The project concerns the development of a technology for manufacturing ingots with a low carbon footprint for extruding aluminum profiles from the 6xxx series. The effect of the low carbon footprint of the ingots in question is to be achieved by using an above-standard amount of recycled raw materials (post-production and post-amaortization scraps of various grades and qualities) for the preparation of alloys. One of the current trends in the world is the circular economy implemented in all areas of life, which saves not only raw materials but especially energy for their processing. This idea includes the project concerned with the implementation of research and development works aimed at developing parameters, monitoring and control of the process of preparing aluminium alloys from a charge with an above-standard share of scrap, about 90%, casting ingots and developing a modified process for their heat treatment. The developed solutions will implement the idea of Industry 4.0. by developing hybrid digital twins (HDT) for two elements of the line, i.e. a melting furnace and a heat treatment furnace. The use of HDT will allow you to: prediction of the system condition (furnace), safety assessment and analysis of the process. The result of the project will be REMELT90TM ingots (produced with an above-standard share of scrap, about 90%) with high quality parameters from recycled raw materials produced in LCO2ETTM technology (Low CO2 Emission Technology) using mathematical models. These ingots will be designed for the process of extrusion of ReEx90TM profiles from 6xxx series aluminum alloys (so-called. "green profiles", i.e. made from recycled materials and technologies with a low carbon footprint).