Waupaca Foundry, the world’s leading producer of gray iron, ductile iron, and austempered ductile iron castings, has begun the concluding phase of a multi-year capital investment program valued at more than $100 million. The initiative is focused on upgrading facilities, strengthening workplace safety, and deploying advanced foundry technologies to better serve customer demand.
The final phase includes a $20 million modernization project at the company’s Plant 4 in Marinette, Wisconsin. The upgrade involves a full overhaul of the plant’s melt charging system, replacing legacy vibratory shaker equipment with modern steel slat conveyor technology. The project also introduces new weighing systems and an integrated drying process that feeds charge materials directly into furnace charge buckets. Scheduled for completion in late January, the improvements are expected to enhance operational efficiency and reliability at the Marinette site.
The announcement was made in conjunction with Manufacturing Day, a nationwide observance highlighting innovation in manufacturing and the skilled workforce that drives it. The timing reflects Waupaca Foundry’s ongoing commitment to maintaining world-class manufacturing capabilities in the United States.
Mike Hawthorne, Chief Executive Officer of Waupaca Foundry, said that sustained investment is essential to maintaining leadership in American manufacturing. He noted that Manufacturing Day offers an opportunity to highlight the company’s belief in domestic production and the value of advanced manufacturing expertise. According to Hawthorne, customers who partner with Waupaca Foundry benefit from products made in the U.S. by highly skilled workers using leading-edge foundry technology.
This latest phase builds on a long-standing investment strategy. Since 2016, Waupaca Foundry has committed more than $400 million to capital improvements aimed at developing and continuously upgrading its state-of-the-art operations. Past investments have included enhanced safety systems, such as programmable safety controls and strengthened lockout procedures; energy-efficient technologies that improve productivity while reducing environmental impact; improvements to workplace air quality, climate control, and ergonomics; and the deployment of advanced automation and manufacturing equipment to improve quality and consistency.
These investments directly support Waupaca Foundry’s workforce of nearly 3,500 employees across Wisconsin and Indiana. More than half of the company’s employees have been with the organization for over a decade, reflecting a strong culture of retention and skill development. The capital programs are designed not only to modernize equipment but also to create safer, more efficient workplaces that foster long-term career growth. Mr Hawthorne emphasized that the investments are ultimately about supporting people as much as technology, noting the company’s pride in providing stable, high-quality manufacturing jobs for generations of American workers.
Looking ahead, Waupaca Foundry plans additional strategic investments to sustain its technology leadership and continue improving manufacturing capabilities. The company also remains actively engaged in the communities where it operates, supporting education, emergency services, and local civic and environmental initiatives through donations, partnerships, and volunteer involvement.
