most 50% of you would prefer not to tell us how much you made last year. The first ever MODERN CASTING
O
census of the domestic metalcasting industry examined 1,644 plants, nearly 80% of the estimated 2,040 operat- ing in the country today. The details provided by each plant include their location, employee number, sales fig- ures, casting weights produced, aver- age production runs, materials poured and processes conducted. Following are the results of the survey.
Breakdown by State Ohio (9.6% of the total), Penn-
sylvania (7.9%), California (7.5%), Wisconsin (7.4%) and Illinois (6.9%) have the greatest number of metal- casting facilities in the nation. Alaska and Wyoming have the fewest, each with 0.1% of the total. Fig. 1. offers the full state-by-state breakdown of the industry.
Breakdown by Employees The majority of the facilities in the
country (57.5% of respondents) have between 1 and 59 employees. About 32% have 1-29 employees; 25.3% have 30-59. (Two hundred seventy nine
Fig. 1. Ohio has the largest number of metalcasting facilities with 9.6% of the total respon- dents being located there. Thirty-four states have fewer than 2% of the total.
plants did not respond to this question.) The largest number of employees
reported by any one company was 3,000. After eliminating the greatest and least numbers of employees re- ported (to correct for the extremes), the average number of employees per facility was 103. The median number of employees (the center of the distribution) was 43.5. Only 1.1%
of facilities reported more than 1,000 employees. Of the 1,354 facilities that reported between 1-999 employees, 98% employed fewer than 500.
Breakdown by Sales Sales dollars per year were reported
by only 51% of respondents (842). About 20% of the respondents reported fewer than $1 million in sales; 50.4% reported sales equal to or more than $1 million and less than $10 million. The remainder (29.3%) reported revenues equal to or greater than $10 million. A large number of facilities (18.3%) reported sales in excess of $20 million. The average sales, correcting for outli- ers, was $23,281,719.
Breakdown by Weight The majority of respondents (51.7%)
reported an average casting weight of ounces to 19 lbs. The largest average casting weight reported was 15,000 lbs. Discarding the extremes, the average casting weight poured across all facili- ties was 102 lbs. The median average casting weight was 15.5 lbs.
Breakdown by Average Production Run The majority of respondents
Fig. 2. Aluminum is the dominant material in the domestic casting industry, with 46% of the reporting facilities including the metal in their pouring mix. Iron casting also remains strong, mostly on the strength of ductile iron’s growth.
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(61.4%) tally their average produc- tion run between 1-299 pieces. Almost 25% of the respondents call their sweet-spot 1-50 pieces. About 22% reported average runs between
MODERN CASTING / January 2011
hio has the most metalcast- ing facilities. The largest casting company in the country has 3,000 employ- ees in multiple plants. Al-
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