Wabash Castings Inc., Wabash, Indiana, has installed a new, $1.5 million JOEST Complete Shaker System that will improve operations and reduce landfill waste. The new shaker system allows the aluminum casting manufacturer to reclaim and reuse approximately 500 tons of sand per month, removing it from the landfill stream.

“We are continually seeking operational improvements that not only create production efficiencies but, equally important, reduce our environmental footprint,” said Sachin Shivaram, CEO of Wisconsin Aluminum Foundry (WAF), which acquired Wabash Castings in 2021. “This investment achieves both.”

The new system works by using a variable frequency, combined with a variable angle shakeout conveyor to breakdown large chunks of mold sand into reusable sand. The spent molds are placed into a hopper and, as they are conveyed through the system, are vibrated to break apart, turning them once again into sand particles. The sand is then reused for new molds and reduces the amount of new sand needed by nearly 50%. 

“Not only are we reducing the amount of waste being produced, but we’re also reducing the need for new sand and new sand deliveries,” explained Eric Terrell, vice president and general manager at Wabash Castings. “This improves operational costs, while further reducing our carbon footprint. It’s part of WAF’s overall goal to improve operations through environmentally friendly solutions.”