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Metaldyne International UK Ltd


Metaldyne is a leading global designer and supplier of metal-formed components and assemblies for powertrain applications including engine connecting rods, transmission valve bodies, forged and finished differential gears and pinions, differential assemblies, balance shaft modules, crankshaft dampers and crankshaft pulleys.

With a core competency in metalworking, Metaldyne hold a renowned reputation for their technical capability and quality product.


Metaldyne prioritise their environmental efforts in a bid to reduce their carbon footprint. Their global locations continually seek out new ways to conserve energy, reduce carbon emissions and optimise performance.

All of the Metaldyne locations are ISO 14001 compliant.


As Metaldyne continually strive for unrivalled excellence in design, development and innovation, they aim to ensure that their practices cause minimal environmental impact.

Carbon reduction and energy management strategies are robustly supported and Metaldyne are active in their efforts to identify, assess and implement new energy reducing initiatives.

As manufacturers themselves of high quality, precision technology, Metaldyne actively seek out energy reducing technologies which guarantee reliability, efficiency and consistent performance.


Metaldyne identified Voltage Optimisation as an ideal solution to implement on their sites offering as it does significant energy savings as well as other benefits such as improved power quality.

Powerstar, fully manufactured in the UK and offering guaranteed results, was selected as the preferred Voltage Optimisation system giving Metaldyne complete confidence in the quality, pedigree and technical excellence of the solution they were investing in.

Powerstar’s proven track record of reliability, as well as 100% guaranteed savings further supported the decision to invest.

Powerstar’s engineering and projects team worked closely with Metaldyne throughout and the surveys, installation and commissioning were carried out seamlessly and without disruptions to business activity.

Metaldyne Powerstar installation


Powerstar was installed at Metaldyne’s Halifax branch during May 2013.

Electricity consumption savings were guaranteed to be at least 3.7%. Analysis of the site’s electricity data shows an 8.3% annual electricity consumption saving following the installation of Powerstar.

This equates to a 322,569kWh reduction per annum or a £26,612 per year, straight to the bottom line.

Equally important, through reduced electricity consumption Metaldyne have significantly reduced their impact on the environment, saving 169.2 tonnes of CO2. per annum.

Additional to the carbon and financial savings achieved, Metaldyne are also benefiting from prolonged life expectancy of electrical equipment and a guaranteed ROI.


“After looking around the market for Voltage Optimisation units, we found that EMSc (UK) Ltd’s Powerstar unit provided the best overall evaluation of our site, most realistic cost savings and after a seamless installation, they have certainly delivered what was forecast in the way of cost savings for our business.

As we are working to reduce our energy consumption and CO2 emissions with various projects, to get a saving at source is always a bonus, and will add to the savings some of our projects are already making.”

Matthew Sykes

Maintenance Leader & EHS Coordinator


Figure 1: Average consumption by half hour comparing pre and post Powerstar install at Metaldyne Int (UK) Ltd.

Figure 1 above shows the average consumption by half hourly periods pre and post Powerstar install at Metaldyne Int (UK) Ltd.

The blue line shows the kWh pre Powerstar install and the green line shows post install kWh.

It is clear to see the significant reduction in kWh as a result of the successful implementation of this project as well as the overall cost, efficiency and environmental benefits to Metaldyne.

View the Case Study PDF Here


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