and cost, which bolsters a metalcaster’s overall message of corporate responsibility. One trend that is begin- ning to take hold in the industry is waste heat recov- ery. For example, a facility’s engineers can modify the melting system to more effi- ciently use waste heat. If heat from a furnace otherwise escapes without purpose, it can be used to preheat the material for the next charge. Historically, metalcasting facilities


“Whether it’s a project with the


local community or a small project that allows you to start beneficial reuse, you need to pick the project that works for you.”—Bryant Esch


have received a single utility bill for electricity or gas usage. But specialized measuring systems are becoming more prevalent in the industry. Energy experts have developed sub-metering practices that measure consumption on specific pieces of equipment, allowing metalcast- ers to see exactly where energy is used. Brian Reinke, an energy consultant


with TDI Energy Solutions, Lemont, Ill., sees process improvement as another area of potential savings. For example,


improving training procedures for those operating furnaces, air compres- sors and dust collectors, can lead to reductions in energy consumption. “Tis is something we run into


constantly,” he said. “Inconsistent operations and insufficient training can be very costly, but largely hidden in day-to-day operations. Once dis- covered, they can be easily addressed.” Additionally, programs are avail-


able to provide energy audits of manufacturing facilities. Energy con- sultants evaluate an entire operation,


and many state and local governments and universi- ties offer audit programs. Industry trade groups, including AFS, offer audits specific to the metalcasting industry. Considering the grow-


ing emphasis on increasing efficiency and reducing waste, the general public is becoming more recep- tive to smart, safe uses of


industrial byproducts. Still, met- alcasters can actively work to ease remaining skepticism from commu- nity leaders and government officials. “Tere is an up swell of desire


to reuse industrial products, but you still are fighting perceptions of people who don’t understand,” Esch said. “Te kneejerk reaction can be negative and that’s why getting involved with your community is so important. Communication is vital. Once the community is informed, they can be really receptive.”


PUBLIC-PRIVATE PARTNERSHIP A WIN-WIN


Waupaca Foundry Inc., Waupaca, Wis., operates six plants in Wisconsin, Indiana and Tennessee. Of the industrial byprod- ucts coming out of Waupaca Foundry’s sites, approximately 70% of the sand, slag and dust will head to some sort of beneficial reuse. These efforts mean 400 tons a year end up in construc- tion, agriculture or landscaping applications instead of finding a permanent home in the landfill. Waupaca Foundry has completed more than 120 beneficial reuse projects. One notable example began in February 2012, when the company’s three Waupaca-area foundries agreed to donate 200,000 cu. yards of foundry byproduct for the construc- tion of a 42-ft. sledding hill at the City of Waupaca’s Swan Park Recreation Facility. The foundry slag and sand was used as unconfined geotechnical fill, which removed a need for natively mined construction materials.


Finished in May 2014, the project and the donated material proved an obvious benefit for the City of Waupaca. For Waupaca Foundry Inc., the project positives came in a number of areas. For one, the reuse of such a large volume of material reduced depen- dence on the company owned and operated landfills. “We have no middleman when it comes to disposal,” said Bryant Esch, environmental coordinator, Waupaca Foundry. “When we do beneficial reuse, we have investments in transpor- tation and project managements. We run into situations where the short-term cost to us is more than what it costs to put it into our landfill. But in the long run, 30 years from now, how much is a


Waupaca Foundry donated 200,000 cu. yards of sand for the sledding hill.


landfill going to cost? How hard will it be to get a landfill? Anything we can do to avoid using one now is a good idea.” The collaboration also strengthened the relationship between


Waupaca Foundry and the local community. The sledding hill represents a highly visible example of what can be done with met- alcasting byproducts. The key was the company’s work with the city to plan the project and manage it from concept to completion. “Swan Park is in the middle of a large residential area,” Esch said. “There was a lot to consider in regards to noise and truck traffic where kids were playing. In the end, with our communica- tion and planning, we did not have a single negative comment. From two years ago until now, at completion, we haven’t heard one negative comment. That is amazing—and it’s a testament to the project management from Waupaca Foundry and the city.”


June 2014 MODERN CASTING | 31


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