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Wisconsin Foundry Industry Overview

Wisconsin's foundry industry encompasses 125 foundries employing around 21,000 people, generating $3.5 billion in sales and an $870 million payroll. Notably, 80% of foundries have fewer than 100 employees. Ranked 3rd nationally, the industry faces barriers like international competition and environmental regulations. The WCMA promotes energy efficiency through education and workshops, focusing on targeted assessments and best practices. Current energy reduction efforts include compressor modifications and cupola heat recovery projects. Future initiatives aim to address HVAC efficiency and waste heat utilization.

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Wisconsin Foundry Industry Overview

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  1. Wisconsin Foundry Industry Overview • 125 foundries • 80% - 100 employees or less • 21,000 employees • Payroll $870 million • $3.5 billion in sales • Wisconsin 3d Ranked Foundry State • Nationally 200 – 250 trillion Btu per year

  2. WCMA Energy Initiatives • Focus on education and facilitation • Incorporated energy issues into the standing Environmental Committee • Best Practices Handbook & May 2006 Workshop • Targeted Site Assessments – future Regional Workshops • No goal set to date

  3. Foundry Industry – Barriers to Energy Reduction • International competition – priority is survival and market-share. Capital priorities. • Demographics  internal resources (many hats for one individual) • Environmental requirements – air pollution control

  4. Energy Use Profile – Cupola Shop APC/AMU

  5. Foundry Support • Small Foundries will require more individual attention and financial assistance • Large Foundries continued financial incentives and tax credits • All require education/awareness and research/development

  6. Assistance Model DOE – Industrial Technologies Program Research *AFS * Universities Focus on Energy Local Foundry WCMA

  7. Assistance Considerations • Existing model is effective • Do not forget about the basics • Do not assume that a 2 year pay back is a “slam dunk”

  8. Historical Practices • Scrap recycling  life cycle perspective • Sand recycling  life cycle perspective • Preheat of cupola blast air (1980) • Inductor and furnace efficiency • Purchasing practices

  9. Recent Energy Reduction Activities • Compressor system modifications and control • Cupola heat recovery for space heat  50,000 dekatherm annual savings • Lighting Projects  $325K invested to date • Premium efficiency motor project

  10. Future Reduction Activities • HVAC smart building controls • Plant 1 Cupola Heat Recovery • Compressor System Retrofits • Lighting Retrofits • Waste Heat to Electricity  8 MW (long term 6 –8 year payback)

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