Pacific Alloy Casting Company is a 70-year-old modern foundry that produces high-quality iron and steel castings, and gray and ductile irons used for common industrial castings. In their flexible manufacturing facilities, Pacific Alloy applies advanced foundry technology to comprehensively provide casting design assistance, pattern construction, casting production, and finish machining for a number of industries. Pacific Alloy’s castings range from a few ounces to 12,000 pounds and include pump parts, crusher parts, agricultural products, asphalt products, surface mining products, HSI blow bars, and progressive cavity pumps.

Pacific Alloy is a foundry focused on reducing costs, eliminating waste, and maximizing returns on investments, which led them to seek an energy management system that would lower their power bill and improve the efficiency of their operations. To determine the potential for savings, Powerit Solutions conducted an energy assessment at the plant, identified controllable loads with plant personnel, and concluded that the Powerit Solutions’ system could effectively control furnace loads to offset demand charges without adversely affecting production rates, building safety, or building comfort. The initial load strategy was to minimize coincident peak demand during the operation of the facility’s two largest loads, a 600 kW induction furnace and a 1500 kW induction furnace.