2 BK SP MKT GlobalEyes Edition 17 November 2015_English - page 3

The implementation of Eco-friendly practices and environmental programs,
even seemingly simple ones, is about more than just checking boxes and
being seen to be ‘green’. The sustainable use of energy and key resources for
manufacturing operations like Bradken can have a significant financial impact,
particularly in times of lower work volumes.
A number of Bradken’s Australian foundries have felt the burden of high energy
usage and waste disposal costs of late and have successfully completed
projects to help alleviate the strain.
In April 2015 Bradken’s Acacia Ridge foundry in Queensland completed an energy
efficiency project to combat the high level of peak demand (kWh) the site was drawing
from the network. Our foundries require large amounts of energy to melt scrap metal to
produce new castings (up to 60% of electricity use). The team at Acacia Ridge installed
a live data usage metre incorporating a digital display unit adjacent to the furnace
melting deck which sources accurate and timely energy usage information directly from
the mains heating circuit.
While the constant management of furnace demand proved challenging, the drive from
the site to accomplish significant savings ensured a constructive effort enabling the
site to achieve immediate results. The site has been able to sustainably decrease peak
demand power spend by 30%, and overall reduce the electricity component of the cost
per dressed kilo of manufactured goods from $2.58 to $2.00 (AUD). The unit had a
payback within less than one month and enabled the site to avoid the need to pass on
any manufacturing cost increases to customers.
In December 2014 Bradken’s foundry in Wodonga, Victoria
completed a $6,700,000 project to update the site’s sand
reclamation system in response to increasing waste disposal
costs and difficulty in developing beneficial off site sand
reuse projects.
The new system provides increased sand reclamation
capabilities for the hard sand system allowing moulds to be
produced with up to 75% used sand, reducing the amount
of new sand being purchased and as well as the amount
of spent sand being sent off site. It is estimated that this
upgrade will lead to an annual cost saving of $450,000
based on current production levels.
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