For most foundries, electricity to power induction furnaces is the second most significant operating cost, after charge materials. As such, addressing rising energy costs is essential to economic survival. One foundry saw its power bill jump from $100,000/month to around $200,000/month over a five-month period, without increasing their production level.

The goal of any plan to limit the impact of rising energy costs must be to minimize a foundry’s energy cost per ton of metal produced. This approach encourages foundries to focus both on minimizing power costs by optimizing how they operate under their electrical rate structure, and on finding ways to increase production without increasing their electrical costs.

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