An experimental campaign was conducted by Rio Tinto™, Alcoa™, and PyroGenesis™ to further investigate plasma as a heating source for aluminiumAluminium furnaces, with the goal of reducing their carbonCarbon footprint. For this purpose, a 300 kg pilot furnace was used, primarily as a castingCasting furnace but also as a meltingMelting furnace to prepare various commercial alloys, replicating processes used in industrial cast houses. The impact of replacing the furnace’s natural gas burner with a plasma torchPlasma torch was investigated in both operating modes. Results show that plasma improves the furnace’s thermal performance, leading to significant energy savingsEnergy saving, shorter meltingMelting times, and reduced dross generation, all without compromising metal qualityQuality. However, dross generation proved to be highly sensitive to air infiltration, and improvements were necessary at the beginning of the campaign to achieve the observed positive results. Proper furnace sealing also emerged as a key factor in minimizing NOx emissionsEmissions and reducing noise levels.