Aluminium is highly recyclable yet industry still uses 64% primary aluminium with associated CO2 emissions, energy consumption and pollution. Defects caused by porosity and oxides lead to rejects (up to 30%) especially when recycled materials are used due to high levels of hydrogen, oxides and other impurities. Conventional treatments are inefficient and do not fully eliminate the problem. HSMC-AL will industrialise a novel High Shear Melt Conditioning (“HSMC”) technology to enhance efficiency and sustainability by reducing defects and reject scrap and increasing the utilisation of recycled materials. The project will develop an industrialised demonstrator for testing under operational production conditions at a large-scale casting foundry (TRL7). It will provide profitable new business for the consortium partners with a 16:1 return on investment in this project, creating 170 new jobs within five years of sales. The project directly addresses the Eureka SMART innovation domains of Advanced Manufacturing Processes and Sustainable Manufacturing with application sector Capital goods, Aerospace, Automotive, Railway, and Consumer goods sectors. The UK-Turkey consortium comprises HSMC developer ZYOMAX, casting manufacturer DOKTAS, supply chain partners SYALONS (ceramic components) and TWIN (quality and control) and research partner Brunel University London BCAST.