Boro’ Foundry cuts gas use 40% and eliminates landfill sand waste

Boro’ Foundry says a series of operational upgrades in the West Midlands has diverted all of its waste foundry sand from landfill and reduced gas consumption by about 40%. The changes include a new waste partnership, automated ladle preheating and a compliant exhaust system that improve efficiency, sustainability and production quality.

Why it matters: - Boro’ Foundry says the changes cut operating costs, reduce environmental impact and improve competitiveness for British manufacturing. - The upgrades also lower the risk of casting defects and remakes by tightening control over heating and extraction processes.

What happened: - Boro’ Foundry, a fourth-generation family business in the West Midlands, announced major operational investments that eliminate its sand waste to landfill and reduce energy use. - A new arrangement with Booth Ventures Waste Ltd, established in August 2026, sends remaining waste foundry sand to local quarry restoration at Sandown Quarry in Walsall. - Existing routes already repurpose used sand for tarmac production, and the new arrangement means 100% of Boro’ Foundry’s annual waste sand is now diverted from landfill. - The company installed a permanent PLC-controlled ladle preheating system that cut gas consumption by about 40% over a nine-month measurement period. - The company also installed a new Local Exhaust Ventilation system for the sand hopper in June 2026.

The details: - The automated burner brings ladles to precise temperatures in about 20 minutes. - Previous manual operations took two to three hours to reach the same point. - Faster and more precise heating reduces the chance of casting defects and remakes. - The new LEV system brings extraction equipment up to current compliance standards. - The LEV upgrade also improves ongoing maintenance.

Between the lines: - The project blends sustainability with plant efficiency, showing how environmental upgrades can also support output quality and cost control. - The partnership with Booth Ventures Waste Ltd adds a local circular-economy route for material that would otherwise have gone to landfill. - Sales Director Sam Edwards said reducing energy use and waste is fundamental to the future of British manufacturing and helps the foundry compete in a global market.

What's next: - Boro’ Foundry is positioning the upgrades as part of a long-term approach to responsible manufacturing and continuous improvement. - The company points readers to its full case study for more details on engineering capabilities and sustainability initiatives the full case study.

The bottom line: - Boro’ Foundry has turned a waste problem into a cleaner production model while cutting gas use sharply and improving process control.