Waupaca Foundry’s casting processes require large volumes of sand, which is continually used, reconditioned and reused. Sand shaken off of completed castings is recaptured and recycled in the process. More than 800,000 tons of sand is re-used each year.
Sand that can no longer be used for creating quality iron castings does not have to end up in a landfill. Over 70% of the sand used for making castings is recycled every year. This ‘spent’ sand finds new life in applications from road and general construction, and agricultural use to and geotechnical fill. It adds up to over 400,000 tons! It keeps the sand out of landfills and reduces the need for mining new materials.
The sand used in the casting process could be the roadbed you drive on to get to one of the plants.
ECO-PARK Created with Foundry Sand
Thousands of tons of foundry sand that could no longer be reconditioned and reused to make molds avoided the landfill and was instead put to good use. That sand is now benefitting the community of Waupaca, Wisconsin through a unique development project.
Local Population Reaps the Benefits of Repurposed Sand
Etowah, Tennessee, is home to Waupaca Foundry Plant 6. It is also home to a lot of cows. The care of the bovine population had become increasingly difficult for the McMinn County dairy farmers due to the scarcity of affordable sand bedding.
Utilities Benefit From Foundry By-Product
Once upon a time, foundry slag had a boring reputation. Its unglamorous name was synonymous with unwanted leftovers. You could imagine it as the unfortunate, unusable “eggshells” tossed away after the “omelet” was made, relegated to linger in landfills.
Having a Say in the Lay of the Land
The land around the church wasn’t very useful — the ground was uneven, making construction projects nearly impossible. Partnering with the congregation community, however, Waupaca Foundry helped make a dream project become reality.
Improved Parking Is A Lifesaver
For Waupaca Foundry Plant 5, the existing parking and access road configuration leave a lot to be desired. So when we set about improving the situation, we were determined to get it right—and include a few bonus improvements for the community along the way.
Winter Thrills Begin with Foundry Sand
At Waupaca Foundry, we believe it’s imperative to continue finding smarter ways to use our natural resources—recycling, repurposing, and reusing materials everywhere we can.
Foundry Sand Reused for Environmental Benefits
Clay may seem like an uninteresting topic, but for many industries having a supply of the proper type of clay can be critical. The landfill industry, among others including the agriculture and general construction industries, have applications which demand low hydraulic conductivity barriers.
Foundry Sand Reclaims the Land, Makes the Grade
Waupaca Foundry has a long history of reusing foundry sand as many times as possible in the production of iron castings. Then, Waupaca Foundry promotes environmentally beneficial strategies to repurpose these sands, as well as slags and sand fines, that can no longer be used in the casting process.
Fine-Feathered Farm Gets New Foundation Using Foundry Sand
The Stein Turkey Farm in Evanston, Indiana, is a successful contract turkey operation, totaling 230 acres of land, five 20,000-square-foot buildings, and the capacity to market 100,000 poults (chicks) yearly. Essential to its continued success is ensuring a healthy environment for its turkey tenants.
Foundry Sand a Big Help to Farmers
Waupaca Foundry is proud of its sustainability efforts. In the case of reusing foundry sand, thousands of tons are kept out of landfills each year, which is good for the foundry, good for the environment, and good for farms. It’s a win-win-win.