Waupaca Foundry’s Plant 1 engineering and maintenance teams achieved a major milestone in worker safety and environmental health. In just under two weeks in 2024, the team completed a capital project at its gray iron foundry located on Division Street in Waupaca, Wis. A decades-old vibratory conveyor system was replaced with an upgraded, ergonomically designed solution that is already transforming daily life for operators sorting iron castings to blast equipment for cleaning and finishing to become finished parts.

The original vibratory system was removed and replaced with a conveyor system and surrounding infrastructure, including a new catwalk, ergonomic matting, and electrical and pneumatic upgrades. This wasn’t just an equipment swap; it was a complete rebuild of the area where iron castings are separated from the sand molds after they have cooled and solidified.

Engineering Manager Michael Barden emphasized that while the system at Plant 1 may resemble those at other facilities mechanically, it’s the first in Waupaca Foundry history where an operator directly works alongside the steel belt. This made safety and environmental health top priorities in redesign.

The original system used springs to lift or bounce iron castings slightly as they moved, causing fine dust to be released into the air and creating a loud clatter as metal hit metal. Before the upgrade, operators worked in high-noise, high-dust conditions, requiring double hearing protection and supplied air hood respirators to meet OSHA permissible limits for both noise and particulate matter. Despite previous attempts to lower noise and silica levels, none had delivered the needed results. 

"We had tried dust collection systems, noise barriers, and other solutions, but we couldn’t get ahead of it," said Barden. "This upgrade gave us the results we needed."

Those results are remarkable: According to Environmental Engineer Shianna Wheeler, the new equipment reduced silica exposure by an average of 98%, reclassifying the work area from a respirator-required zone to one where only basic PPE is necessary.

Cleaning Room Foreman Kevin Webster noted the impact firsthand. “Before the upgrade, the mill room team wore air hoods and double hearing protection daily,” Webster said. “Now, with the new equipment and better dust control, we’ve brought exposure way down. Cutting down on dust and noise means a safer, more enjoyable job for everyone in the department. And that’s something we can all feel good about. It’s made a noticeable difference for the team."

Noise levels in the area have dropped by 8%, eliminating the need for double hearing protection,
Wheeler said. Visibly, the workspace is cleaner and more orderly, proof that engineering, health, and morale can all move forward together. In addition, the new system is expected to reduce conveyor maintenance downtime, offsetting rising maintenance and energy costs.

By taking bold steps to replace outdated equipment and reimagine the space with employees in mind, Waupaca Foundry continues to live its values: investing in its people and shaping a better workplace for the future.