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INDUSTRY news


DOE Recognizes Waupaca for Effi ciency


Offi cials at Waupaca Foundry, Inc.,


Waupaca, Wis., received a commen- dation from the U.S. Department of Energy’s (DOE) Better Buildings, Better Plants Program (see www4.eere.energy. gov/challenge/home). In this program, companies voluntarily make energy ef- fi ciency a business goal, establish energy management plans and commit to reduce the energy intensity of manufac- turing operations by 25% over 10 years. T e letter of commendation sites


reports showing the metalcasting facility reduced energy intensity by 6.3% in 2011, giving it a cumulative improve- ment of 16.5% against its baseline year of 2009. Waupaca Foundry is one of only 19 fi rms with operations in Wisconsin participating in the program; 100 indus- trial companies are participating. According to CEO Gary Gigante, sustainability is central to ductile and gray iron casting operations. “You might call foundries the original recyclers,” he said. “In addition to using scrap steel and iron in our product, we recycle the sand used in the iron cast- ing process and have made signifi cant investments in energy reduction.” Spe- cifi c sustainability initiatives include: • About 70% of the company’s byproducts are reused in local projects including road and gen- eral construction, agriculture and geotechnical fi ll.


• Closed-loop cooling water systems have reduced plant water cooling demands by 80% or more. Non-contact cooling water discharges were reduced to near zero and daily water use was reduced by 225,000 gallons. In 2009, Waupaca Foundry


received the Wisconsin Governor’s Award for Environmental Excellence for a project that used waste heat from the cupola furnace to heat a metalcast- ing facility in Waupaca through the Wisconsin winters. T e cupola furnace melts scrap iron. Waupaca supplies iron castings to the


automotive, commercial vehicle, agricul- ture, construction, and industrial markets, operating six U.S. manufacturing facilities employing 3,700 people. 


Jan/Feb 2013 | METAL CASTING DESIGN & PURCHASING | 9


PCC Buys Synchronous Precision Castparts Corp., Port-


land, Ore., has agreed to acquire Synchronous Aerospace Group (Syn- chronous), Prescott, Ariz., a build-to- print supplier of complex mechanical assemblies for commercial aerospace and defense markets. Its core capabili- ties include gantry machining, hard-


metal machining, high-speed machin- ing, turning, sheet-metal forming, and metal and composite bonding. Precision Castparts Corp. is a global


manufacturer serving the aerospace, power, and general industrial markets. Synchronous has approximately 690 employees in four U.S. locations. 


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