its activities in the field of circular economy, an area where it’s carrying out pioneering work. For instance, vehicle production now involves the increased separation and recycling of crucial material groups, so these can be reused by the industry within the framework of ‘closed loops’.

Cooperation with BASF and the ALBA Group

Within the supply chain and depending on market availability, secondary materials are increasingly being used in BMW Group vehicles. Moreover, together with its partners, the company is providing important impetus when it comes to developing secondary materials. One example is the company’s pilot project with BASF and the ALBA Group for the increased recycling of plastics used in cars.

The aim of the project is to reduce the use of primary plastics by means of a comprehensive recycling system. To this end, the ALBA Group analyses end-of-life BMW Group vehicles to establish whether a car-to-car reuse of the plastic is possible. In a second step, BASF assesses whether chemical recycling of the pre-sorted waste can be used in order to obtain pyrolysis oil. This can be then used as a basis for new products made of plastic. In the future, a new door trim or other components could be manufactured from a used instrument panel, for example.

Closed loop rather than downcycling: ‘Circular Design’ as the basis of a circular economy

In order to achieve higher recycling rates and whilst also guaranteeing the high quality of secondary materials, the materials must be extracted in their purest form as early as possibly during the recycling process. For example, the onboard wiring systems must be easy to remove, in order to avoid mixing steel with copper from the cable harnesses in the vehicles. If this mixing does take place, the secondary steel loses its essential material properties and therefore no longer meets the high safety requirements of the automotive industry. To support this early and easy extraction of materials, the interior of a car must increasingly be made of monomaterials, so that at the end of the car’s lifecycle, as much as possible can be transferred back into the usable material cycle. Basically, reducing the number of materials can help to improve the quality of recycled materials. Currently, vehicles consist of about 8,000 to 10,000 different materials.

To achieve this, the BMW Group is now focusing on a ‘Circular Design’ concept, which is designed to guarantee the economical dismantling capacity of vehicles. It is essential that disassembly of the vehicle and its individual components is fast and cost-efficient to ensure that prices of secondary materials are competitive. It all starts with the construction of the vehicle, which must be done in such a way that allows materials to be removed at the end of the vehicle’s service life without different types of material being mixed with each other. 

RE:BMW at the IAA Mobility – a visionary outlook on circular economy

The BMW Group is putting circular economy at the centre of its presence at the IAA Mobility 2021 in Munich, where the company will offer a visionary outlook on the potentials of a circular economy and sustainable mobility. The BMW i Vision Circular embodies the company’s ambitious claim to be the most sustainable manufacturer for individual premium mobility.

This visionary vehicle, designed according to the four principles of the circular economy Re:think, Re:duce, Re:use, Re:cycle, shows how individual, sustainable and luxurious urban mobility could look in 2040. The BMW i Vision Circular is manufactured from 100 percent secondary materials or renewable raw materials, and is 100 percent recyclable.

This car demonstrates that climate protection and individual mobility do not necessarily contradict each other. On the contrary, it shows that using new technologies and innovation, the BMW Group can fulfill the planet’s requirements for greater sustainability without customers having to forgo individual mobility.

In case of queries please refer to:

Corporate Commmunications

Max-Morten Borgmann, Communications Corporate

Telephone: +49 89 382-24118, Max-Morten.Borgmann@bmwgroup.com

Kai Zöbelein, Communications Sustainability

Telephone: +49 89 382-21170, Kai.Zoebelein@bmwgroup.com

Eckhard Wannieck, Head of Communications Corporate, Finance, Sales

Telephone: +49 89 382-24544, Eckhard.Wannieck@bmwgroup.com

Bernd Eckstein, Head of Communications Purchasing, Supplier Network, Sustainability

Telephone: +49 89 382-59490, Bernd.Eckstein@bmw.de

Internet: https://newsroom.bmwgroup.com/global/en

E-mail: presse@bmwgroup.com

The BMW Group

With its four brands BMW, MINI, Rolls-Royce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial and mobility services. The BMW Group production network comprises 31 production and assembly facilities in 15 countries; the company has a global sales network in more than 140 countries.

In 2020, the BMW Group sold over 2.3 million passenger vehicles and more than 169,000 motorcycles worldwide. The profit before tax in the financial year 2020 was € 5.222 billion on revenues amounting to € 98.990 billion. As of 31 December 2020, the BMW Group had a workforce of 120,726 employees.

The success of the BMW Group has always been based on long-term thinking and responsible action. The company set the course for the future at an early stage and consistently makes sustainability and efficient resource management central to its strategic direction, from the supply chain through production to the end of the use phase of all products.

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