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Waupaca Foundry, Inc.

Tier 1 participant since 3/2/2015

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Waupaca Foundry is headquartered in Waupaca and operates seven iron casting foundries in Wisconsin, Indiana, Pennsylvania and Tennessee; and a machining and assembly plant in Illinois. With over 4,400 employees, Waupaca Foundry is the world’s largest producer of gray, ductile, austempered ductile and compacted graphite iron, melting more than 10,000 tons of iron daily. Casting sizes range between 2 to 350 pounds and serve the automotive, commercial vehicle, rail, agriculture and construction markets as well as oil and gas, hydraulics, material handling and other industrial segments.

Environmental activities

Waupaca Foundry re-melts/re-uses over 800,000 tons of metal annually and 75% of the foundry’s sand by-product is reused for road and general construction, agriculture and geotechnical fill.

Waupaca Foundry was awarded the 2009 Governor’s Award for Environmental Excellence by the state of Wisconsin for a heat recovery project, which reduced the amount of natural gas required annually by 600,000 decatherms, an amount equivalent to the emissions from 791 passenger cars. Waupaca Foundry is also a program partner of the Better Plants Program, a U.S. Department of Energy program where they pledge to reduce industrial energy intensity by 25 percent over the next decade. Waupaca Foundry has a 10-year vision for sustainability with achievable goals for reducing their environmental impact:

  • Reduce energy use intensity by 25%
  • Promoting alternative processes and maintaining state of the art pollution control technologies
  • Reducing spent foundry sand generation by 30% while promoting offsite reuse/recycling opportunities of remaining spent foundry materials to achieve zero landfill disposal
  • Reduce water use consumption by 80% by 2020

Documents

Reports

Commitment outline

Acceptance letter

Application

DNR contact Company contact
Weston Wegener
101 S Webster - EA/7
PO Box 7921
Madison WI 53707-7921
608-267-9753
Cell: 608-284-0908
Bryant Esch
Environmental coordinator
1955 Brunner Dr.
Waupaca WI 54981
715-258-6674
Waupaca Foundry, Inc.