is accountable and empowered by management. The energy champion should serve as the go-to person for all energy issues and should be responsible for building employee awareness, setting energy reduction goals, coordinating all energy efforts in the organization, establishing metrics for measuring and tracking progress toward goals, and reporting progress and successes to both shop floor personnel and management. In smaller metalcasting facilities, it may be impossible for a single individual to fulfill this role, and the energy leader may be a shared function among two or more. An energy team also should be established. This team must include members from all areas of the metalcasting company, including operations, maintenance, engineering, environmental, front office, purchasing and administra- tion. The energy manager must be the team leader, but a senior man- ager should serve as team sponsor to demonstrate corporate manage- ment backing. Assess your performance. Before beginning a formal energy reduc- tion program, each facility must determine current energy spending and establish a baseline to monitor progress. Once a baseline is estab- lished, the energy team can begin to measure and track energy use. It is important that clear metrics that encompass all energy utilized in the facility are used to measure progress. A common metric correlates energy units and products, such as KwH per ton of castings shipped. If the metalcasting facility is using both gas and electricity, a single unit can be created. For example, cubic feet of natural gas can be converted to KwH, or both units can be con- verted to Btu. Many metalcasters receive a single electric or gas bill for the entire facility and don’t know specifically where the energy is being used. To accurately assess energy spending, it may be neces- sary to install sub-meters to measure the exact energy consumed by each individual piece of equipment or process (see sidebar “Energy Saving Case Studies”).


22 | MODERN CASTING April 2011


ENERGY RESOURCES ENERGY STAR


The U.S. Environmental Protection Agency’s ENERGY STAR program is designed to help metalcasters reduce energy through a systematic approach to energy management and demonstrate environmental responsibility. The program is intended to help develop a comprehensive energy management strategy by pro- viding tools and resources will help you measure energy use, reduce consumption and validate savings. The program offers web-based training to launch the effort.


Energy Audits and Assistance


Several programs are available that provide energy audits of manufacturing facilities. Individual consultants are available, as well as state and local govern- ments and universities. Industry trade groups, such as the American Foundry Society, often offer audits specific to metalcasting.


Set goals and develop a plan. Each


metalcaster should immediately set goals for reduction. Te Environmen- tal Protection Agency’s ENERGY STAR challenge (see sidebar “Energy Resources”) is a good start, asking for a 10% reduction over five years.


In the


coming years, the metalcasting industry will face many challenges, including


unpredictable energy market forces and the


eventual effect of climate control


regulations, which could drive energy costs higher.


Having a defined action plan and detailed implementation strategy will help move toward energy saving goals. Te energy team will begin to look for energy reduction opportunities throughout the operation. Although melting is the major point of use, sig- nificant savings can be seen in HVAC, ventilation, air compressors and light- ing, as well as other areas. For example, one study showed that an improved ventilation hood design can reduce static pressure and require as much as 50-75% less horsepower to operate, and metalcasting facilities have seen considerable savings in air compressors and improved plant lighting. Evaluate progress and celebrate suc-


cess. Each new energy saving program should be carefully monitored so the reduction in consumption is clearly defined and communicated. Celebrat- ing and publicizing the achievement of energy reduction goals is an important step in changing the internal company culture to be more energy conscious. Many metalcasters have done this by recognizing individuals that suggest energy saving ideas or hosting a public event to focus on achievements.


ONLINE RESOURCE For more information on how to implement an energy management system, visit www.afsinc.org/content/ view/1033/312/.


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