Image courtesy of Waupaca Foundry
Waupaca Foundry, a Wisconsin-based supplier of recycled-content iron castings, has started the final stage of a multiyear, $100 million-plus capital investment program to modernize operations, enhance worker safety and provide advanced foundry technology to meet the needs of its customers.
The final investment phase includes a $20 million upgrade to the company's Plant 4 facility in Marinette, Wisconsin, which includes a complete replacement of the facility’s melt charging system. The modernization project replaces vibratory shaker equipment with advanced steel slat conveyor systems, new weigh scales and an integrated charge material drying system that feeds directly into charge buckets for the furnaces.
Completion of the project is slated for late January 2026.
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Waupaca Foundry notes the announcement comes on Manufacturing Day, which was created to celebrate modern manufacturing and the skilled workers who make it possible, and underscores the company’s dedication to “world-class manufacturing capabilities in the United States.”
“American manufacturing excellence requires continuous investment in people, processes and technology,” Waupaca Foundry CEO Mike Hawthorne says. “Manufacturing Day provides the perfect opportunity to showcase our unwavering belief in the strength of U.S. manufacturing and producing the highest quality iron castings here at home. When our customers choose Waupaca Foundry, they’re choosing products made by skilled American workers using the most advanced foundry technology in the world.”
Since 2016 Waupaca Foundry has invested more than $400 million in capital improvements to build and continuously enhance its operations. The company says completed enhancements include:
- Advanced safety systems: The company has added safety PLC installations and enhanced lockout protocols across all five of its facilities.
- Energy efficient technologies: The company is implementing steel slat conveyors and electric charging systems to reduce environmental impact while improving operational efficiency.
- Workplace environment improvements: Enhanced air quality systems, temperature control and ergonomic automation have been added to create more comfortable and modern work environments.
- Advanced manufacturing equipment: The company has added what it calls state-of-the-art machinery and automation technology to enhance quality, consistency and production capabilities.
The company says these upgrades support its workforce of nearly 3,500 employees in Wisconsin and Indiana, with more than half of team members having more than 10 years of service.
“This isn’t just about equipment, it’s about creating an environment where American manufacturing workers can thrive,” Hawthorne says. “We’re proud that generations of families have built careers at Waupaca Foundry, and these investments ensure we continue providing good American manufacturing jobs for generations to come.”
The company notes that beyond direct facility investments, it supports communities where it operates through equipment donations to schools and universities, supports local emergency services and participates in business, civic and environmental initiatives.
Waupaca Foundry supplies iron castings to the automotive, commercial vehicle, agriculture, construction and industrial markets, producing gray and ductile iron castings.