BSC Die Casting & Finishing Ltd

BSC Die Casting & Finishing Ltd cast Zinc and Aluminium, perform plastic injection moulding and finishing and Aluminium die casting processes.

Client Summary

BSC Die Casting & Finishing Ltd cast Zinc and Aluminium, perform plastic injection moulding and finishing and Aluminium die casting processes. They are one of the largest independent die casting facilities in the UK, with over 82 employees. The dominant markets are window and door hardware, drinks dispensers, industrial cleaning, and HVAC systems.

Participating In The Programme

The company has strong low, and net-zero carbon strategies, integrated in their business growth strategy:
“We plan to embark on a managed three-year carbon reduction programme that will position us favourably with new and existing customers, save money and help us contribute to the health of the planet. ”
This is the main reason why they have registered to the BEAS Energy Intensive support programme.

How Rising Energy Costs Were Impacting Their Business

The inherent nature of the business is energy intensive. Tonnes of metal is heated up to 700°C to melt for the die casting process, which requires vast amounts of energy. As such, BSC Die Casting & Finishing were affected significantly by the recent rise in energy costs.

Insights from the Energy Assessment

Behavioural changes were recommended as a result of the assessment in order to minimise the waste heat escaping from the furnaces. It was noted during the review that there were significant compressed air leaks on site, contributing to an unnecessarily high baseload of electricity consumption. There are three 400-tonne capacity die casting machines (DCMs) which are 60 years old and inefficient. It was recommended to replace the die casting machines with new more energy efficient plant. Use of recuperative burners which capture the waste heat from flue gases was also recommended to reduce gas consumption of the furnace.

Impact of Implementing the Recommendations

As a result of the recommendations included in the report, BSC Die Casting and Finishing Ltd are expected to save 690,800 kWh, 134.5 tonnes CO2e and circa £55,000 per annum.

Testimonial

“From the first interaction with Pro Enviro we found the process to be very user friendly. The demonstrable knowledge and attitude of Nersi and James towards the programme, and the potential to help our business was galvanising. The insight and potential benefits we saw from the energy audit and subsequent reporting provided us with multiple practical and realistic opportunities to reduce our energy consumption, and carbon emissions. We have recommended the scheme and Pro Enviro to numerous other suppliers and customers. ”

Chris Dent, Operations Manager