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Badger Foundry Company 109 Years of Excellence

Badger Foundry Company 109 Years of Excellence. 1910 - 2019. Our Product is Iron… Our Strength… People Quality Policy.

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Badger Foundry Company 109 Years of Excellence

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  1. Badger Foundry Company109 Years of Excellence

  2. 1910 - 2019

  3. Our Product is Iron… Our Strength… PeopleQuality 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

  4. Our Product is Iron… Our Strength… PeopleSignificant Milestones 1980s 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 2002 1910 Badger installs overhead sand transportation equipment improving efficiency of the production process Badger installs a 1,000 lb/min. continuous mixer and reclamation equipment to enhance large casting production Badger Foundry Co. is founded in Racine, WI 1970s 1995 1920 • Angus Callender, current president, becomes president of Badger • 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 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. Angus Callender (current president’s grandfather) becomes a controlling shareholder 1949 2005 Badger’s operations are moved to an acquired space of 35,000 sq. ft. in Winona, MN Badger installs electric furnace dedicated to the production of ductile iron castings giving the Company new abilities

  5. Our Product is Iron… Our Strength… PeopleKey Strategic Items / beliefs • Employees – Average length of service is 21 years. • Committed to employee safety • Financial Strength • ISO 9001-2015 Certified • On time delivery • Personal and proactive service on each account. • Design Support

  6. Our Product is Iron… Our Strength… PeopleCapabilities 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: 24X24, 40X40, 36X62inches(Designed to fit your product) No Bake Flask Size: Custom, up to 80X80 inches

  7. Our Product is Iron… Our Strength… PeopleFacility • 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

  8. Our Product is Iron… Our Strength… PeoplePlant Layout

  9. Our Product is Iron… Our Strength… PeopleProduct Management • Badger maintains a high quality supplier base to accommodate Tier 1 functions. • Paint • Heat Treat • Machine

  10. Our Product is Iron… Our Strength… PeopleContinuous Improvement • Housekeeping • Lean • 5’s • 2009 – 7 Events • 2010 – 5 Events • 2011 – 6 Events • 2012 – 5 Events • 2013 – 3 Event • 2014 – 3 Events • 2015 – 4 Events • 2016 – 4 Events • 2017 – 5 Events • 2018 – 4 Events • 195 Employees

  11. Our Product is Iron… Our Strength… PeopleEnvironmental Programs • Air Pollution Control Equipment • On-site sand disposal • Several recycling programs • Reclaim Processes • Storm Water and Air Emission Controls • Title V

  12. Our Product is Iron… Our Strength… PeopleEnvironmental Programs Raw material storage. Byproducts are segregated and stored for recycling.

  13. Our Product is Iron… Our Strength… People Environmental Programs • 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 CO2 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

  14. Our Product is Iron… Our Strength… PeopleProcess Flow Raw Materials Pattern/Tooling Produce Core Melt Produce Mold Green Sand No Bake Pour Finish

  15. Our Product is Iron… Our Strength… PeopleRaw Material • High quality materials are purchased • Supplier Approval Process • Detailed Specifications • Dedicated working Relationship • Advanced planning activity

  16. Our Product is Iron… Our Strength… PeoplePattern Engineering • 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.

  17. Fusion 3D Printer

  18. Casting Fill Simulation

  19. Casting Solidification Simulation Showing liquid above 15%. View angle x/y/z: 32/40/135

  20. Our Product is Iron… Our Strength… PeopleMelt Process • Extensive process control and chemistry analysis. • Ductile – Specifically prepared batches / heats to meet each customers needs.

  21. Our Product is Iron… Our Strength… PeopleLab • Fully Equipped Lab • Chemistry: • Leco – Carbon Determinater • Spectrometer – 17 Elements • Complete Greensand and Chemically Bonded Sand Testing

  22. Our Product is Iron… Our Strength… PeopleMolding Process • No Bake • Green Sand • Automated sand control

  23. Our Product is Iron… Our Strength… PeopleCore Process • Complex core design and assembly. • Proprietary blends to accommodate customer needs. • Shell cores

  24. Our Product is Iron… Our Strength… PeopleFinishing Process • Hanger & Tumble Blast • Skilled Inspectors

  25. Our Product is Iron… Our Strength… PeopleProcess Instructions

  26. Our Product is Iron… Our Strength… PeopleOur Product

  27. Our Product is Iron… Our Strength… PeopleContacts Jeff Schaetz Curt McCluskey V.P. Manufacturing Manager Tooling Engineer (507)452-5760 (507)452-5760 jschaetz@badgerfoundry.comcmccluskey@badgerfoundry.com Chuck Will Mike Costello V.P. Sales Quality Manager (262)650-8480 (507)452-5760 cwill@wi.rr.commcostello@badgerfoundry.com Kim Hardy Neal Malavsky Sales New Job Startup Manager (507)452-5760 Office (507)452-5760 Sales@badgerfoundry.com nmalavsky@badgerfoundry.com

  28. Our Product is Iron… Our Strength… PeopleLocation 1058 East Mark Street Winona, MN 55987

  29. Our Product is Iron… Our Strength… PeopleVisitor Protocol To ensure the safety of visitors and employees, a visitor Protocol is required.

  30. Thank You

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