Morrison Bros. Co. - Dubuque, Iowa
Forging ahead with energy-efficiency Located in the heart of the Midwest, Morrison Bros. Co. foundry specializes in providing small to medium runs of brass and aluminum alloys. But you could also say they specialize in keeping a step ahead of the competition. This Dubuque, Iowa, based business started in 1855 making boilers. By the turn of the century, they were fabricating tanks and equipment for the oil industry. Today, their products cover a broad spectrum of the industry, including tank trim for retail gasoline service stations, aboveground storage tank equipment, transportation, environmental monitoring, bulk fuel storage, and certain industrial applications for fuel and water systems. Being responsive to their customers' evolving needs requires that their facilities stay up-to-date and their operations stay lean.
That's why they are investing in energy efficiency.
"Our company is known industry-wide for being innovative, bringing new products to the market," said Fred Henneberry, Maintenance Supervisor at Morrison Bros.
"We work to make a difference in our field; it makes sense to do the same in our operations."
With that in mind, Morrison Bros. decided they wanted to incorporate energy-saving equipment and practices throughout their business. But where to start? In the fiery foundry area or the more temperate production, warehouse and office space? Should they focus on retrofitting existing buildings or new construction projects?
Alliant Energy identified a practical, simple and relatively inexpensive way to cut their current energy costs, lighting. They started by switching out the existing fixtures with T-8's throughout their warehouse and production facility. The new lighting not only saves money, but also creates a well-lit, safer environment for the workers. Energy-efficient lighting also played a major role in their new addition: more warehouse and office space.
"We recommended they use our Commercial New Construction program," said Craig Clefisch, Key Account Manager for Alliant Energy. "Energy efficiency is built in from the beginning, starting with free custom energy design - it's tailored to the specific needs of each building and business." Commercial New Construction (CNC) starts early in the design phase with analysis of the plans to identify a mix of cost-effective strategies that curtail energy waste.
"Because this was mostly office space and storage, they focused on lighting and the HVAC system," said Henneberry. "Heating and cooling this type of space is, of course, less challenging than in our foundry and production areas, but it's amazing how a right-sized HVAC system can cut costs and provide a consistently comfortable work area."
The lighting and HVAC system in their new addition saves Morrison Bros. Co. 19,369 kWh annually, saving them an estimated $5,500 a year on their energy costs. The T-8's throughout the rest of the facility conserve 6,000 kWh per year, bringing their energy savings grand total to 25,369 kWh per year.
Using CNC for the new addition saved money on the project itself. Alliant Energy pays all or most of the design team expenses related to working with an energy consultant. Project owners also earn incentives for implementing recommended strategies that result in energy savings of at least 15 percent better than energy code. That netted Morrison Bros. an additional $968 in incentives.
The lighting project in their existing buildings qualified for Alliant Energy's Cash-Back Rewards, a prescriptive rebate program for business customers. They earned $1,909 in Cash-Back Rewards.
"Lighting is just the beginning,” said Henneberry. "It's helped us reduce our operating costs, and gives us the opportunity to pursue strategies that directly affect the foundry and production processes."
"It ranges from simple tuning and maintenance procedures to heat recapturing systems and isolating furnaces," said Clefisch. "Our energy-expertise can help them prioritize their projects, plus our Custom Rebates, Commercial New Construction and prescriptive rebate programs can make it more cost effective."
"Not to mention more environmentally responsible. You don't normally associate the primary metals industry with being green - but it is possible," said Henneberry. "We're a company built on innovation, and working with Alliant Energy to become more energy-efficient and green fits well with that philosophy."
To learn more about Energy Efficiency programs from Alliant Energy visit www.alliantenergy.com/business or call 1-866-ALLIANT (1-866-255-4268).
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