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ThyssenKrupp Waupaca to Reopen, Expand Shuttered Plant 6 TyssenKrupp Waupaca (TKW),

Waupaca, Wis., announced it will resume production at its Plant 6 in Etowah, Tenn., in January 2012 and add approximately 20,000 sq. ft. of manufacturing space to the facility. According to a company press

release, the decision to reopen and expand the plant was made in response to increasing market demand for gray and ductile iron castings. “Te reopening of our Etowah

foundry is good news for our customers and for the state of Tennessee, but also for the men and women we will be able to put back to work,” said Gary Gigan- te, TKW president and chief executive officer. “Our facility is one of the most technologically advanced in the iron castings industry, and we are proud to once again be open for business.” TKW will add the new manu-

facturing space, as well as new melt, core and mill room equipment for ductile iron production, to its existing 270,000-sq.-ft. facility, which operates four high-speed vertical green sand molding machines. According to the company state-

ment, startup of the metalcasting facil- ity will occur in two phases. After the new equipment is installed in the third quarter of 2011, phase one will focus on gray iron production and begin in the first quarter of 2012. Full produc-

ThyssenKrupp Waupaca’s Plant 6 is a high-production, vertical green sand molding facility.

tion is expected to begin no later than the end of the third quarter. Phase two will include the launching of ductile iron production in the second quarter of 2012. Full production is expected by the first quarter of 2013. Castings manufactured at Plant 6

are used by the passenger car and light truck, material handling, agriculture, construction, hydraulic and commer- cial vehicle market segments. At full production, the facility is capable of producing 200,000 tons of gray and ductile iron castings. TKW announced it will hire more than 250 hourly em-

Renault to Put $120 Million in Casting Plant Renault, Boulogne-Billancourt,

France, said it will invest about $120.5 million in its Fonderie de Bretagne, Caudan, France, to make the facility more competitive and ensure longevity. According to a company press release, Renault has put $55 million in the facil- ity in the last three years and will make the additional $120.5 million investment over the next six years. Te company said more than 400 jobs will be retained. Renault said the money will be used

to install a new production line with a capacity of 40,000 metric tons per year to replace an existing line that accounts for 70% of its business. Te new line will give the company the ability to produce

ployees for the re-start of the foundry starting in August, with a further 200 jobs expected to be added through 2014. Te company said it will begin with the rehiring of former employees impacted by the 2010 idling. In May, the executive board of

TKW parent Tyssenkrupp AG, Es- sen, Germany, announced its intention to divest the iron casting division as part of its plan to reduce debt and fo- cus on the automotive sector, particu- larly in emerging markets. Te parent company has declined to update the status of the divesture.

ductile iron castings, including chassis and powertrain parts. “Tis investment confirms Renault’s

industrial anchor in France,” said Gé- rard Leclercq, executive vice president of manufacturing and supply chain. Renault said investments also will

be made in improving safety and working conditions (roofs, heat- ing, extraction and gantries), quality and environmental preservation. Te company plans to begin a study phase for the new projects in 2012, followed by substantial investment in 2013 and startup of the new line in 2014. It expects the line to be up to full capacity by 2015.

AFW Foundry Launches Sand Reuse Project

AFW Foundry, Lannon, Wis., has begun a metalcasting sand reuse proj- ect that is expected to save $85,250 per year in landfill costs, in addition to offering other benefits. A spokesperson for AFW said

the program, launched through the Wisconsin Profitable Sustainability Ini- tiative (PSI), also is expected to reduce raw material expenditures and shrink the plant’s environmental footprint. “Te program came along at an opportune time,” said Amy Dvornik,

August 2011 MODERN CASTING | 9 (continued on page 14)

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