Excellence is Expected

Search
Close this search box.

CWM Recycling Stats – September 2024

In September 2024, CWM sent the following materials to Imperial Recycling for processing:

  • 986 lbs. of cardboard
  • 111 lbs. of paper
  • 108 lbs. of plastic
  • 1,347 lbs. of wood

Additionally, our partner Groot collected approximately 630 lbs. of mixed recyclables, including cans, bottles, plastic containers, and paper, from various locations within the facility.

Overall, CWM successfully diverted 3,788 lbs. of recyclable materials from landfills in September!

CWM Recycling Stats – August 2024

In August 2024, CWM sent the following materials to Imperial Recycling for processing:

  • 1,504 lbs. of cardboard
  • 36 lbs. of paper
  • 207 lbs. of plastic
  • 1,900 lbs. of wood

Our partner, Groot, also collected a variety of mixed recyclables, including roughly 730 lbs. of cans, bottles, plastic containers, and paper from different areas around the facility. Additionally, we recycled 165 lbs. of electronics.

In total, CWM diverted 4,542 lbs. of recyclable material from landfills in August 2024!

Four Future Trends in Die Casting

Die casting is a manufacturing process well known for its precision and efficiency. It is used to make components for various applications across multiple industries. As technology advances and innovations emerge, the die casting industry evolves, and leading die casting companies embrace these new developments and opportunities.

This blog delves into the modern trends that are shaping the future of die casting, from the latest technological advancements to cutting-edge techniques and sustainability considerations; here’s what the future of die casting looks like:

1. Innovations in Die Casting Techniques

a. Automation and Robotics

The integration of automation, including robots and cobots, is revolutionizing die casting processes:

  • Automated Systems: Robots and cobots enhance efficiency and consistency in die casting, CNC machining, and assembly operations. Automated systems streamline the processes, reducing human error and increasing production rates.
  • Smart Technology: Incorporating sensors and real-time monitoring systems allows process optimization. Smart technologies enable precise control over parameters, leading to higher quality and more consistent products.
  • Improved Safety: Automation in die casting reduces worker exposure to hazards, minimizes injury risk from repetitive tasks, and creates a safer work environment by handling dangerous operations.

b. Advanced Prototyping Technologies

Advancements in prototyping technologies ensure that designs are validated before production, which can help reduce project lead times.

  • Rapid Prototyping: Techniques like 3D printing accelerate prototype development by reducing lead times and costs. This technology not only transforms manufacturing through its ability to create complex part geometries but also enables rapid design adjustments and more efficient product development.

2. Environmental and Sustainability Considerations

a. Energy Efficiency

The die casting industry is making strides toward greater energy efficiency:

  • Reduced Energy Consumption: New technologies and materials are being developed to lower energy usage during casting. Innovations in process design and material handling contribute to more sustainable production practices.
  • Recycling and Waste Reduction: Advances in recycling technologies are addressing the challenge of scrap metal and waste reduction. Improved recycling processes help reduce the environmental footprint of die casting operations.

b. Sustainable Materials

Sustainability is becoming a key focus in material development:

  • Eco-Friendly Alloys: Alloys such as aluminum, magnesium, and zinc are eco-friendly due to their recyclability and lower environmental impact than other materials – especially plastic. Aluminum, for instance, can be recycled indefinitely without loss of quality, reducing the need for raw material extraction and energy consumption.
  • Biodegradable Materials: While still in the exploratory phase, biodegradable materials hold promise for reducing the industry’s overall environmental impact. These materials include biodegradable polymers and composites used as lubricants or cleaners that break down more readily in the environment than traditional chemicals.

3. Quality Control and Process Improvement

a. Enhanced Inspection Techniques

Ensuring high-quality outcomes is crucial in die casting:

  • Non-Destructive Testing (NDT): Advances in NDT methods enhance the ability to detect defects without damaging the components. These techniques—like X-rays or light testing methods—ensure products meet rigorous quality standards.
  • AI and Machine Learning: Artificial intelligence and machine learning are emerging as powerful tools for predictive maintenance and defect detection. These technologies enable more proactive quality control and process management.

b. Process Optimization

Optimizing die casting processes is critical to improving efficiency:

  • Simulation and Modeling: Advanced software for simulation (like Magmasoft) and modeling programs to help predict die casting outcomes and refine processes. These tools reduce errors and enhance process efficiency.
  • Lean Manufacturing: Lean principles are applied to die casting to minimize waste and improve operational efficiency. Techniques like value stream mapping and continuous improvement drive better performance and reduced costs.

