Quaker City Castings Invests in Sand Reclaimer

At Quaker City Castings, innovation and sustainability go hand in hand. That’s why we’ve made a major investment in the future of our sand casting operations with the installation of a state-of-the-art sand reclamation system—designed to improve efficiency, reduce waste, and reinforce our long-term commitment to environmentally responsible manufacturing.

This multi-year project has been years in the planning and construction. We’re proud to report that our new thermal sand reclaimer is fully installed and operational, helping us recycle sand from our no-bake sand casting process and return it to production with minimal environmental impact.

Why Reclaim Sand in a Foundry?

Sand casting is one of the most widely used metal casting methods due to its flexibility, cost-effectiveness, and ability to produce large, complex parts. In the no-bake sand casting process, chemically bonded sand molds are created to shape molten metal into precise components. After the metal cools and solidifies, the sand mold breaks away—but traditionally, much of that used sand was discarded as waste.

Sand Reclamation Changes The Equation

By thermally and mechanically processing used sand, we can remove binders, impurities, and contaminants, returning high-quality sand back into the production line. This reduces the demand for virgin sand, lowers disposal costs, and significantly improves the environmental footprint of the casting process.

Inside the New Sand Reclaimer at Quaker City Castings

The centerpiece of our new system is the thermal reclaim unit—an 18-foot-tall machine housed in a brand-new steel building purpose-built to support its size and function. With sand elevators and hoppers reaching up to 25 feet, the new facility dwarfs the older system it replaces.

According to Quaker City Castings owner Joe Korff:

“The new reclaiming system replaces a smaller, outdated unit and is designed to support our growing production needs for years to come. This investment reflects our confidence in the resurgence of American manufacturing and our commitment to smart, sustainable growth.”

Components of the Sand Reclamation System

This was no simple upgrade. Our new sand reclamation system includes:

  • Thermal Reclaim Unit – Burns off residual binders and contaminants at high temperatures.
  • Magnetic Separator – Removes any remaining ferrous materials from the sand stream.
  • Sand Transporters and Elevators – Move reclaimed sand throughout the system for cooling and distribution.
  • Cooling Towers and Hoppers – Bring the sand back down to ambient temperature before reuse.
  • Additive Mixer and Silos – Adjust the chemistry of reclaimed sand to meet specific casting requirements.
  • Dust Collection and Air Handling Systems – Keep operations clean, safe, and compliant with EPA standards.

Our maintenance crew has been instrumental in integrating these systems—laying new gas, air, water, and electrical lines, installing sand piping, and calibrating control systems for full operational efficiency.

Environmental and Operational Benefits

This new system brings a host of improvements to our no-bake sand foundry:

  • Reduced Waste: A significant portion of used sand is now recycled rather than discarded.
  • Lower Costs: By reducing our reliance on fresh sand and minimizing disposal, we lower overall production costs.
  • Improved Sand Quality: Reclaimed sand processed through thermal methods often performs better than fresh sand, with more uniform grain and reduced moisture content.
  • Energy Efficiency: While thermal reclaiming requires energy, the system is optimized for heat recapture and efficient operation, making it more sustainable than constant fresh sand sourcing and disposal.

Supporting Our Mission of “Made in America” Manufacturing

For over 90 years, Quaker City Castings has supported American industry with high-performance iron, steel, and nickel-alloy castings. We’ve always believed that long-term success means investing not only in production capacity, but in the sustainability and resilience of our processes.

Our new sand reclamation system is more than an equipment upgrade, it’s a statement of confidence in the future of domestic manufacturing. As supply chains tighten and environmental regulations grow more stringent, foundries that embrace sustainable innovation will lead the way. We’re proud to be one of them.

About Quaker City Castings

Located in Salem, Ohio, Quaker City Castings is a leading provider of precision-engineered castings using no-bake sand casting and centrifugal casting methods. We pour a wide range of materials including:

We also manufacture high-performance PowerBore Cylinder Sleeves and diesel engine piston rings, supplying industries like energy, transportation, heavy machinery, and defense.

From complex, mission-critical components to small-run prototypes, we combine foundry craftsmanship with modern technology—and now, with more sustainable operations than ever before.

Final Thoughts

As foundries across America look for smarter, greener ways to meet modern production demands, sand reclamation stands out as a key solution. At Quaker City Castings, we’re proud to be leading the charge by investing in systems that improve our environmental impact, product quality, and long-term efficiency.

Whether you’re sourcing sand castings, exploring custom alloys, or looking for a full-service casting partner, we’re here to help.

Contact us today to learn more about our foundry capabilities—and how our new sand reclamation system is shaping the future of American casting.