AB&I Foundry Increases Efficiencies in Manufacturing Cast Iron Pipe
March 7, 2017
AB&I FOUNDRY INCREASES EFFICIENCIES IN MANUFACTURING CAST IRON PIPE
Oakland, CA. March 7, 2017 – AB&I Foundry, an Oakland-based company that manufactures cast iron pipe and fittings for the plumbing industry, announces the successful installation of a specialized heat exchanger called a recuperator that increases manufacturing efficiencies in the melt operation.
The recuperator is a specialized heat exchanger that utilizes heat (energy) from the exhaust gasses and reheats the ambient air used in the combustion (melt) process. The new process reduces the need for natural gas and electricity used in the iron melting process – a $1M annual energy savings.
The recuperator was recycled from AB&I’s parent company and retrofitted for melting scrap metals into molten iron used to make cast iron pipe and fittings. “AB&I was able to reuse and repurpose a piece of equipment from a plant that had closed and incorporated it into our operation. We are continually identifying and implementing sustainable measures to save on natural resources,” said Dave Robinson, vice president of operations at AB&I Foundry.
“It’s impressive that AB&I could take a large hot-blast recuperator unit − not originally designed for AB&I’s melt system – retrofit it and make it work, while at the same time significantly improving efficiency in the foundry,” said Kurt Winter, executive vice president of McWane Plumbing Group. “The unit’s size provides system stability and allows for those times when pushing the melt rate to meet production requirements is necessary.”
AB&I moved the unit that weighs more than 74,000 pounds and is 65-feet long, from Alabama to its Oakland plant. Structural modifications were made to the cupola tower allowing the recuperator to be integrated it into the existing manufacturing operation.
Contact: Francesca Dunbar
Director of Group Marketing
About AB&I Foundry
AB&I Foundry, based in Oakland, CA, is a division of McWane, Inc. Born in the shadows of the Great San Francisco Earthquake of 1906, AB&I Foundry has been producing quality cast iron products for over a hundred years. Acquired by McWane in 2006, AB&I manufactures a full-line of cast iron soil pipe and fittings for DWV systems. In addition, AB&I has become a modern, highly-technological full- service provider of custom OEM gray iron castings for companies nationwide. Through a comprehensive program of water treatment, air pollution reduction, recycling, and solid-waste management, AB&I has set the standard for responsible foundry practices and policies.
About McWane Inc.
McWane, Inc. is a family-owned business based in Birmingham, Alabama, with companies across the U.S. and around the world. The McWane family of companies casts ductile iron products, including pipe, valves, hydrants, fittings and plumbing products; manufactures fire extinguishers, fire suppression systems and steel pressure vessels; and builds network switches and monitoring equipment. McWane is a leader in delivering clean, safe drinking water while focusing on safe, environmentally friendly manufacturing processes. With more than 7,000 team members, McWane has a longstanding commitment of supporting the communities where our team members live and work. For more information, visit mcwane.com.