Sustaining excellence in automotive manufacturing

Alucast, a respected aluminium die-casting company based in the Black Country, specialises in high-integrity structural components for leading automotive brands, including Aston Martin and Bentley. With 100 skilled employees across four dedicated foundries, Alucast delivers precision-crafted chassis and suspension parts for the high- performance automotive sector. Recognised for exceptional quality, the company operates in an energy-intensive environment, where melting aluminium consumes substantial resources.

Navigating the energy cost challenge

With annual energy expenditures approaching £800,000, energy efficiency became a strategic imperative for Alucast. Rising costs, exacerbated by market volatility in 2022, prompted the management team to seek sustainable and economically viable solutions. Through the Decarbonisation Net Zero programme, Alucast embarked on a comprehensive energy audit, pinpointing precise opportunities to reduce consumption and enhance operational efficiency.

Pro Enviro’s detailed assessment recommended several impactful measures. These included installing 36 sub-meters to precisely monitor energy use, replacing outdated furnaces with energy-efficient models, upgrading furnace lids for better insulation, and repairing compressed air leaks to reduce unnecessary compressor workload. Pro Enviro facilitated the grant application process, securing matched funding towards Alucast’s investment, making the project financially viable.

Independence powered by innovation

Implementing these recommendations produced immediate and significant results, achieving considerable savings within the first six month. These improvements represent around 1 million kilowatt-hours saved annually, directly aligning with Alucast’s net-zero ambitions and significantly reducing the company’s carbon footprint.

Further, the installation of sub-meters has transformed Alucast’s operational culture, creating heightened awareness and responsibility among staff for energy use. Regular analysis of sub-meter data during daily operational meetings drives continual improvement and sustained efficiency.