Look up “energy efficiency” in the dictionary, and a century-old iron foundry probably isn’t the first example you’d expect to find. Yet in South Milwaukee, Emerson’s Appleton Group Foundry is rewriting that story—showing how tradition and innovation can work hand in hand.

For more than 100 years, the foundry has poured hot iron and manufactured cast-iron parts that power industries across the country. Today, that same facility is proving that efficiency and sustainability can thrive even in one of the most energy-intensive manufacturing environments. In May 2025, Emerson Appleton earned a Focus on Energy Efficiency Excellence Award, joining just 11 recipients recognized statewide.

Between 2017 and 2024, Emerson Appleton completed 20 energy efficiency projects with support from Focus on Energy and We Energies. The results speak for themselves:

• More than $1.3 million in annual energy cost savings.
• Over 10,000 megawatt-hours of electricity saved each year—enough to power more than 1,200 Wisconsin homes.
• 665,000 MMBtu of natural gas conserved.
• A 41% reduction in overall energy use across the foundry.

“These are the kinds of numbers you can see right on the utility meters,” said Plant Manager John Schuster. “We got a 40% reduction in our kilowatt use per melt and nearly a 30% reduction in our gas usage. The meters don’t lie.”

None of this happened overnight. Emerson Appleton worked closely with Focus on Energy’s Energy Advisor Paul Kling, who helped identify projects and guide them through implementation.

“So far, they’ve had 20 incentives,” Kling said. “They’re saving $50,000 in gas at today’s rates, and about $1.25 million in electric costs. That’s $1.3 million in savings every year.”

Projects included everything from LED lighting and variable frequency drives to advanced controls and induction melting systems. Each upgrade not only saved energy but also cut costs and reduced emissions.

As State Senator Chris Larson noted during the award ceremony, “Emerson Appleton Group has really been a flag bearer…a poster child for what this industry can be and should strive to be. They’re showing that it can be done.”

Energy efficiency at the South Milwaukee foundry isn’t just about technology—it’s about culture. Emerson has a network of more than 120 Green Teams worldwide, with the South Milwaukee team leading by example.

“The stuff doesn’t happen on its own,” Schuster explained. “You can have a goal, but if you’re not taking those steps every day and working through the spreadsheets, then it doesn’t happen. It takes a lot of people putting in effort and working together on the same things.”

That culture of teamwork and accountability has allowed Emerson Appleton to maintain momentum year after year. Each success builds confidence in the next project, creating a cycle of savings and sustainability.