Waupaca Foundry, a world-class manufacturer of ductile and gray iron castings, has long prioritized sustainability in its operations. By implementing advanced sand reclamation processes across multiple locations, Waupaca has significantly minimized its environmental impact while reducing costs through sand reuse. Central to this transformation is a 3-step process featuring two Simpson Pro-Claim systems—one at the beginning and one at the end—with a thermal reclamation unit in the middle. This arrangement creates a highly efficient green sand to core sand reuse process.
The Reclamation Process
Waupaca’s sand reclamation system begins with dry returned green sand being processed through the first Simpson Pro-Claim unit using pneumatic technology. This step assists in the removal of any chemical binders, residual dry raw materials, and debris, increasing the efficiency of the sand for thermal reclamation. The sand is then subjected to high heat in the thermal unit, which burns off any remaining organic material. Finally, the sand passes through a second Pro-Claim system to assist in removing any residual dust fines and final cleaning, aiding in the optimal grain size and quality for the sand and core-making processes.
This well-engineered process allows Waupaca to reuse its sand more than 30 times before it becomes non-viable. This efficiency reduces the need for new sand, cuts landfill waste, and enables beneficial reuse—all in alignment with Waupaca’s sustainability goals.
Sustainability in Action
For Waupaca, sustainability is more than a goal – it’s a commitment to the environment and the community. By implementing sand reclamation, the foundry has reduced its reliance on raw sand resources, which are often mined locally, and decreased the volume of waste sent to landfills. The ability to reuse sand within the foundry’s operations has also reduced transportation costs and emissions associated with sourcing and disposing of materials.
Waupaca’s approach reflects a broader industry shift toward circular resource management. By keeping sand within its production cycle for as long as possible, the foundry maximizes material efficiency and minimizes environmental impact.
Cost Control and Operational Benefits
While sustainability is at the forefront, Waupaca’s reclamation process also delivers tangible cost control and operational benefits. Reusing sand multiple times reduces the need for new sand purchases, which in turn decreases procurement and transportation expenses. Additionally, the Pro-Claim is low-maintenance, requires minimal operational oversight, and integrates seamlessly into existing workflows, providing a high return on investment.
A Longstanding Partnership
Simpson has been a trusted partner to Waupaca Foundry for decades, offering reliable, high-quality solutions tailored to their needs. The Pro-Claim units’ reliable performance and Simpson’s dedicated partnership and technical support have been instrumental in Waupaca’s journey toward sustainability.
Looking Ahead
Waupaca Foundry’s success with sand reclamation demonstrates how innovative processes can drive both environmental and cost containment benefits to the foundry industry. By reducing waste, conserving resources, and promoting efficient operations, Waupaca has set a benchmark for sustainability in the metal casting industry.
With continued advancements in sand reclamation technologies, the foundry is well-positioned to maintain its leadership in sustainable practices while supporting its customers with high-quality, environmentally responsible castings.
