The technology of high-pressure die casting thin-walled castings requires increased demands on the stability of technological processes and pressure casting parameters. The wall thickness of the studied zinc alloy castings (ZP0410) ranges from 0.4 to 1.2 mm. In general, it is necessary to use higher mould operating temperatures and a higher casting speed when filling the mould cavity when casting thin-walled castings. There is an increased load on the mould (tool) and the die casting machine during this casting process and the use of more demanding parameters. It results in a shortening of mould service life. There is currently no own returnable material (alloy ZP0410) used in the given production conditions in the production of thin-walled castings. Only the primary alloy ZL0410 is used now. It must be emphasized that the ability to implement the recycling of these returnable materials is becoming increasingly important. However, it is necessary to ensure that the quality of production is not reduced. The research was carried out aimed at determining the current state. Methods of roughness analysis, computed tomography, and metallography of casting defects from casting machine failures even after plating are used in the study of existing production technology in addition to standard long-term monitoring of melt quality. The findings of these research activities were briefly summarized in the paper. The experimental development of the technology of using our own returnable material in this quality-intensive production is in progress now.