Investment Casting in Utah: A Sustainable Approach to Manufacturing
According to the U.S. Energy Information Administration, Utah's industrial sector consumes a quarter of the region's power, and the state's power grid is the largest consumer of natural gas in the area. As such, ensuring that Utah's manufacturing efforts adopt sustainable and eco-friendly options can make the sector much more energy-efficient.
Many businesses now use investment casting in Utah as a sustainable method of manufacturing products. However, how do these efforts position Utah as a leader in green solutions?
Read on to discover how investment casting:
Supports the region's eco-friendly industrial process goals
Allow the region to boost its manufacturing output
Cuts emissions with the use of optimized supply chains
Contribute to environmental sustainability
Position Utah as a pioneer in green standards
Discover what Utah can get out of such efforts today.
Why Utah Leads in Sustainable Investment Casting
Over the past few decades, Utah foundries have grown closer in their collaboration efforts.
As such, in recent years, they have fostered further innovation, leading to greater sustainability.
Some of the ways it has done this include adopting:
Easier access to raw materials to reduce the region's carbon footprint
Sustainable manufacturing methods to meet local government initiatives
Foundries closer to other facilities to reduce transportation needs
Workforce training programs with a focus on green casting techniques
Utah Valley University and Salt Lake Community College even provide specialized programs that support the local area. The university offers a proficiency certificate in Advanced Manufacturing, for example, which students can leverage to ensure they have the right skills to enter the workforce with entry-level manufacturing technician skills.
These advancements have allowed a portion of the population involved in the manufacturing industry to understand and grow their expertise in sustainability. As such, many foundries in Utah now use investment casting, which has come alongside efforts related to:
Recycling programs to reduce material waste
Flashfire systems to minimize the environmental impact of manufacturing
Research to discover more green manufacturing solutions
Leveraging environmentally friendly materials in investment casting
While many other areas of the industry use similar methods, it is essential to note that investment casting itself is part of an active effort to promote more sustainable manufacturing. Due to its efficiency, the process is inherently more sustainable than many other manufacturing efforts.
The process produces significantly less material waste and reduces both the need for excess machining and the creation of scrap material.
Eco-Friendly Materials and Processes in Utah's Investment Casting
Utah's foundries have actively leveraged green technology to reduce operational costs and carbon emissions. With various government initiatives, this reduced output of pollutants saves businesses from further expenses.
Leveraging Advanced Manufacturing Equipment
Newer equipment, such as computer numerical control machines (CNC) or 3D printing for mold creation, allow foundries to produce near-net-shape parts. These create more accurate results, reducing the machining efforts needed after casting and reducing excess material and energy usage.
Prioritizing Circular Production Systems
Local industries can reduce the amount of material needed in future production cycles by reusing waste materials such as:
Spent sand
Wax from molds
Water
Scrap metal
Some industrial practices even allow the amount of material recovered to be up to 95%, meaning an extremely high level of reusability and minimal need for renewing manufacturing resources. This saving reduces the environmental impacts of mining and transporting raw materials and dramatically reduces foundry operational costs.
Energy-Efficient Furnaces and Other Technological Updates
Many foundries in Utah now use induction furnaces to reduce their energy needs compared to more traditional gas-fired furnaces. These furnaces also use modern insulation to minimize heat loss, and improvements are regularly made to their construction to improve energy retention as workers operate them.
Modern technology also allows workers to monitor their energy output, helping them adjust the furnace settings automatically to optimize heat retention. Together, these efforts lower each furnace's operational costs and reduce its energy consumption during the casting process.
More reliable and stable temperatures also reduce the thermal effect foundries face, increasing the lifespan of investment casting equipment due to reduced damage.
Implementation of Energy-Efficient Flashfire Systems
Flashfire systems help with the mold-cleaning process by burning off wax residue. In doing so, they thoroughly clean the mold using significantly less energy and water than other methods.
Flashfire methods are faster than many other production methods, saving the manufacturer time and money that they reinvest elsewhere in the business.
Renewable Energy Use in Foundries
Many of Utah's investment casting foundries have started integrating renewable energy sources into their operations. By installing solar panels or leveraging renewable energy credits to offset their carbon footprint, they reduce their greenhouse gas emissions. This effort positions the state as a model for integrating clean energy into their local industrial processes.
Smart Manufacturing
Foundries in Utah have begun adopting Internet of Things (IoT) monitoring systems to help them track their energy consumption in real time. IoT technology allows them to detect when a facility suddenly falls behind in sustainability, allowing them to send maintenance or repair crews to the area.
These sudden drops in sustainability often indicate a failure or reduction in quality or speed. Addressing these issues also helps the foundry maintain a competitive edge and boost its output.
Use of Biodegradable and Recyclable Mold Materials
Recent research into biodegradable ceramics and eco-friendly casting binders has allowed foundries to create molds that break down more easily and naturally once used. Alternatively, they can more easily reclaim other molds for additional use.
Doing this reduces landfill waste and also positions the very act of environmental consciousness as a money-saving effort.
Driving Sustainability with Investment Casting in Utah
Investment Casting in Utah offers a clear advancement in eco-friendly manufacturing in the region, which other industrial processes should use as a benchmark. Investment casting leverages advanced technology and, alongside the state's investment in local talent, positions Utah as a leader in green manufacturing.
Our specialists at IPC Foundry are happy to discuss the nuances of these efforts. We are committed to renewable energy and waste reduction during the casting process to ensure long-term benefits, successful green efforts, and consistent savings during manufacturing. Contact us to learn more and see how our efforts can benefit you.
Image Attribution:
Pixabay.com royalty-free image #3180684, 'bronze casting, bronze, fluid' uploaded by user Valeryna, retrieved from https://pixabay.com/photos/bronze-casting-bronze-fluid-metal-3180684/ on September 15th, 2021. License details available at https://pixabay.com/en/service/terms/#usage - image is licensed under Creative Commons CC0 license