Lethbridge Iron Works Co. Ltd. (Leth Iron) has been an important link in Alberta’s manufacturing sector since 1898, supporting industries from agriculture to construction with high-quality cast metal products. Today, the company operates two plants with more than 100,000 square feet of production space and employs 120 people.

“With many of our systems aging, we knew we had to find ways to run the facility more efficiently to stay competitive,” said Gowtham Boyala, Engineering Manager at Leth Iron. “We needed a clear picture of our operations so we could make smarter decisions and strengthen performance for the long term.”

After attending an informational webinar, Boyala and his team realized that ERA’s Strategic Energy Management for Industry program could provide exactly what they were missing. The program offers the structure, expertise, and support companies need to understand their energy use and strengthen performance.

Supported by the SEMI team, Leth Iron is participating in Strategic Energy Management training, a structured approach to improving energy performance. The training helps employees understand how the plant uses energy, allowing them to set goals and monitor progress. Through group training, coaching, and peer-to-peer learning, employees are gaining practical tools to integrate energy efficiency into daily operations.

“Energy awareness is now part of everyday decision making,” Boyala says. “People across the facility can use their training to spot issues early, adjust equipment use, and share new ideas that support efficiency.”

Through SEMI’s Capital Retrofits component, the company is now developing a major capital plan that includes a new moulding line designed to triple capacity while using power more efficiently than the system it will replace. Their goal is to save at least 1 to 2 per cent of energy at the facility.

SEMI has also created momentum beyond the plant. Leth Iron is now sharing its experience with peers through the American Foundry Society, contributing to events and offering lessons learned across the foundry industry.

By combining more than a century of experience with modern energy management tools, Leth Iron is showing how established manufacturers can unlock new efficiency, strengthen competitiveness, and chart a more sustainable path forward.

“As one of the highest energy users in the city, every improvement we make creates value for our community members,” Boyala adds. “SEMI has given us the insight and support to make meaningful changes, and we are genuinely grateful for the opportunity to strengthen our operation and our community.”

Quick Facts

• ERA’s SEMI program provides industrial and manufacturing facilities with funding support, expertise, and training in energy management.
• SEMI is a $50 million program, with funding provided by the Government of Alberta and Natural Resources Canada (NRCan). It is designed to help the province’s industrial and manufacturing sectors increase competitiveness, improve energy efficiency, and reduce greenhouse gas emissions.
• Lethbridge Iron Works Co. Ltd. was established in 1898 as a foundry providing cast iron parts to the nearby coal mines and agriculture industry. Today, the Leth Iron facility uses automated equipment to produce consistent high-quality castings that exceed the demands of industries ranging from agriculture to rail, to automotive and beyond.