Production, Pattern, and Foundry (PPF)
The Client
Production, Pattern, and Foundry (PPF), located in Mound House,Nevada, manufactures advanced aluminum casting solutions from concept throughfull production. The facility includes three buildings totaling approximately120,000 square feet, housing a main foundry, machine shop, and paint shop. PPFproduces high-quality aluminum castings using both greensand and permanent mold processes and employs approximately 75 people at the primary facility.
The Challenge
PPF faced significant energy consumption challenges driven by its aluminum melting and casting operations, which require intensive use of electricity and natural gas. The company lacked energy monitoring systems and efficient process controls, making it difficult to identify inefficiencies and manage costs. Additionally, aging equipment, inefficient heating practices, and rising energy costs created a need for a comprehensive strategy to reduce operating expenses while maintaining production performance.
The Solution and Manufacture Nevada's Role
Manufacture Nevada conducted a comprehensive Energy Audit aligned with ASHRAE standards across PPF's three manufacturing facilities. The assessment evaluated major energy-consuming systems and equipment throughout the operation, including lighting, compressed air systems, motors, and production equipment. Through the audit process, Manufacture Nevada provided detailed insights into facility energy usage, identified opportunities for efficiency improvements, and established a baseline for future energy management and investment decisions.
Results
- Improved visibility into energy consumption across three manufacturing facilities.
- Identified potential efficiency improvements related to lighting, compressed air systems, motors, and other equipment.
- Established a baseline for future energy planning and capital investment decisions.
- Highlighted opportunities for long-term utility cost savings and operational efficiencies.
- Created a roadmap to support future energy-saving initiatives as funding and business priorities allow.
Expected Impacts
- Up to 44% reduction in total energy costs through combined efficiency measures
- 36% reduction in carbon emissions (approximately 1.95 million pounds of CO2 annually)
- Identification of $38,000 in additional savings through utility rate
PPF's Testimonial on Manufacture Nevada's Impact
"The audit provided useful information that will help guide future energy-saving initiatives as funding and business priorities allow." — Tiffany Schembre, Client Relationship and Sales Manager
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