Badger Foundry Company
110 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
Badger installs a 1,000 lb/min.
continuous mixer and reclamation
equipment to enhance large casting
production
Our Product is Iron… Our Strength… People
Significant Milestones
Badger Foundry Co. is
founded in Racine, WI
1910
Angus Callender (current
president’s grandfather)
becomes a controlling
shareholder
1920
Richard Callender (current
president’s father) takes
over as president of Badger
1940
Badger’s operations are moved to
an acquired space of 35,000 sq. ft.
in Winona, MN
1949
Badger installs overhead sand
transportation equipment improving
efficiency of the production process
1952
Badger makes significant capital investment
particularly in the core area and expands its
facility size to 115,000 sq. ft.
1980s
2002
•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
1970s
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.
1995
Badger installs electric furnace
dedicated to the production of
ductile iron castings giving the
Company new abilities
2005
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
Our Product is Iron… Our Strength… People
Key Strategic Items / beliefs
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
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
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.
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
Our Product is Iron… Our Strength… People
Process Flow
Finish
Pattern/Tooling
Produce Core
Produce Mold
Raw Materials
Green Sand No Bake
Melt
Pour
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.
Fusion 3D Printer
Casting Fill Simulation
Casting Solidification Simulation
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 Mark Johnson
V.P. Manufacturing Manager Quality Engineer
(507)452-5760 (507)452-5760
jschaetz@badgerfoundry.com mjohnson@badgerfoundry.com
Chuck Will Mike Costello
V.P. Sales Quality Manager
(262)650-8480 (507)452-5760
cwill@wi.rr.com mcostello@badgerfoundry.com
Kim Hardy Neal Malavsky
Sales New Job Startup Manager
(507)452-5760 Office (507)452-5760
Sales@badgerfoundry.com nmalavsky@badgerfoundry.com
Our Product is Iron… Our Strength… People
Location
1058 East Mark Street
Winona, MN 55987
Our Product is Iron… Our Strength… People
Visitor Protocol
To ensure the safety of visitors and
employees, a visitor Protocol is
required.
