Success Stories

Ford Motor Company, Ohio Turnpike, Abrams Creek, Interstate 271

Ford Motor Company Casting Plant

• Bid Sand in 1980 and 1983
• Awarded Sand Contract in 1986
- subcontracted with BFI 1995-2003
- subcontracted with MPS 2003

In 1986 Kurtz Bros., Inc. responded to the need for recycling of foundry sand; prior to Kurtz Bros., Inc.'s innovative approach, this material was not being recycled. Since partnering with Ford, Kurtz Bros., Inc. has beneficially reused over 5,000,000 tons of SFS (Spent Foundry Sand). This has resulted in huge cost savings to Ford Motor Company throughout the years. Kurtz Bros., Inc. originally handled the foundry sand under Ohio Environmental Protection Agency (OEPA) EPA policy 4.07. In 1993, Kurtz Bros., Inc. was part of a working group with Ohio Cast Metals Association (OCMA) and OEPA that resulted in policy 400.007 in November 1994. Concurrently, Kurtz Bros., Inc. worked with OEPA to have even more flexibility with Ford's SFS. The result? In 1996 Kurtz Bros., Inc. was granted unrestricted topsoil uses with Ford's SFS. Kurtz Bros., Inc.'s continued efforts with OEPA and in December 2001 was granted the first Permit to Install (PTI) for topsoil utilizing SFS (expanding on the 1996 permit). General Motors has since followed our lead.

• Mill Ponds - Cores - Dross Mix - Kurtz Bros., Inc. reduced mill ponds cleaning from three to two ponds per year

Mill ponds were deemed a solid waste in 1986. Because the waste is so wet, it posed an additional burden for disposal. Kurtz Bros., Inc. suggested mixing mill ponds with cores; this resulted in an outstanding solution to the problem. Another area in which Kurtz Bros., Inc. responded positively was in the area of dross disposal. Kurtz Bros., Inc. contributed this and subsequent idea of initial blends. This idea and the resulting cost savings revisions have significantly benefited the Cleveland Casting Plant over the years. As we proceed forward, we are exploring options to further reduce the cost of dross disposal.