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People First: Waupaca’s Blueprint for a Modern, Safer Foundry

08 April 2026

People First: Waupaca’s Blueprint for a Modern, Safer Foundry

In today’s foundry landscape, success starts with people. As the labor market tightens, creating a safer, more comfortable workplace is a necessity for attracting and retaining skilled operators.

A recent feature in Modern Casting showcases how Waupaca Foundry (Plant 1) tackled two of the industry’s most persistent challenges: silica dust and excessive noise.

For years, the team relied on a 90-foot vibratory conveyor for casting sorting. Despite significant investments in dust collection and sound barriers, conditions remained largely unchanged:

  • Noise levels frequently exceeded 100 dB, requiring double hearing protection
  • Silica exposure averaged 75 μg/m³, making respirators mandatory
  • Harsh conditions made worker retention an ongoing challenge

The turning point came when Waupaca replaced the vibratory system with the innovative Magaldi Superbelt® conveyor for automatic casting sorting - a solution designed to eliminate the root causes of dust and noise rather than simply mitigate them. The results were transformative!

 

👉 READ the full technical breakdown and the testimonials from the Waupaca team in the March issue of Modern Casting

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