Doncasters Blaenavon Introduces Major Energy Efficiency Project


MELBOURNE, UK: The Doncasters Group has implemented a major energy efficiency project at Doncasters Blaenavon, which is set to reduce energy usage by 14%.

Explaining the rationale for the project, Eric J. Lewis, CEO, of the Doncasters Group
said: "Against the backdrop of global warming, adopting 'green' working practices is
essential for a business like Doncasters Blaenavon, which has high energy usage.
As a result we take environmental management very seriously and are committed to
reducing our carbon footprint at the same time as improving our business efficiency."

Doncasters Blaenavon, which manufactures forged rings, blades and discs for the
aerospace, industrial gas turbine and specialised engineering industries, has already
made significant strides in improving its energy efficiency and reducing carbon
emissions. As a result it has received significant rebates on the Government's
Climate Change Levy (CLL).

As part of its commitment to continuous improvement, the new energy efficiency
project - the introduction of an Energy Monitoring and Targeting System (EMaT) -
will build on this solid base and further reduce Doncasters Blaenavon's carbon
footprint.

Graham Cartwright, Energy Manager at Doncasters Blaenavon, said: "The new
EMaT means we will be able to improve the efficiency of the business further. It will
provide quantitative data that will allow us to examine each business process and
piece of plant, thereby giving us the information we need for making the decisions
that will ensure we continue to make improvements."

The EMaT is a combined hardware and software solution that uses advanced wireless technology. The solution at Doncasters Blaenavon consists of a number of transmitter modules spread around the site that use the WiSNet (Wireless Sensor Network) hardware to send data wirelessly to the server. The EMaT software provides an easy to use energy reporting tool that allows daily, weekly and monthly energy costs and consumption to be analysed quickly.

Graham Cartwright continued: "Individually configured, the system automatically
generates exception reports highlighting waste and has the ability to produce
statistical data for greater control. "It allows engineers to instantly identify energy wasteful practices whilst simultaneously providing a mechanism to gauge the benefits of implementing a series of energy related control actions. In this way, the performance of the plant down to individual machines can be benchmarked on a week by week basis.

"As well as supporting the management of our current energy usage the EMaT
enables scenario planning. The system is capable of targeting individual pieces of
plant facilitating 'what if' simulations prior to the implementation of a change. This
means we can continually search for and explore efficiencies and so continue to
reduce further our carbon footprint."

Doncasters Blaenavon is a part of Doncasters' aerospace division, a world leader in
the manufacture of components for the civil and military aero engine markets. The
company's clients include all the leading aero engine manufacturers such as Rolls-
Royce, Pratt & Whitney, GE, Snecma and MTU.

At the Blaenavon site, forged rings, casings, blades and discs for the aerospace,
industrial gas turbine and specialized engineering industries are manufactured using
materials such as nickel, cobalt, titanium, aluminium alloys and stainless steel.
Processes include: ring rolling; near net profiling; flash butt welding; and machining
and project management of engine ready parts.

The Doncasters Group is a leading international manufacturer that supplies precision
components and assemblies to the aerospace, power generation, specialty automotive and
medical orthopaedic industries. Doncasters excels in working with alloys and metals that are difficult to shape and form.

The company's unparalleled range of products and processes has been developed to offer
customers a broad, vertically integrated capability. Core manufacturing processes include precision casting, forging, fabrication, machining and production of superalloys.

Key products include airfoils, structures, casings, rings, exhausts and combustion
components for gas turbine applications, aerostructures and components for airframe
applications, femoral knees, tibial trays, humeral stems, femoral hips and bone plates for orthopaedic applications and compressor and turbine wheels for the turbocharger market. The company offers well-developed supply chain integration solutions, delivering complex assemblies and engine-ready components to its customers.
Doncasters employs some 4,700 people at over 20 sites across Europe, the USA and
Mexico. The Group has institutionalised lean manufacturing and Six Sigma principles
throughout its operations.

For more information contact:
Caroline Gamble, Doncasters Group Ltd.
T: 44 (0) 1332 864900
cgamble@doncasters.com

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