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.
Warm Reception For Heat Recovery Project
Every year the Waupaca Foundry plants across the U.S. melt more than 2.2 million tons of scrap metal. As you can imagine, this intensive energy process gives off an abundance of heat.
Clear Skies with Advanced Baghouse Technology
Creating thousands of castings per day can be a dirty job. Dust, sand and other particles move throughout the foundry air, but thanks to Waupaca Foundry’s air-filtration system and advanced baghouse technology, we keep the air as clean as possible inside the plant and outside in the blue sky above.
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.
Reshoring Helps Home Fitness Company Meet Consumer Demand
A U.S.-based fitness equipment manufacturer localized three new assembly and manufacturing lines, as well as a majority of its parts and component supply chain. Ballooning consumer demand for at-home exercise accessories strained its off-short supply chain. Partnering with Waupaca Foundry as its casting supplier allows the company to save money and streamline assembly processes within the United States.
High-Strength Ductile Iron Control Arm Meets Lightweighting Objectives
Aluminum components are often utilized for their lightweight capabilities in the automotive industry. However, Waupaca Foundry, in collaboration with Hitachi Metals America, successfully converted the Ford CD4 platform lower control arm from aluminum to high-strength ductile iron, not only achieving weight and cost savings for the company but also relieving the company’s supply chain that was facing disruption due to the high volume of production.
Innovation and Problem-Solving Mitigate Supply Chain Risk
Through collaborative engineering and a prototype 3D-printed core assembly, Waupaca Foundry provided a solution that could improve quality, delivery and cost for a compressor body already in production. It also meant reliably changing the iron casting manufacturing process from horizontal to vertical molding, as well as reshoring the part to a U.S. supply base—with complete peace of mind.
Ensuring an Environmentally Brighter Future
In 2013, Waupaca Foundry launched an initiative to begin retrofitting its six locations with LED light fixtures. Replacing all lighting units in Waupaca Foundry’s total 2.2 million square feet of plant space could save upwards of 40 million kilowatt hours per year.