Castalloy Achieves Rapid ROI with the Simpson Pro-Claim®
Written by Tom Arenholz
Article also featured in Simple Solutions That Work
Castalloy Foundry in Waukesha, Wisconsin, faced a pressing challenge with its aging thermal sand reclamation unit. While the system had served the foundry for years, it had become inefficient and increasingly difficult to maintain. Rising energy costs, frequent downtime, and costly maintenance were putting pressure on operations, while dependence on new sand and high disposal expenses drove up overall production costs.
Castalloy needed a solution that would reduce these operational burdens while maintaining consistent casting quality and production throughput. The chemically bonded no-bake foundry sought a modern reclamation system that could improve efficiency, reduce energy costs, and support sustainability goals without disrupting daily operations.
“Reducing energy use while lowering our environmental footprint was a top priority, and the results have exceeded expectations. Reducing new sand purchases by 70%, lowering disposal by 60%, and eliminating gas use — while saving over $574,000 in the first year, the benefits are clear.” - David DeValkenaere, Managing Director
Solution
To meet these goals, Castalloy installed a Simpson Pro-Claim® continuous pneumatic sand reclaimer in July 2024. Unlike the older thermal unit, the pneumatic reclaimer reclaims sand efficiently without the use of gas, lowering both operational costs and environmental impact. It delivers consistent sand grain distribution, helping maintain reliable casting performance while minimizing waste.
The reclaimer was integrated into the foundry’s workflow, allowing for an increased volume of reclaimed sand which lowered the reliance on new sand. Its durable construction and low-maintenance design also ensure long-term reliability, addressing the maintenance challenges Castalloy faced with the previous thermal system.
“This project delivered exactly what we were looking for — lower operating costs, reduced environmental impact, and a more dependable process. Achieving full ROI in under a year speaks for itself.” - David DeValkenaere, Managing Director
Results & Impact
The results in the first year have been dramatic compared to the previous 12 months:
- $360,000 savings from reduced new sand purchases and freight costs—a 70% reduction in new sand usage.
- $174,000 disposal savings, lowering disposal costs and freight by 60%.
- $40,000 in gas savings, as the reclaimer operates without gas, eliminating roughly 212 metric tons of CO₂ emissions annually—equivalent to removing 46 passenger cars from the road or planting over 5,000 trees.
In total, Castalloy has realized $574,000 in first-year savings, while also significantly reducing its environmental footprint.
Increased Production and Consistent Quality
During the first year after the installation of the Pro-Claim, pouring production increased 33% compared to the previous year, all while maintaining consistent sand quality and stable scrap rates. This demonstrates both financial and environmental benefits but also supports higher throughput than the previous thermal unit without compromising casting performance.
Low Maintenance and Long-Term Durability
Routine maintenance has been minimal, limited mainly to targets, blast tubes, and air cylinders. The first wear part replacement occurred after 15 months of operation, highlighting the system’s durability and reliability—an immediate improvement over the older thermal unit, which required frequent repairs.
Full ROI Achieved in Under One Year
Typically, a return on investment is seen within one to three years. Castalloy, however, achieved full ROI in less than a year—demonstrating the immediate financial and operational impact of switching from an outdated thermal system to the efficient Pro-Claim pneumatic sand reclaimer. By reducing new sand usage, lowering disposal costs, and eliminating gas consumption, produced both cost savings and measurable sustainability improvements.
“The biggest impact has been the combination of cost savings and operational stability. We’re spending less on sand, disposal, and energy, and the system runs with far less maintenance than what we had before.” - David DeValkenaere, Managing Director
Castalloy Foundry successfully modernized its sand reclamation process with substantial cost savings, enhanced sand reclamation production capacity, and reduced environmental impact. Pneumatic sand reclamation offers an efficient, low-cost way to recover chemically bonded and green sand for reuse, significantly reducing raw material and disposal expenses while maintaining consistent sand quality. Its air-driven process requires no gas, making it highly energy-efficient reclamation solution.
