Wabash Castings Inc. in Wabash, IN, recently installed a new, Joest complete shaker system to reclaim molding sand from its casting process. The reported $1.5-million project will improve the green-sand operation by allowing WCI to reclaim approximately 500 tons/month of sand from its mold shakeout, reusing the sand and preventing it from being landfilled.
The Indiana aluminum foundry produces complex-cored parts like pumps, manifolds, and turbo chargers, among others, for automotive manufacturers (including EVs), heavy-duty truck builders, off-highway and construction equipment producers, and other general manufacturing operations.
“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 machine uses variable-frequency vibration, combined with a variable angle shakeout conveyor to breakdown large chunks of mold sand so that it can be collected for reuse. Spent molds are placed into a hopper and, as they are conveyed through the system, vibratory action reduces the lumps to sand particles. The sand is then available for mold production again.
According to Wabash Castings, the shaker process will reduce by nearly 50% the amount of new sand required for its mold production. Currently, it has several tanker loads of sand delivered daily, but once the shaker system is fully operational the number of deliveries will be fewer than 10 per month.
“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 Wabash Castings v.p. and general manager Eric Terrell. “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.”