“It’s not easy to find a partner in the sand-casting space that can support prototyping and transition to production volumes for the relatively larger castings we need. Badger Alloys was able to leverage the things they learned in our prototyping to provide a quality product in production.
That complete level of service offerings is uncommon among casting suppliers.”
– Gary Provenzano, Vice President, Operations for Sapphire Technologies
Customer Profile
Sapphire Technologies develops and manufactures energy recovery systems that harness the power of gas expansion to produce reliable and clean electricity – reducing global carbon footprint. Their systems are designed to convert energy wasted in pressure reduction processes into electric power without interrupting operations. By recovering this wasted pressure energy, they help companies maximize plant efficiencies, improve productivity, reduce carbon emissions, offset electrical costs and generate cashflow.
Goal/Solution
To create its FreeSpin In-Line Turboexpander, Sapphire Technologies needed a full-service castings provider that could partner with them from start to finish. They sought a supplier that could take their project from a concept through to scaled production quantities. Sapphire Technologies selected Badger Alloys for our ability to:
Results/Benefits
A “Business Friend of the Environment” Award winner (Wisconsin Manufacturers & Commerce) and inaugural member of ME3 – Milwaukee Economy, Energy & Environment, Badger Alloys has consistently shown dedication to diminishing its own carbon footprint. When contacted by Sapphire Technologies to partner on this innovative, sustainable initiative, President & CEO Rob Cowen jumped at the challenge. “We strive to be at the forefront of technological innovation in all areas, and especially as it relates to environmental sustainability,” he said. “When we got the opportunity to work with a customer that is literally changing the landscape of the way we generate green energy, I knew it would be a successful partnership.”
Because Sapphire Technologies’ innovative products are first of their kind, Badger Alloys has grown with them. “Badger Alloys’ Engineering Team was able to leverage their knowledge and solidification analysis to develop pattern tooling from our models and experience they gained from the prototyping,” said Sapphire Technologies Vice President – Operations Gary Provenzano. “Working with their metallurgists and engineers, we ended up selecting a new material that meets our requirements, is easier to cast and is more cost effective.”
Sapphire Technologies has maximized the successful launch of their innovative product by leveraging every value-added service Badger Alloys has to offer in the casting manufacturing process. “That complete level of service offerings is uncommon among casting suppliers,” said Provenzano.
Sapphire Technologies Castings in Action
The Sapphire Technologies solutions convert otherwise wasted pressure energy into clean electric power. With an estimated output of 2.6 million kilowatts of green energy per year, one FreeSpin In-Line Turboexpander (FIT) can power 241 homes’ electricity use for one year or 7.5 million miles driven by an electric vehicle!
Badger Alloys is proud to partner with this forward-thinking company to provide innovative green energy solutions.
