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
1940
Richard Callender (current
presidents father) takes
over as president of Badger
1910
Badger installs overhead sand
Badger Foundry Co. is
transportation equipment improving
founded in Racine, WI
efficiency of the production process
1920
Angus Callender (current
presidents grandfather)
becomes a controlling
shareholder
1949
Badgers operations are moved to
an acquired space of 35,000 sq. ft.
in Winona, MN
1980s
Badger makes significant capital investment
particularly in the core area and expands its
facility size to 115,000 sq. ft.
1952 2002
Badger installs a 1,000 lb/min.
continuous mixer and reclamation
equipment to enhance large casting
production
1970s 1995
Angus Callender, Badger implements
current president, no-bake process that
becomes president of gives the Company the
Badger ability to produce large
castings of up to 5,000
Badger builds a new
lbs. and added sq.
60,000 sq. ft. facility
footage to bring the
and moves to the new
total to 135,000 sq. ft.
space
Badger adds 20,000 2005
sq. ft. of space and
Badger installs electric furnace
installs new machinery
dedicated to the production of
to increase production
ductile iron castings giving the
capacity
Company new abilities
 Our Product is Iron Our Strength People
Key Strategic Items / beliefs
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: 24X24, 40X40, 36X62inches (Designed to fit your product)

No Bake Flask Size:

Custom, up to 80X80 inches
 Our Product is Iron Our Strength People
Facility
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
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

Housekeeping
Lean
5s
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

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
Raw material storage.
Byproducts are segregated
and stored for recycling.
 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
Our Product is Iron Our Strength People
Process Flow

Raw Materials Pattern/Tooling

Produce Core
Melt

Produce Mold

Green Sand No Bake

Pour

Finish
 Our Product is Iron Our Strength People
Raw Material
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
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 View angle x/y/z:

15%. 32/40/135
 Our Product is Iron Our Strength People
Melt Process
Extensive process control and chemistry
analysis.
Ductile Specifically prepared batches /
heats to meet each customers needs.
 Our Product is Iron Our Strength People
Lab
Fully Equipped Lab
Chemistry:
Leco Carbon Determinater
Spectrometer 17 Elements
Complete Greensand and Chemically
Bonded Sand Testing
 Our Product is Iron Our Strength People
Molding Process
No Bake
Green Sand
Automated sand control
 Our Product is Iron Our Strength People
Core Process
Complex core design and assembly.
Proprietary blends to accommodate
customer needs.
Shell cores
 Our Product is Iron Our Strength People
Finishing Process
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 Loren Wadewitz
V.P. Manufacturing Manager Quality Manager
(507)452-5760 (507)452-5760
jschaetz@badgerfoundry.com lwadewitz@badgerfoundry.com

Chuck Will Frank Kunce

V.P. Sales Foundry Engineering Mgr
(262)650-8480 (507)452-5760
cwill@wi.rr.com fkunce@badgerfoundry.com

Kim Hardy Mike Bader

Sales Account Manager - Sales
(507)452-5760 Cell (920)373-5725
Sales@badgerfoundry.com Office (507)452-5760
mbbadgerfoundry@gmail.com
 Our Product is Iron Our Strength People
Location
1058 East Mark Street
Winona, MN 55987