--- title: How MAC Pulse Valves Improved Energy Efficiency at a Smelter description: Learn how NEFF worked with a leading aluminum smelting company to promote sustainability and boost energy efficiency with MAC Pulse Valves image: https://neffautomation.com/hubfs/SACaseStudy-Images-01-01.png --- # How MAC Pulse Valves Improved Energy Efficiency at a Smelter ![Aluminum Smelting Dust Collection System](https://neffautomation.com/hs-fs/hubfs/SACaseStudy-Images-01-01.png?width=962&height=680&name=SACaseStudy-Images-01-01.png) Industry Metals Challenge The customer was facing issues with their baghouse. High energy costs and frequent valve changes drove them to look for better options. Results After testing 95 MAC Pulse Valves and seeing instant results, the Aluminum Smelter decided to go ahead with over 300 total valves, completely eliminating their previous diaphragm valves. This results in nearly $65K of annual energy, filter life, and maintenance savings. [ neffautomation.com/macvalves ](https://neffautomation.com/macvalves?hsLang=en) 300+ Valves installed 0.73 ROI in Years $65K Annual cost savings ## "We're not having the same problems, less repairs are needed, and we knew this would help reduce compressed air." ![](https://neffautomation.com/hubfs/Untitled-1-01-3.png) Maintenance Manager Leading Aluminum Smelting Company ![Aluminum Smelting](https://neffautomation.com/hs-fs/hubfs/SACaseStudy-Images-02.png?width=580&height=410&name=SACaseStudy-Images-02.png) ## Aluminum Smelting Aluminum smelting is a critical step in creating pure aluminum alloy for use in the transportation, construction, and packaging industries. Dust, gas, and other byproducts are generated that effect air quality, which is tightly monitored for workplace safety. Traditional filtration and dust collection systems are utilized to improve air quality, but these systems are often equipped with outdated valve technology that can lead to poor sustainability and high energy usage. ## The Challenge NEFF Automation recently worked with a leading aluminum smelting company that was facing two major problems with their dust collection system: 1. **High Maintenance Costs:** Daily maintenance demands were straining resources and causing operational inefficiencies. 2. **Excessive Air Consumption:** Leaking valves, which the company wasn’t even aware of, were driving up air consumption, leading to significant energy waste and added costs. It’s easy to see how these issues were a constant headache. Maintenance problems slow down production, and leaking valves are essentially money slipping away. NEFF identified the baghouse as an area of focus for process improvement and energy savings. The benefits of switching to MAC Pulse Valves include increased cleaning capacity per pulse, reduced compressed air demand, extended bag life, and much more.   ## The Solution ![Pulse Valve Installation](https://neffautomation.com/hs-fs/hubfs/SACaseStudy-Images-01-03.png?width=768&height=543&name=SACaseStudy-Images-01-03.png)Once the customer's problems were clearly identified, NEFF brought in a demo case so the aluminum smelting company could see how MAC's Pulse Valve technology worked. This demonstration made the customer confident that switching from their old diaphragm valves to MAC Pulse Valves would promote sustainability and energy efficiency.  > **"****I haven't seen one negative thing on the valves that we have installed."** Maintenance Manager @ Leading Aluminum Smelter Company ## The Results ![MAC Pulse Valves](https://neffautomation.com/hs-fs/hubfs/SACaseStudy-Images-01-02.png?width=962&height=680&name=SACaseStudy-Images-01-02.png)Initially, the customer was going to test 95 valves for one bag house. Because of the customer's confidence in NEFF's products, evaluation process, and a strong projected ROI, the customer decided to skip the trial process and go with a full-plant conversion! NEFF Automation supports metal manufacturers across the Midwest and Northeast by implementing cost-effective, sustainable solutions that promote energy efficiency and operational cost reduction. Watch the case study video below:   ## Start Your Dust Collection Initiative With NEFF Automation [![Get