Waupaca Foundry Plant 4, a ductile iron foundry located in Marinette, Wisconsin, installed two new heavy-duty Magaldi Superbelt conveyor systems designed to improve downtime by as much as 60%. The company says it anticipates a two-year return on investment due to reduced maintenance and energy costs along with significantly reduced silica dust and noise pollution.

“Preparation and planning was critical leading into the project due to the scope of work required given the defined shutdown install window,” said Jarrod Osborn, vice president of manufacturing engineering for Waupaca Foundry.

The New Magaldi Superbelt conveyors improved gate and sprue transportation uptime and reduced energy and maintenance costs. Running more quietly and improving indoor air quality, the foundry says the new conveyors improved the foundry workplace.

“The safety benefits of the new system were as important as the bottom-line savings,” Osborn said.  “By replacing the vibrating system, we significantly reduced the amount of airborne dust and created a healthier working environment for our team.” 

This is the second major capital project at the Marinette foundry in recent years. Plant 4 completed a multi-year power service upgrade in 2023. The plant is 327,000 square feet and can run six different grades of ductile iron concurrently using eco-conscious electric melt technology since its opening in 1973.