Customer Success Story: The Waupaca Foundry’s Sand Recovery Journey

The Waupaca Foundry, a world-leading manufacturer of ductile iron and grey cast iron castings, has long placed great emphasis on sustainability in its operations. By introducing advanced sand reclamation processes at several sites, Waupaca has significantly minimised its environmental impact whilst simultaneously reducing costs through the reuse of sand. At the heart of this transformation is a three-stage process featuring two Simpson Pro-Claim systems – one at the start and one at the end – with a thermal reclamation unit in the middle. This configuration creates a highly efficient process for reusing green sand to produce core sand.

The recovery process

Waupaca’s sand regeneration system begins with the processing of dry green sand by the first Simpson Pro-Claim unit, which utilises pneumatic technology. This step helps to remove chemical binders, residual dry raw materials and deposits, thereby increasing the sand’s efficiency for thermal processing. 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, which aids in the removal of fine dust residues and final cleaning to achieve optimal grain size and quality for sand and core production.

This sophisticated process enables Waupaca to reuse its sand more than 30 times before it becomes unusable. This efficiency reduces the need for new sand, minimises landfill waste and enables useful reuse – all in line with Waupaca’s sustainability goals.

Sustainability in practice

For Waupaca, sustainability is more than just a goal: it is a commitment to the environment and the community. By introducing sand recovery, the foundry has reduced its reliance on raw sand resources – which are often mined locally – and cut the volume of waste sent to landfill. Reusing the sand within the foundry’s operations has also helped to reduce transport costs and the emissions associated with the procurement and disposal of materials.

Waupaca’s approach reflects a broader shift within the industry towards circular resource management. By keeping the sand in the production cycle for as long as possible, the foundry maximises material efficiency and minimises its environmental impact.

Cost control and operational benefits

Whilst sustainability is the primary focus, Waupaca’s reclamation process also offers tangible cost control and operational benefits. By reusing sand multiple times, the need for new sand is reduced, which in turn lowers procurement and transport costs. Furthermore, the Pro-Claim is low-maintenance, requires minimal operational supervision and integrates seamlessly into existing workflows, enabling a high return on investment.

A long-standing partnership

Simpson has been a trusted partner of the Waupaca foundry for decades, providing reliable, high-quality solutions tailored to its needs. The reliable performance of the Pro-Claim equipment, combined with Simpson’s dedicated partnership and technical support, has been instrumental in supporting Waupaca on its journey towards sustainability.

Outlook

Waupaca Foundry’s success in sand reclamation demonstrates how innovative processes in the foundry industry can deliver benefits both for the environment and for cost control. By reducing waste, conserving resources and promoting efficient operational processes, Waupaca has set a benchmark for sustainability in the metal casting industry.

With ongoing advances in sand recovery technologies, the foundry is well positioned to maintain its leadership in sustainable practices whilst supporting its customers with high-quality, environmentally friendly castings.