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The foundry won the American Foundry Society’s (AFS) 2023 Green Foundry Award for its ongoing commitment to sustainable production processes and energy reduction. The foundry was honored for creating a corporate sustainability report—Waupaca Foundry is the first independent U.S. iron casting supplier to establish and communicate sustainability objectives and publish a corporate sustainability report for its stakeholders.
According to the U.S. Bureau of Labor Statistics, mechanical and industrial engineers are second and third in projected job growth among engineers. Together, these two occupations will be among the fastest growing occupations in manufacturing.
It has been over 30 years since Waupaca Foundry has had horizontal molding capabilities. In May of 1967, Waupaca Foundry installed its first vertical molding machine, and by the early 1990s, the last of the horizontal molding machines were removed. Since then the iron casting supplier has become known for high-volume, high quality iron casting production with its in-house design, built, installed, and maintained vertical molding machines.. “As we build new equipment we are constantly looking to add innovative features that add safety, quality, productivity, and reliability,” Vice President of Engineering, Jarrod Osborn.
Teacher Scot Scarda is helping transitional students learn work skills that will make it a smooth transition. “Teaching children the skills to succeed in the world of work is always the overarching goal of education, so to be able to address those needs directly is important for their growth and success in life,” he said. Besides learning in the classroom setting, students get involved in volunteer work experiences, job shadowing and vocational tours. “Through volunteering, students learn the skills and responsibilities associated with a work environment, along with earning dignity and respect,” Scarda said. “It’s an excellent way for students to contribute to our community.”
Fred says. “Waupaca Foundry offered better benefits than anyone else in the area.” He also had a special feeling about the Foundry and his future. “I looked at it as something that could definitely turn into a career, which after 32 years it has become. This is my home away from home.” he says.
He brought that experience and expertise to Waupaca Foundry when he joined the company 31 years ago. His first three years were spent at ductile iron foundry, Plant 4 in Marinette, Wisconsin, followed by a transfer to gray and ductile iron foundry, Plant 5 in Tell City, Indiana, where he’s worked since it opened in 1996. He is a mechanical Technician who loves all the ingenuity and innovation associated with creating efficiencies and increasing production. He says, “Working in maintenance and engineering is amazing. The company allows us to take machines and re-engineer the hydraulics and pneumatics, so they perform at even a higher rate that is foundry specific.”
The rise of automated intelligence has transformed the manufacturing landscape. Waupaca Foundry continues to invest in technology that brings consistently high quality and greater value to OEMs, Tier 1 manufacturers, and machining operations worldwide.
As a company built on hard work, innovation, and valuing its employees, Waupaca Foundry stands strong as the most respected iron foundry company in the world. But in an industry where technology is ever evolving and the lifespan of electrical equipment is relatively short, keeping up with capital improvements and automation is vital to improving cost structure, work safety, and iron casting quality and delivery.
Foundry Management & Technology Ferrous foundry group Waupaca Foundry Inc. has earned three awards from national, state, and industry groups recognizing its commitment to cutting energy consumption, and to finding “smart” ways to use and protect natural resources. Its energy projects included overhauling an air-compressor system at Plant 1 in Waupaca, Wis.; installing a dehumidification system at Plant 5 located in Tell City, Ind.; and adopting a smart exhaust-fan system at Plant 2/3 located in Waupaca, Wis.
Foundries are the ultimate recyclers. For generations, Waupaca Foundry has created new products out of recycled steel scrap and iron and re-uses many of the raw materials used in creating iron castings. However, foundries are also energy-intensive businesses and it is imperative that Waupaca keeps finding smarter ways to use and preserve the plant's natural resources.
