(WAUPACA, WI) Sep. 7, 2017 — Waupaca Foundry has received a 2017 Excellence in Energy Efficiency Award from Wisconsin's Focus on Energy program.
The Waupaca-based business is the world's largest iron foundry and a national leader in energy management.
When Waupaca Foundry Plant 1 achieved certification to the ISO 50001 International Standard for Energy Management Systems in 2016 it was just the second Wisconsin facility (and the only United States based foundry) to receive such certification.
"By implementing and maintaining ISO 50001 certification, Waupaca Foundry is demonstrating its commitment to improving its energy performance, staying globally competitive and maintaining jobs in Wisconsin," said Wisconsin Public Service Commissioner Lon Roberts.
This commitment to energy efficiency placed it among 15 elite recipients that received the Excellence in Energy Efficiency Award from Focus on Energy and Wisconsin's Public Service Commission.
Energy is one of the largest costs of manufacturing with an annual price tag of about $180,000,000, across all Waupaca Foundry locations.
"By continually improving our environmental sustainability, we are not only reducing our impact on the environment but remaining competitive in a global marketplace," said Bryant Esch, environmental coordinator for Waupaca Foundry.
With support and guidance from Focus on Energy and Wisconsin Public Service, Waupaca Foundry completed a series of equipment upgrades that saved more than 4.4 million kilowatt hours of electricity and 250,000 therms of natural gas.
- Inefficient lighting throughout the plant's manufacturing, office and employee areas was retrofitted with more than 800 energy efficient light-emitting diode (LED) fixtures.
- Outdated compressors were replaced with new, more efficient models throughout the plant. At the same time, ductwork and additional equipment was installed to capture waste heat to be used to heat buildings during cold weather.
- Electric and natural gas metering was converted to a new energy management system.
The projects were made possible by custom and prescriptive incentives provided by Focus on Energy, a statewide energy efficiency and renewable energy program funded by participating Wisconsin utilities.
A charter member of the U.S. Department of Energy's Better Plants Program, Waupaca Foundry had a long and effective history of effective energy management prior to ISO certification.
Waupaca Foundry employs about 4,400 people and uses state-of-the-art technology to produce ductile iron and gray iron castings. It services the automotive, commercial vehicle, agriculture, construction and industrial markets as North America's leading supplier of iron castings. Four of the company's seven manufacturing facilities are located in Wisconsin (three in Waupaca, one in Marinette).
Focus on Energy works with eligible Wisconsin residents and businesses to install cost effective energy efficiency and renewable energy projects. A list of all 2017 Excellence in Energy Efficiency Award recipients is available here.
Pictured at the September 6 awards presentation, front row (left to right): Terri Schultz, Waupaca Area Chamber of Commerce President; Marco Gonzalez, Waupaca Foundry Energy Coordinator; Brian Tesch, Waupaca Foundry Plant Manager; Lon Roberts, Wisconsin Public Service Commissioner; Alex Ignatowski, Wisconsin Public Service Commission Executive Assistant; Travis Jones, Focus on Energy Trade Ally and Utility Engagement Manager. Back row: David Thiel, Waupaca County Economic Development Corporation Executive Director; Richard Feustel, Focus on Energy Contractor; Steve Lewellan, Focus on Energy Contractor and Wisconsin Cast Metals Association Director; Andrea Hansen, Focus on Energy Marketing and Communications Director; Bryant Esch, Waupaca Foundry Environmental Coordinator.