a Quote](https://no-cache.hubspot.com/cta/default/24279054/interactive-179452982346.png) ](https://neffautomation.com/hs/cta/wi/redirect?encryptedPayload=AVxigLJ8N45ugo0IhVXFmt7OS98yeRDpGppn64c0%2BH5Nx0XPTFsELPL7PCYKmlw2oo%2BV2MR0LI9v7sAL3brThE7ADEyrPBS6p6sY5I4STZaFhZfe%2Bv03vD8M1MkLV4XXOr2OITdWsnhK3%2Bemmgso965N5aMF%2FEqYZrXky%2FjobqKKAWLPbZBq%2F5I%3D&webInteractiveContentId=179452982346&portalId=24279054&hsLang=en) ## Related case studies ```json { "@context" : "https://schema.org", "@type" : "Organization", "address" : { "@type" : "PostalAddress", "addressCountry" : "US", "addressLocality" : "Indianapolis", "addressRegion" : "IN", "postalCode" : "46256", "streetAddress" : "9325 Uptown Drive - Suite 100" }, "areaServed" : [ { "@type" : "State", "name" : "Connecticut" }, { "@type" : "State", "name" : "Indiana" }, { "@type" : "State", "name" : "Kentucky" }, { "@type" : "State", "name" : "Maine" }, { "@type" : "State", "name" : "Massachusetts" }, { "@type" : "State", "name" : "Michigan" }, { "@type" : "State", "name" : "New Hampshire" }, { "@type" : "State", "name" : "New Jersey" }, { "@type" : "State", "name" : "New York" }, { "@type" : "State", "name" : "Ohio" }, { "@type" : "State", "name" : "Pennsylvania" }, { "@type" : "State", "name" : "Rhode Island" }, { "@type" : "State", "name" : "Vermont" }, { "@type" : "State", "name" : "West Virginia" }, { "@type" : "State", "name" : "Wisconsin" } ], "description" : "Industrial automation solutions including electrical components, machine safety, vision systems, motion control, pneumatics, robotics, sensing, and structural systems serving Connecticut, Indiana, Kentucky, Maine, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin", "email" : "sales@neffautomation.com", "hasOfferCatalog" : { "@type" : "OfferCatalog", "itemListElement" : [ { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Cabinet interface solutions, cordsets, IO-systems, networking equipment, and electrical automation components", "name" : "Electrical Components" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Optoelectronic sensors, safety relays, light curtains, and industrial safety systems", "name" : "Machine Safety Technology" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Industrial machine vision, traceability systems, quality inspection, optical character recognition (OCR), and robotic guidance solutions", "name" : "Machine Vision Systems" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Motion controllers, servo motors, stepper motors, drives, conveyors, and electro-mechanical solutions", "name" : "Motion Control Systems" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Air valves, vacuum systems, pneumatic actuators, cylinders, air preparation equipment, and pneumatic technology", "name" : "Pneumatic Components" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Traditional industrial robots, collaborative robots (cobots), machine tending solutions, welding automation, and palletizing systems", "name" : "Industrial Robotics" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Object detection sensors, proximity sensors, photoelectric sensors, and sensors for extreme industrial environments", "name" : "Industrial Sensors" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "T-slot aluminum profiles, extrusions, and structural components for automation projects and machine frames", "name" : "Structural Framing Systems" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Industrial power supplies, DIN rail power supplies, and power distribution equipment", "name" : "Power Supply Units" } }, { "@type" : "Offer", "itemOffered" : { "@type" : "Product", "description" : "Managed and unmanaged industrial Ethernet switches for factory networks", "name" : "Industrial Ethernet Switches" } } ], "name" : "Industrial Automation Products & Solutions" }, "logo" : "https://neffautomation.com/hubfs/24279054/NEFF_Logo_300dpi-01.png", "name" : "NEFF Automation", "sameAs" : [ "https://www.linkedin.com/company/neff-automation/", "https://www.facebook.com/neffautomationsolutions", "https://www.youtube.com/@neffautomationexperts3632" ], "telephone" : "+1-317-841-9244", "url" : "https://neffautomation.com" } ```