Storied path to carbon and climate neutrality

Foundries are the ultimate recyclers. For generations, Waupaca Foundry has created new products out of recycled steel scrap and iron and re-uses many of the raw materials used in creating iron castings. However, foundries are also energy-intensive businesses and it is imperative that Waupaca keeps finding smarter ways to use and preserve the plant's natural resources. 

Waupaca Foundry 2023 sustainability goals are as follows: 

• Reduce energy intensity by 5% by end of FY 2023, using FY 2019 energy use as the baseline (MMBTU per ton of iron melted)
• Reduce the cumulative electrical consumption carbon footprint 30% by end of FY 2023, via investment in new renewable energy developments facilitated by virtual power purchase agreements (VPPA).
• Maintain air pollution control systems considered as “best available” by the U.S. Environmental Protection Agency and associated state regulatory agencies for all processes regardless of the original installation date.  
• Achieve a cumulative 80% beneficial reuse of spent foundry materials by end of FY 2023 (% tons beneficially reused against total tons generated)
• Reduce water use consumption by 10% by end of FY 2023 (baseline 2020)(gallons) 

Waupaca Foundry had a 10-year vision for sustainability with achievable goals for reducing its environmental impact by 2020. The results are in: 

• GOAL: Reduce energy use by 25 percent over the next 10 years, using fiscal 2009 energy use as the baseline (mmBtu/ton of iron shipped).
  RESULT: Energy intensity was reduced by 21%, but temporarily setback to 17% improvement due to COVID-19 related issues
• GOAL: Maintain air pollution control systems considered as “best available” by the U.S. Environmental Protection Agency and associated state regulatory agencies for all processes regardless of the original installation date.
  RESULT: Achieved
• GOAL: Reduce spent foundry sand generation by 30 percent in 10 years (baseline 2010) (tons). Investigate the feasibility of developing alternative uses for remaining foundry byproducts by Calendar 2020.
  RESULT: 80% of foundry sand and 74% of all foundry by-products beneficially reused
• GOAL: Reduce water use consumption by 80 percent in 10 years (baseline 2010) (gallons/ton of melt).
  RESULT: 71% reduction achieved

Waupaca Foundry maintains an Environment Management System and is registered to ISO 14001: 2015 at all foundry locations.