A Green Foundry?

[Adrienne Selko]

In a time of declining sales, SA Baxter, a manufacturer of high-end architectural hardware, had its best Q4 ever. And is so often the case these days, a company that is doing well is also doing “good.”

SA Baxter’s foundry, based in New York’s Hudson Valley, is eco-friendly. How friendly you might ask? Well its foundry emits less carbon over an entire year than a fraction of the average small car. Not impressed? The company has Zero Discharge of any solid waste into the local waste water system.

Scott Baxter explains how he can achieve all of this. First of all he says that what he does at his foundry, isn’t done elsewhere.

When building the foundry he considered all aspects of its environmental impact. He analyzed how the byproducts and manufacturing process would affect the air, the water and his employees.

He then implemented systems and processes that produce low emissions, no discharge into area water and chose materials, such as lead-free brass, that would protect employees from airborne pollution.

All of the company’s products are lead-free making SA Baxter the only company to manufacture lead free hardware products in its industry.

His customers appreciate his effort. “When people are weighing their decision on what to purchase, the fact that my company is ‘green’ is a definite advantage. It can be the decisive factor in some cases. And customers are willing to pay a higher price if they know a company is environmentally responsible.”

Baxter would also like to see a global standard when it comes to product quality and environmental integrity. “It would certainly be good for U.S. manufacturing if the playing field was level when it comes to maintaining production standards.”

[IronMan]

I think the question mark in the subject of this post might be an example of a general misunderstanding of the role foundries play in being "green".

Without a lot of fancy programs, new technology equipment, certifications, regulatory red tape, etc., most US foundries are by and large extremely green.

I think it is fair to say that any steel, iron, or ductile iron foundry is melting roughly 80% to 90% scrap material with only a small amount of pig iron for chemistry control. I wouldn't be surprised if the industry average for ferrous foundries is 90% of DIRECT MATERIAL is from recycled scrap. I expect the non ferrous foundries are similar in recycled content.

The US foundry industry is also primarily melting with electric induction furnaces having had most of the cupola operations put out of business by regulations a long time ago.

Considering the bulk of other resources a foundry consumes is silica sand, clay, and some other binder materials, I challenge anyone to find an industry that is nearly as green.

If you showed a picture of an iron foundry and a semiconductor factory to the average American and asked them which is "greener" I suspect the Semiconductor factory would win hands down. This is far from the truth as some of the chemicals used by the Semiconductor factory are so toxic that even a minor leak of certain gases like Silane, etc. are deadly on contact. Not to mention the other acids and process chemicals like arsenic that are commonly used.

Yes, it is admirable and impressive the degree to which technology can be used to clean up the mess of some manufacturing process, but let's give an old industry it's proper due. When your direct materials are 90% recycled and you're only other direct input is electricity and sand, do you really need to fuss about all the other stuff?

Foundries and steel mills need to do a better job of educating the public about the impressive role they play in recycling and re-use of material. I have my doubts about how green it is to cut down forests to make ethanol, or putting a bunch of plastics and batteries into automobiles that may or may not be recyclable. But, when you make something out of iron, steel, or aluminum you know your product may never end up in a landfill, and your domestic foundry or mill will put the scrap back into good use.

Let's educate America and take the question mark out of Adrianne's post and understanding of our industry.