can modify the melting system to more efficiently use waste heat. If heat from a furnace otherwise escapes without purpose, it can be used to preheat the material for the next charge. Historically, metalcasting facili-
ties have received a single utility bill for electricity or gas usage. But specialized measuring systems are becoming more prevalent in the industry. Energy experts have developed sub-metering practices that place individual sub-meters on separate furnaces, compressors, bag house, etc. By measuring energy consumption on specific pieces of equipment, metalcasters can see exactly where the energy is used. Brian Reinke, an energy consultant
with TDI Energy Solutions, Lemont, Ill., identifies process improvement as another area of potential savings. For example, improving training procedures for those operating furnaces, air com- pressors and dust collectors, can lead to reductions in energy consumption.
“We routinely find significant
energy savings opportunities for foundries, and many of them require little to no capital expense,” Reinke said. “People are especially interested when we discover ways to increase their throughput and save money on their utility bills at the same time. Tis provides both higher profit and the potential to produce more castings.” In response to economic and envi-
ronmental pressures, metalcasters will continue to look for ways to reduce consumption and waste. Te larger idea—whether it’s called a sustain- ability program or green initiative— remains a plan for the future and an expectation of longevity. “Really, [buyers] are looking for
long-term planning instead of a focus on the short term,” Lenahan said. “What are metalcasters doing to retain talent? What are they doing to recycle industrial byproducts? What are they doing to maintain a positive reputation?”
40 | METAL CASTING DESIGN & PURCHASING | May/Jun 2014
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