Waupaca Foundry

Waupaca, WI

Incentive: $100,000

Utility: We Energies & Wisconsin Public Service

Program: Large Energy Users

 

 

Waupaca Foundry, Inc. is North America’s leading supplier of iron castings to the automotive, commercial vehicle, agriculture, construction, and industrial markets, produces gray iton castings, ductile iron castings, HNMTM series high-strength ductile iron, and austempered ductile iron castings using state of-the-art processes and technology. Waupaca Foundry is headquartered in Waupaca, Wisconsin and operates seven iron foundries located in Waupaca, Wisconsin, Marinette, Wisconsin, Tell City, Indiana, Etowah, Tennessee, and Lawrenceville, Pennsylvania. The company also operates two machining and assembly plants in Effingham, Illinois, and Wellsboro, Pennsylvania. Waupaca employs approximately 4,400 people in total.

On October 20, 2016, Waupaca Foundry was awarded the accredited ISO 50001 Energy Management Systems (EnMS) certification. The foundry is the first metal caster in the United States to receive this certification. In recognition of the tremendous accomplishment Waupaca Foundry was awarded a Focus on Energy 2017 Energy Efficiency Excellence Award in March. By implementing and maintaining this ISO 50001 certified EnMS, Waupaca Foundry is demonstrating its commitment to improving their energy performance, staying competitive in a challenging business environment and maintaining jobs in the state of Wisconsin.

From 2010 to 2016, Waupaca Foundry has saved over 4.4 million kWh and some 250,000 therms. Focus on Energy provided support in the form of technical assistance and well over $600,000 in project incentives. Among the more recent project activities are:

  • Converting LED lighting throughout the plant’s manufacturing, office, and employee areas. The retrofit effort has replaced inefficient lighting with LED technology, with over 800 energy efficient LED fixtures installed within the past two years.
  • Replacing outdated compressors with new, more efficient models throughout the plant. At the same time, ductwork and additional equipment has been installed to capture the waste heat and use it to heat buildings during the colder months.
  • Expanding and networking electric and natural gas metering to the newly installed energy management system. The system allows monitoring of real time energy use at departmental levels and archives historic data to allow analysis and comparison.

“Waupaca Foundry is honored to have been selected for the 2017 Energy Efficiency Excellence Award. It’s good to know that our corporate commitment to sustainability is recognized outside of our organization.”

-Energy Manager (Retired)

Mike Hoecker PE, CEM

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