Waupaca Foundry, Inc. has been honored with the 2025 Safety and Insight Award from the American Foundry Society for its innovative material handling system upgrade at its Waupaca-based Plant 1.
The project, led by Project Manager Michael Barden and Environmental Engineer Shianna Wheeler, replaced an outdated vibratory conveyor system with a new belt conveyor, delivering extraordinary improvements in worker safety and environmental conditions.
The original 90-foot flat-stroke vibratory conveyor had long presented challenges for the foundry’s workforce. The equipment contributed to excessive noise levels exceeding 100 dB and elevated airborne silica dust, creating a regulated silica area where workers required dual hearing protection. Despite implementing dust collection systems, noise barriers, and sound-dampening devices, the environmental hazards persisted.
Following a two-week installation period in December 2024, the results exceeded expectations. Post-installation industrial hygiene testing revealed a 98 percent reduction in silica exposure, reclassifying the area to no longer require respirators or regulated silica protocols. Simultaneously, noise levels dropped from 105 dB to 92 dB, eliminating the need for workers to wear double hearing protection.