Pennex Aluminum, a foundry located in Wellsville, PA, operates an energy-intensive process involving melting, casting, and finishing aluminum products. With high fuel and electricity requirements, energy costs represented a significant share of operating expenses. To address these challenges, Pennex partnered with the Industrial Training and Assessment Center (ITAC) program. In February 2006, an ITAC team conducted a no-cost, on-site energy assessment of the facility.
The assessment identified several opportunities to reduce energy use and costs. Key recommendations included repairing compressed air leaks, improving furnace insulation, and optimizing motor systems. The ITAC also advised implementing better maintenance practices to ensure equipment efficiency over the long term. These targeted improvements provided a balance of quick-payback fixes and medium-term capital investments, allowing Pennex to plan implementation in phases.
By acting on the ITAC’s recommendations, Pennex achieved more than $60,000 in annual energy savings, with many measures paying back in less than two years. Beyond financial savings, the improvements enhanced furnace reliability, reduced wasted energy, and lowered greenhouse gas emissions associated with foundry operations.
This case highlights how ITAC assessments bring value even to highly energy-intensive industries. For Pennex Aluminum, the assessment delivered both immediate cost reductions and long-term improvements, strengthening competitiveness in the metals sector.