HOW DOES YOUR FACILITY COMPARE?
Wonder if your plant could be solar powered? See how your operation com- pares to Pacific Alloy Casting Co. Inc., South Gate, Calif., which draws 8% of its monthly needs from panels on its roof. • Annual Production: 2,400 tons. • Molding Lines: Automatic green sand molding machine, nobake sand cast- ing line.
Pacific Alloy fulfills almost 10% of its energy needs via newly installed solar panels. The power helps the green sand and nobake plant offset the high costs associated with melting and heat treating.
manufacturer like Pacific Alloy, that translates to almost a tenth of its over- all needs. However, varying amounts of energy are produced at different times during the day. While a lack of sun in the evening might mean 0% of its energy needs are met, the system produces more energy than the facility can use during summer afternoons when Pacific Alloy is not melting. “During our first partial month
of operation, the panels gave us 8% of our total electricity consumed,” Leach said. “Tis will decline as the daylight hours become shorter. Win- ter generation will be about half the summer generation.” As solar energy becomes increas-
ingly economical, more metalcasting companies may join Pacific Alloy in the solar game. DOE Secretary Steven Chu recently announced an initiative to bring the costs of utility- scale solar energy systems down about 75% to roughly $1 per watt by 2020. “I [believe] we should generate as
much of our own power as we can, if we can do so with a reasonable invest- ment and payback period,” Leach said. Pacific Alloy has installed demand
control software to help minimize its consumption levels and temper its energy bills further (see sidebar “Other Environmental Initiatives”). Te com- pany also has considered its environ-
mental future. Leach said he has had several discussions with knowledgable people about additional self generation of electricity, but the experts say it is not realistic. For now, the 95-employee job shop will be satisfied with stabi- lized electric expenses and the ability to be more cost competitive. Tat ability will be integral to
Pacific Alloy’s future plans to expand capacity, Leach said. “Since 1880, the Leach family has
• Melting Capability: Four electric induction melting furnaces.
• Metals Cast: Abrasion-resistant cast irons, austempered ductile iron, austenitic ductile iron, austenitic gray iron, carbon steel, ductile iron, gray iron, heat resistant steels, stainless steel, high chrome iron, Ni-Hard.
• Value-Added Services: Full-service machining and heat treating.
reinvented our foundry several times, changing to meet demands of the marketplace,” he said. “What do you call 132 years foundry ownership and operation? A good start.”
ONLINE RESOURCE
For more information about the potential for using solar energy in your state, visit
energy.gov/maps/solar-energy-potential.
January 2012 MODERN CASTING | 37
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