Waupaca cuts energy use, earns award

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By The Staff

TELL CITY - Thyssen-Krupp Waupaca Inc. recently earned an environmental- stewardship award from Energy Management Systems Inc. for significantly reducing its energy consumption, according to a news release from Kiley Kellermeyer, account executive with MZD Advertising, Marketing and Public Relations, Indianapolis,

Waupaca "leads their industry in energy efficiency by continually implementing innovative solutions," Kellermeyer wrote. "Through changes made by EMS, the ... plant in Tell City, Ind. has reduced its air pollution by 4,984 tons of (carbon dioxide) per year, the equivalent of taking 14,160 cars off the road over the next 20 years or enough energy to power 411 homes - a step that will make a big difference to the world."

"We wanted to implement an energy reduction plan to control our costs," said Dale Gengelbach, engineering manager for ThyssenKrupp Waupaca. "These cost savings will help us to stay competitive in our industry."

Gengelbach achieved this goal, too, as EMS is estimated to have helped the company save almost $700,000 annually on gas and electric charges, Kellermeyer wrote, and an additional $164,362 through a federal tax deduction contained in the Energy Policy Act of 2005.

According to Gengelbach, the heating, ventilating and air-conditioning system in the plant was leaking energy - a serious problem, both financially and environmentally. The equipment could only be controlled manually, which was time-consuming, and much of the equipment was left on or off at the wrong times. As a result, energy was being wasted and energy costs were rising, affecting the profitability of the plant. Maintenance costs were also too high.

Gengelbach began consultations with EMS, and together, Waupaca and EMS came up with a plan to fit the plant's demands, Kellermeyer wrote.

"EMS's turnkey process provided the best vehicle to get us there. Without the EMS system we had no control," added Gengelbach.

Through the installation of an energy-management system, Waupaca can now monitor and control all of their HVAC equipment from one computer. Their new system saves money by reducing energy consumption and saves time in managing and controlling it.

From the energy audit to the complete installation, Waupaca saw savings in their books and to the environment in less than six months.

For his part, Gengelbach is pleased with the system.

"It is working great," he said. "We are finding more and more ways to capture savings without compromising the plant and its employees."

ThyssenKrupp Waupaca is a TS-16949- , ISO 14001- , and OHSAS 18001-certified producer of gray, ductile and compacted graphite iron castings, melting more than 9,500 tons per day. It has plants in six locations, including Tell City.