Delivering Excellence & Reducing Carbon Emissions

Updating Air Systems Results in Efficiency, Substantial Savings

Foundry, a family-owned, fourth-generation company in Beaver Dam, Wisconsin, regularly reinvests in its foundry’s systems to make its iron casting facility safer and more efficient.

Working with Wasmer Company of Sheboygan, Wisc., Kirsh recently undertook a review of its compressed air system and nitrogen supply, both mission critical.

Safety and efficiency were achieved with an added bonus of removing greenhouse gas emissions equal to 86 cars.

Compressed air operates many of the systems in the foundry. Tools in every step of the process — from molding to finishing customer parts — depend on compressed air. However, as Kirsh’s compressed air system aged, it became less efficient. An inefficient piping layout, as well as leaks in Kirsh’s existing system meant much more compressed air was being used than was needed. This cost the company money during every hour of operation.

Pipes were re-routed and leaks were addressed, greatly increasing system functionality and safety. The cost savings were substantial and operational improvement was immediate.

Nitrogen supplies are subject to great price volatility. In this case, Wasmer suggested Kirsh generate its own nitrogen rather than rely on outside suppliers. Again, the investment provided instantaneous return on both function and cost.

The energy cost savings for the complete project were nearly $50,000 in the first year. Installation of the nitrogen generation plant resulted in $8,602 in savings. The project paid for itself in less than 18 months.

The added benefit of this work is Kirsh’s carbon footprint reduction. By fixing systems that were inefficient and costly, Kirsh reduced their energy usage by 550,874 kWh, equivalent to the carbon dioxide absorbed by planting 8,125 trees and removing those 85 cars from the road.

Kirsh’s history of innovation goes beyond costs to delivering excellence for our employees, our community and our customers.