Lost Foam: A Clean, Green, Environmentally Friendly Process

The days should be long gone when this facility is perceived as an industrial polluter. We are no longer in the die casting business, which was once upon a time noted for its die lube mist filled bays, oily wastes, and associated PCB contaminant problems. And, while die casting, to be sure, has since seen vast environmental improvements, we at Massena no longer employ that process.

We are now in the business of producing aluminum powertrain components via the Lost Foam Process. Lost Foam, besides being the most revolutionary foundry process yet conceived, is also one of the cleanest, greenest, most environmentally friendly processes in the world today.

The attributes of the Lost Foam process contribute to its being a more effective user of the resources it consumes. For example, Lost Foam offers such characteristics as zero degree draft on locators, as well as minimum draft angles throughout the parts produced. Near net shape castings are also attainable in Lost Foam. Leveraging the attributes of Lost Foam enables the production of previously too complex, if not impossible, casting configurations. This process not only enhances the value of the products, but it also reduces downstream machining, assembly, and other processing operations. This not only further contributes to the generation of less wastes for the environment, but also to less use of natural resources, as well, than what would be required for other casting processes with their associated downstream operations.

In addition to this and the fact that the process uses only a few ounces of material (polystyrene and glue) to produce a part, Lost Foam is focused on recycling at every stage of the process.

To wit:

¨ Received ISO-14001 Certification on 10/16/00

¨ 94% of our aluminum metal usage is recycled aluminum scrap

¨ 98% of the water used on site is recycled

¨ 100% of the water from our process is collected and treated on-site in a DEC permitted water treatment system that includes – separation, activated sludge oxidation, clarification, filtering, and disinfecting

¨ 100% of all storm water from improved plant grounds is collected and treated prior to discharge to river

¨ 100% of all water discharged from the site (excludes landfill), be it process related or natural precipitation, is also filtered through activated carbon column absorption units before being allowed to enter the St. Lawrence River

¨ 100% of our process sand is reclaimed and recycled

¨ sand is reclaimed by heating to 600 degrees F for removal of all volatile organic compounds (VOCs)

¨ VOCs are treated to state-of-the-art catalytic incineration for 99% free emissions to the air

¨ converting our process to Mullite (a man-made, recyclable material) as a replacement for sand (a non-replenishable natural resource) - currently 40% to 60% ratio

¨ 100% of our dross material is recycled

¨ 100% of our machining chips are recycled

¨ 95% of our plastic shot-blast material is recycled (5% fines are not recyclable)

¨ technically a closed-loop recycling; plastic waste is used to make Marblike lawn furniture

¨ 87% of all waste materials are recycled rather than land-filled

6/18/01