4. The Future of Reshoring in Die Casting

a. Economic and Strategic Drivers

Reshoring is becoming an increasingly viable option for die casting operations, driven by several key factors:

  • Cost Competitiveness: While labor costs in traditional offshoring destinations have risen, reshoring can now be cost-competitive due to automation and efficiency improvements. The reduction in shipping and logistics costs also makes reshoring more attractive.
  • Supply Chain Resilience: The recent global disruptions have highlighted the vulnerabilities of extended supply chains. Reshoring helps mitigate risks related to supply chain interruptions and geopolitical tensions, offering greater control over production and delivery times.
  • Local Market Demand: Companies are increasingly responding to local market demands for faster turnaround times and customization. Reshoring allows manufacturers to be closer to their end markets, facilitating quicker adjustments to product specifications and market trends.

Conclusion

The die casting industry is undergoing a remarkable transformation driven by advancements in materials, techniques, and sustainability practices. These emerging trends are shaping the future of die casting, offering opportunities for enhanced performance, efficiency, and environmental stewardship. Industry professionals are encouraged to stay informed about these developments and adapt to the evolving landscape.

For further insights and personalized advice on how these trends can affect a potential die cast part, feel free to reach out to CWM. Our team of experts is here to help you navigate the future of die casting and leverage these innovations for your success. Contact us today to discuss how we can support your goals.

CWM Recycling Stats – July 2024

In July, CWM sent the following materials to Imperial Recycling for recycling:

  • 2,315 lbs. of cardboard
  • 97 lbs. of paper
  • 335 lbs. of plastic
  • 2,723 lbs. of wood

Additionally, our partner Groot collected mixed recyclables, including approximately 705 pounds of cans, bottles, plastic bottles, and paper, from various locations around the facility. We also recycled 20 pounds of styrofoam and 177 pounds of electronics.

In total, CWM diverted 6,372 pounds of recyclable material away from landfills in July 2024!

Deep Dive: CWM’s Recycling Efforts in 2023

At CWM, our unwavering dedication to sustainability is not just a part of our identity; it’s the core of who we are. In addition to our monthly updates on recycling efforts, which we post on our blog, we also want to highlight other goals demonstrating our steadfast commitment to this cause.

Together with our partners and stakeholders, we’re paving the way towards a sustainable tomorrow. This collective effort makes CWM a true ‘Green Biz Leader ‘. Let’s look at some of the metrics that we’ve achieved together.

  • Energy Usage: Each year, we’re making significant strides in reducing the electricity and natural gas we use. We’re currently in year 4 of a 5-year goal to reduce our energy consumption by 5%, and we’re on track to accomplish our goal. This progress gives us hope for a more sustainable future.
  • Die Lubrication: The die casting process requires the application of a chemical lubricant on the die with each cycle of the tool. CWM set a goal to use less die lubricant each year due to the total number of pounds of aluminum processed. When we initiated this goal in 2003, we processed 207 lbs. of aluminum per gallon of die lubricant. Twenty years later, our goal was 1,200 lbs. of aluminum processed per gallon of die lubricant used—and we’re proud to say we achieved our goal.
  • Wastewater: CWM has set a goal to reduce wastewater and generate less than 9.43 gallons of wastewater per hundred pounds of aluminum shipped. Back in 2012, for example, we generated just over 18 gallons of wastewater per hundred pounds of aluminum shipped.  In 2023, we only generated 5.5 gallons of wastewater per hundred pounds of aluminum shipped.
  • Copy Paper: Like many companies, CWM consumes hundreds of thousands of pieces of paper each year for creating reports, shipping documents, invoices, purchase orders, training records, etc. In 2013, we used 651,000 pieces of paper and aimed to reduce that usage by 30% over five years. We met that goal in 2018 and created a new goal to reduce the usage by 25% over the next five years. In 2023, we surpassed our goal by only using 242,116 pieces of copy paper when the target to meet was 298,403 pieces of copy paper.
  • Electronics: In 2023, we recycled 100% of the toner cartridges used and achieved our goal of repurposing computer systems. CWM also aims to recycle/repurpose at least five computer systems annually — that goal was also achieved in 2023.
  • Environmental Partnerships: Collaborating with environmental suppliers is integral to reducing our carbon footprint. We work closely with companies such as Groot Recycling for waste hauling, Hazchem Environmental Corp. for wastewater management, and other reputable waste removal firms for various recycling needs.

