Badger Foundry Company 103 Years of Excellence
Our Product is Iron… Our Strength… People Quality Policy The Quality Policy of Badger Foundry Company is to provide high quality castings and customer services that meet our customers’ expectations. We are committed to continually improving our quality management system processes and increasing Customer Satisfaction through the use of measurable quality objectives. Angus R Callender, President
Our Product is Iron… Our Strength… People Significant Milestones 1980 s 1940 Badger makes significant capital investment particularly in the core area and expands its facility size to 115, 000 sq. ft. Richard Callender (current president’s father) takes over as president of Badger 1952 1910 2002 Badger installs overhead sand transportation equipment improving efficiency of the production process Badger Foundry Co. is founded in Racine, WI 1970 s 1920 • Angus Callender, current president, becomes president of Badger Angus Callender (current president’s grandfather) becomes a controlling shareholder 1949 Badger’s operations are moved to an acquired space of 35, 000 sq. ft. in Winona, MN • Badger builds a new 60, 000 sq. ft. facility and moves to the new space • Badger adds 20, 000 sq. ft. of space and installs new machinery to increase production capacity Badger installs a 1, 000 lb/min. continuous mixer and reclamation equipment to enhance large casting production 1995 Badger implements no -bake process that gives the Company the ability to produce large castings of up to 5, 000 lbs. and added sq. footage to bring the total to 135, 000 sq. ft. 2005 Badger installs electric furnace dedicated to the production of ductile iron castings giving the Company new abilities
Our Product is Iron… Our Strength… People Key Strategic Items / beliefs n n n n Employees – Average length of service is 15 years. Committed to employee safety Financial Strength ISO 9001 -2008 Certified On time delivery Personal and proactive service on each account. Design Support
Our Product is Iron… Our Strength… People Capabilities Iron: Gray and Ductile Iron Casting Weights: Gray - 100 lbs. – 4000 lbs. Ductile – 100 lbs. -2500 lbs. Melt Capacity: Gray - 130 tons/daily Ductile - 35 tons/daily Green Sand Flask Sizes: Typical: 24 X 24, 40 X 40, 36 X 62 inches (Designed to fit your product) No Bake Flask Size: Custom, up to 80 X 80 inches
Our Product is Iron… Our Strength… People Facility n n n Cupola and Electric Melt 40 Ton Holding Furnace 3 Green Sand Molding Lines 2 No Bake Lines – large cast 3 No Bake Core Make Lines Automated Process Control Techniques Extensive Handling Equipment Sand Lab Metrology Pattern Shop 135, 000 sq. ft. facility
Our Product is Iron… Our Strength… People Plant Layout
Our Product is Iron… Our Strength… People Product Management n n Badger maintains a high quality supplier base to accommodate Tier 1 functions. Paint Heat Treat Machine
Our Product is Iron… Our Strength… People Continuous Improvement n n n n n Housekeeping Lean 5’s 2009 – 7 Events 2010 – 5 Events 2011 – 6 Events 2012 – 5 Events 2013 – 2 Event 151 Employees
Our Product is Iron… Our Strength… People Environmental Programs n n n Air Pollution Control Equipment On-site sand disposal Several recycling programs Reclaim Processes Storm Water and Air Emission Controls Title V
Our Product is Iron… Our Strength… People Environmental Programs n n Raw material storage. Byproducts are segregated and stored for recycling.
Our Product is Iron… Our Strength… People Environmental Programs n n n n Beneficial reuse of excess foundry sands. Applications used: Cement production, fill for Ag and general projects. Plant lighting project saving 1, 426, 332 lbs of CO 2 emitted each year. Water usage improvements saving 40% annually. Reclamation of No Bake Sand. Blaster Sand Reclamation. Salvage iron and steel from reuse sand. 120 tons of remelt last (2) years. Coke breeze recycled as a fuel source=94 ton
Our Product is Iron… Our Strength… People Process Flow Raw Materials Melt Pattern/Tooling Produce Core Produce Mold Green Sand No Bake Pour Finish
Our Product is Iron… Our Strength… People Raw Material n n n High quality materials are purchased Supplier Approval Process Detailed Specifications Dedicated working Relationship Advanced planning activity
Our Product is Iron… Our Strength… People Pattern Engineering n n Electronic transfer of blueprint information for work stations using Pro-E, Catia, Anvil, Unigraphics, or I-DEAS. Badger also utilizes online communication tools such as “Same Time” and “Web X”. Solidification Modeling is conducted to ensure casting soundness. Validate casting to model and modeling also available.
Casting Solidification Simulation Showing liquid above 15%. View angle x/y/z: 32/40/135
Our Product is Iron… Our Strength… People Melt Process n n Extensive process control and chemistry analysis. Ductile – Specifically prepared batches / heats to meet each customers needs.
Our Product is Iron… Our Strength… People Lab n Fully Equipped Lab • Chemistry: n n Leco – Carbon Determinater Spectrometer – 17 Elements • Complete Greensand Chemically Bonded Sand Testing
Our Product is Iron… Our Strength… People Molding Process n n n No Bake Green Sand Automated sand control
Our Product is Iron… Our Strength… People Core Process n n n Complex core design and assembly. Proprietary blends to accommodate customer needs. Shell cores
Our Product is Iron… Our Strength… People Finishing Process n n Hanger & Tumble Blast Skilled Inspectors
Our Product is Iron… Our Strength… People Process Instructions
Our Product is Iron… Our Strength… People Our Product
Our Product is Iron… Our Strength… People Contacts Jeff Schaetz V. P. Manufacturing Manager (507)452 -5760 jschaetz@badgerfoundry. com Loren Wadewitz Quality Manager (507)452 -5760 lwadewitz@badgerfoundry. com Chuck Will V. P. Sales (262)650 -8480 cwill@wi. rr. com Frank Kunce Foundry Engineering Mgr (507)452 -5760 fkunce@badgerfoundry. com Kim Hardy Sales (507)452 -5760 Sales@badgerfoundry. com Mike Bader Account Manager - Sales Cell (920)373 -5725 Office (507)452 -5760 mbbadgerfoundry@gmail. com
Our Product is Iron… Our Strength… People Location 1058 East Mark Street Winona, MN 55987
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