A partner in finding solutions: Manitowoc foundry owner vows energy, pollution reduction

By Charlie Mathews, Herald Times Reporter

MANITOWOC — Rob Peaslee, president of Manitowoc Grey Iron Foundry (MGIF), has made a pledge to federal authorities to reduce his plant's energy usage by 25 percent over the next 10 years.

The Division Street manufacturing plant's electricity and gas bill is about $1 million annually as it makes iron castings for parts used in agriculture, construction, mining, off-road automotive and other industries' machines.

"We've already done it ... my energy usage in 2009 was down 40 percent because our business was down 40 percent," Peaslee said with a slight smile.

"Chu said that doesn't count," Peaslee said, referring to U.S. Energy Secretary Steven Chu, head of the department that received voluntary pledges from MGIF, eight other Wisconsin businesses and 32 across America.

But the current president of the Wisconsin Cast Metals Association doesn't believe the recession will last forever.

When foundries resume higher levels of production, Peaslee's plant will have made the changes necessary to remain a participant in the "Save Energy Now LEADER" program.

"These companies' commitments to energy efficiency not only generate significant energy and carbon savings, but also show the entire business community the profitable steps that can be taken to move us all toward a
clean energy future," Chu said.

"Working together with American manufacturers, we will leverage the potential of energy efficiency to create new jobs, make our economy more competitive and reduce carbon pollution," said Chu at the program's launch in Washington, D.C. in December.

Recycling dust cuts energy needs

MGIF has installed a $250,000 "Sonoperoxone" system, partially subsidized by the state of Wisconsin.

"The energy savings are from the recycling of the dust," said Peaslee of the commodity, along with coal, clay and silica that are part of the sand system ingredients serving as the bond to form grey iron molds that may turn into drive train components like axles, steering knuckles or brake components.

Peaslee said the Sonoperoxone system alters bituminous coal to activated charcoal, which then acts as a filter in the casting process.

By reducing sand defects, more castings are produced accurately to specifications the first time, with a lower reject rate. That translates into energy savings by reducing the need for re-melting hot metal and re-making the mold.

"The EPA (Environmental Protection Agency) and the DNR (state Department of Natural Resources) love this thing," Peaslee said of the system helping to reduce greenhouse gases.

MGIF has been involved in energy reduction programs for several years, including participation in Focus on Energy audits.

"They look at lighting, heating, electric motors and target areas for savings … they know what changes can be good paybacks," Peaslee said.

"There are literally dozens of things that can and will be done related to energy savings," Peaslee said. "Even though (MGIF) is small compared to many others in the foundry industry, we are far ahead of the curve."

For example, MGIF has created a more efficient dust collector system. The air is re-filtered and goes back into the plant rather than vented to the outside.

The returned heated air reduces natural gas usage, especially in winter.

"People have asked me why I sign on (to government agency pledges, including with OSHA)," Peaslee said,.

"It's real simple … if you are not part of the solution, you are perceived to be part of the problem," Peaslee said. "I'd much rather do projects in cooperation with government than have oppressive oversight.

"Save Energy Now is an exciting thing to do," Peaslee said. "Potentially, we could be exposed to wonderful new technologies just because we are part of the process." as a freelancer, she spent a lot of time on tasks like sales and billing that weren't connected to the design work she actually wanted to be doing.

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