As we reflect on our major environmental initiatives for all of 2023, it’s evident that Chicago White Metal has made significant strides toward reducing our ecological footprint. Our commitment to sustainability is not just a matter of corporate responsibility; it’s ingrained in our culture and operations.

Looking ahead, CWM is dedicated to environmental sustainability and continuous improvement. We recognize that our journey toward a greener future is ongoing, and we’re committed to exploring innovative solutions and setting ambitious goals to reduce our environmental footprint further. Together, we can make a tangible difference in protecting our planet for future generations.

CWM Recycling Stats – June 2024

In June, CWM sent the following materials to Imperial Recycling for recycling:

  • 1,653 lbs. of cardboard
  • 61 lbs. of paper
  • 203 lbs. of plastic
  • 1,863 lbs. of wood

Additionally, our partner Groot collected mixed recyclables, including approximately 725 pounds of cans, bottles, plastic bottles, and paper, from various locations around the facility.

In total, CWM diverted 4,505 pounds of recyclable material away from landfills in June 2024!

Inside CWM Summer 2024 – Vol. 20 No. 1

In the Summer 2024 edition of Inside CWM you can learn about:

  • What it’s like to work for a “family-owned” business.
  • See who got promoted and find out what their new responsibilities are.
  • Take a deep dive into CWM’s recycling efforts by looking back at 2023.
  • Find out what happened at the 44th annual Golf Outing.
  • Check out pictures of our 2024 company Summer Luncheon.
  • Learn fun facts about die casting, from its origins to the future of die casting.
  • Get anonymous tips from CWM employees.
  • See who won the 2024 NCAA Bracket Challenge and where CWM donated the winnings.

View the PDF: Inside CWM Newsletter –Summer 2024 Edition

CWM Recycling Stats – May 2024

In May, CWM sent the following materials to Imperial Recycling for recycling:

  • 1,187 lbs. of cardboard
  • 116 lbs. of paper
  • 215 lbs. of plastic
  • 2,417 lbs. of wood
  • 2,500 lbs. of concrete

Additionally, our partner Groot collected mixed recyclables, including approximately 795 pounds of cans, bottles, plastic bottles, and paper, from various locations around the facility.

In total, CWM diverted 7,230 pounds of recyclable material away from landfills in May 2024!

Die Cast Solutions No. 53: Optimizing a Fuel Cell Plate

Discover the transformative journey of the Fuel Cell Spring Plate, a vital component in heavy-duty fuel cell systems, crafted through collaborative innovation between CWM and our forward-thinking customer.

This brief delves into the meticulous design enhancements, manufacturing processes, and engineering innovations that culminated in a product surpassing expectations in reliability and performance.

Read more here.

CWM: Enhancing Expertise and Leadership

Anthony Fontana (left), Rob Malarky (center), Nick Bonsignore (right)

Chicago White Metal (CWM) is proud to announce a recent team realignment to bolster expertise and leadership within the sales and engineering departments. These changes mark a strategic shift towards optimizing talent and empowering individuals to drive innovation and excellence across various functions.

Rob Malarky Joins Sales and Marketing as Director of Sales Engineering:

One of the pivotal changes involves the appointment of Rob Malarky to the Sales and Marketing team as Director of Sales Engineering. Rob has been with CWM since 2010; his most recent position was Director of Engineering.

Rob brings a wealth of experience and engineering acumen that will be instrumental in driving CWM’s sales initiatives forward. In his new role, Rob will help to identify new applications and assist customers in transitioning their concepts to successful die casting projects. He will also oversee the technical aspects of CWM’s miniature zinc business.

Anthony Fontana Assumes Leadership Role as Manager of Engineering:

Another significant development is Anthony Fontana’s elevation to the position of Manager of Engineering. Anthony’s promotion underscores his exceptional contributions to CWM since he started here in 2020. In his new capacity, Anthony will lead the Engineering, Process, and Tool Room departments, provide technical support, oversee tooling projects, and nurture talent within the organization.

Nick Bonsignore Appointed as Senior Engineering Project Manager:

Additionally, CWM has appointed Nick Bonsignore as Senior Engineering Project Manager. Nick’s new role will entail expanded responsibilities, including deeper involvement in CWM’s automation initiatives and continued excellence in providing technical assistance for new and existing projects. He will also work closely with Anthony to mentor emerging engineers and support advancement within the department.

These engineering/sales team changes are a testament to CWM’s unwavering commitment to nurturing talent, fostering innovation, and maintaining its position as a leader in the die casting industry. With a strengthened leadership team and enhanced expertise, CWM is in a much better position to meet its customers’ evolving needs.