2013 Metalcaster ProsPectus Waupaca Foundry


Waupaca Foundry has a reputation as solid as the castings we create. Quality is our reputation. It’s our heritage. And it will be our legacy. Quality is what dif- ferentiates Waupaca Foundry from the rest. We hold ourselves to a higher standard. And we stand by it, producing the most consistent, high-quality iron castings in the world. With headquarters and three plants in Wau-


Mission Statement


Waupaca Foundry produces iron castings, focusing on transporta- tion, construction, agriculture and industrial markets worldwide.


We embrace lean manufacturing techniques in all our facilities, and manage other value added services for our customers. Our custom- ers’ expectations are met through innovative technology, continuous improvement culture, and the ef- forts of our dedicated, motivated, highly-trained workforce.


We maintain strong social and envi- ronmental commitments to our em- ployees and communities, including: improvements sustained through


green initiatives, a well maintained and safe environment and the en- couragement of employee’s personal growth through advancement and continuing education.


Metals


Gray Iron, Ductile Iron, Austempered Ductile Iron, Compacted Graphite Iron


Process Vertical Green Sand Molding


paca, Wis., as well as plants in Marinette, Wis., Tell City, Ind., and Etowah, Tenn., Waupaca Foundry operates six foundries and employs more than 3,700 people. Waupaca Foundry produces gray iron, ductile iron, austempered ductile iron, and compacted graphite iron castings, melting more than 9,500 tons a day. Castings up to 350 pounds or 160 kilograms are produced using one of our 33 vertically parted high pressure molding machines by a workforce that puts generations of iron casting expertise to work for our customers every day. Waupaca Foundry consistently produces the most durable, reliable, and innovative castings on the market.


Our Process


Since establishment in 1955, Waupaca Foundry has patented many improvements to the industry’s vertical green sand molding with regard to safety, quality, productivity, and reliability. Our innovative thinking is a large part of how we’ve led the industry in delivering consistent high-quality castings. Waupaca Foundry’s design engineering, high volume melting capabilities, custom and proprietary vertical green sand mold- ing equipment, and automated finishing systems minimize post-process machining requirements and maintains controlled


Waupaca Foundry Plant 1 406 N. Division St., P.O. Box 249, Waupaca, WI 54981


Waupaca Foundry Plant 2/3 1955 Brunner Dr., P.O. Box 249, Waupaca, WI 54981


Waupaca Foundry Plant 4, Marinette, Wis. 805 Ogden Ave., Marinette, WI 54143


Waupaca Foundry Plant 5 9856 State Highway 66, P.O. Box 189, Tell City, IN 47586


Waupaca Foundry Plant 6


134 Waupaca Dr., P.O. Box 510, Etowah, TN 37331


www.waupacafoundry.com 38 METAL CASTING DESIGN & PURCHASING / 2013 Metalcaster Prospectus


chemistry for consistent machining—all resulting in best-in-class iron castings.


Our Technology Waupaca Foundry’s top leaders, manufac- turing teams, engineers, and metallurgists are involved in controlling process consistency and continuously improving our technol- ogy. Our metallurgists and engineers design proprietary processes and customized equip- ment to monitor iron temperature, additives, casting materials and processes to a hyper- detailed level.


And, our engineering support teams help customers to reduce their total manufacturing costs through innovative casting and core passage designs, waste reduction, and mass reduction improving casting consistency and quality. And, in some casting applications we even help reduce the need for multiple cast, fabricated or welded parts. For customers, all of this ensures castings are consistently durable and reliable.


Markets Served Waupaca Foundry produces castings for global market segments including the light truck and passenger car, commercial vehicle, agriculture, construction, material handling and other industrial sectors. Our castings are engineered with the latest technology, meticulously melted, carefully produced on our customer-engineered mold- ing machines and perfected by our automated finishing systems. Together, this provides long-term value to our customers with the most consistent, high-quality iron castings, providing cost savings and dependability. For more information, please visit www.waupacafoundry.com.


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