Foundries Industry Solutions
For more than 35 years, IAC has partnered with foundries across North America and globally to solve critical challenges in emissions control, material handling, and plant performance. From iron and steel foundries to aluminum and nonferrous operations, we deliver turnkey EPC solutions and OEM equipment that withstand the extreme heat, abrasive dust, and high-throughput demands of casting operations.
As one of the top five baghouse manufacturers worldwide, IAC designs and installs air pollution control systems that keep foundries in compliance while protecting uptime. Our expertise extends across every phase of your operation—from cupola furnace ventilation and sand reclamation to bulk storage, conveying, and rotary drying. With vertically integrated capabilities in engineering, fabrication, construction, and service, IAC is your single-source partner for foundry system reliability and efficiency.
Industry Challenges
Foundries operate in some of the most demanding industrial environments, where high temperatures, abrasive dust, and stringent air quality standards converge. Maintaining compliance while keeping throughput high requires systems that are engineered for durability, efficiency, and adaptability.
Key challenges foundries face include:
- Air Pollution Control & Compliance – Silica, metal fumes, and fine particulates must be controlled to meet OSHA, EPA, and global environmental regulations. Inefficient dust collection risks fines, shutdowns, and worker safety.
- High-Temperature, Abrasive Environments – Cupolas, furnaces, and casting lines create extreme operating conditions that rapidly wear down equipment without rugged designs and materials.
- Material Handling & Sand Reclamation – Moving, drying, and recycling foundry sand demands reliable pneumatic and mechanical conveying systems that minimize spillage, energy use, and downtime.
- System Integration in Legacy Plants – Many foundries run older equipment alongside newer systems, creating challenges for integration, automation, and long-term maintenance.
- Downtime & Maintenance – Equipment failures in baghouses, dryers, or loadout systems directly impact production schedules and profitability, making preventative service and quick-response support critical.
IAC addresses these challenges with engineered solutions designed for compliance, throughput optimization, and lifecycle reliability.
Core Capabilities for Foundries
IAC delivers the engineered systems and services that foundries rely on to meet emissions standards, maximize throughput, and extend equipment life. Our vertically integrated approach means every solution is designed, fabricated, installed, and supported with IAC expertise.
Air Pollution Control Systems
- Process and nuisance baghouses – pulse-jet, reverse air, stainless steel, and high-temperature designs
- Cyclone dust collectors for pre-separation and abrasive material handling
- Bin vents and filter receivers for localized dust control
Industrial Drying System
- Direct-fired and indirect rotary dryers for abrasive ores, sand, and minerals
- Patented dryer/cooler design increasing output by up to 134% without added fuel consumption
- Custom internal flighting for optimal heat transfer and moisture control
Material Handling & Sand Reclamation Systems
- Belt, screw, and bucket conveyors engineered for high-load, high-wear service
- Pneumatic conveying systems in dense and dilute phase configurations
- Bulk storage silos, domes, and automated truck/rail loadout systems
Automated Controls
- MCCs and PLC-based systems for integrated plant automation
- Remote monitoring and diagnostics to maximize uptime and throughput
- NFPA-compliant designs with explosion mitigation for combustible dust environments
Custom Fabrication & EPC Execution
With a 500,000 sq. ft. fabrication facility and full EPC capabilities, IAC integrates engineered equipment with on-site construction to deliver turnkey solutions that minimize project risk and accelerate schedules
From abrasion-resistant dryers to high-efficiency filtration systems, IAC equipment is engineered for long service life, low maintenance, and optimal performance in even the harshest mineral processing environments.
Solutions for Foundry Segments
Foundries span a wide range of applications, from iron and steel to aluminum and nonferrous casting. IAC delivers tailored solutions that address the unique requirements of each segment.
- Iron & Steel Foundries
Custom-engineered dust and fume collection systems for cupolas, electric arc furnaces, ladle metallurgy, and casting operations. IAC baghouses and ductwork designs capture high-temperature particulates and metal fumes, ensuring compliance and operator safety. - Nonferrous Foundries (Aluminum, Brass, Bronze)
Lightweight metals require specialized APC systems and pneumatic conveyors. IAC provides stainless steel and corrosion-resistant baghouses, filter receivers, and bulk handling solutions to manage unique material characteristics. - Sand Handling & Reclamation
Rotary dryers, pneumatic conveyors, and screening systems designed for green sand and core sand processes. IAC solutions reduce moisture content, improve reclamation efficiency, and extend baghouse filter life. - Emission Control & Filtration
Dry sorbent injection (DSI), activated carbon injection, and high-performance baghouse retrofits to mitigate mercury, SO₂, HCl, and fine particulates. IAC systems help foundries stay ahead of regulatory requirements while improving operational efficiency.
By integrating these systems with EPC execution and aftermarket service, IAC ensures each foundry segment achieves maximum performance with minimum downtime.
Engineering, Procurement & Construction (EPC)
Foundries rely on EPC partners who can manage complex projects under tight schedules without sacrificing performance or safety. IAC offers a fully integrated EPC model—engineering, procurement, fabrication, and construction—delivered under one roof.
- Turnkey Project Execution
From new greenfield foundries to facility expansions and retrofits, IAC provides end-to-end project management, design, and equipment supply. Our wholly owned subsidiary, Adelphi Construction, self-performs civil, structural, mechanical, and electrical work to maintain schedule control. - Engineering Depth
With 57+ in-house engineers across civil, structural, mechanical, and electrical disciplines, IAC designs and integrates custom APC, drying, and material handling systems that fit seamlessly within foundry operations. - Fabrication & OEM Equipment
IAC’s 500,000 sq. ft. fabrication facility produces rugged baghouses, silos, dryers, and conveying systems designed for the extreme conditions of foundry environments. By controlling fabrication and integration, we deliver quality assurance at every stage. - Fast-Track Schedules
Leveraging our vertically integrated structure, IAC accelerates schedules to bring new or upgraded systems online quickly, minimizing costly downtime.
When you partner with IAC, you gain a single-source EPC provider with the expertise, resources, and accountability to deliver projects on time, on budget, and built to last.
Field Services & Aftermarket Support
Keeping industrial minerals and materials facilities running at peak performance requires more than just quality equipment—it demands expert maintenance, rapid response, and a reliable parts supply. IAC’s Field Services and 55,000+ stocked parts inventory ensures your operation stays online, compliant, and productive.
Maintenance & Repair Services
- Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
- Mechanical repairs including valve, damper, and fan replacement
- Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology
Training
- On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
- Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime
System Optimization
- Burner tuning and dryer flighting analysis to improve efficiency
- Airflow balancing and ductwork inspections to reduce emissions and wear
- Dust control retrofits for improved compliance and product recovery
Parts & Components
- 55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
- Rapid shipment from strategically located warehouses to minimize downtime
- OEM and compatible parts available for multi-brand systems
Partnering with IAC
Foundries demand partners who understand both the complexity of casting operations and the urgency of keeping production online. IAC brings a unique combination of OEM expertise, EPC capabilities, and lifecycle support that few providers can match.
- Proven Industry Experience – Decades of successful projects in foundries worldwide, delivering dust collection, thermal processing, and material handling systems built for demanding conditions.
- Single-Source Accountability – As both an OEM and EPC contractor, IAC eliminates the risks of multi-vendor coordination, ensuring seamless project delivery and long-term reliability.
- Rugged, Field-Proven Equipment – From high-temperature baghouses to abrasion-resistant rotary dryers, our equipment is engineered to last, reducing maintenance cycles and total cost of ownership.
- Comprehensive Parts & Service – With 55,000+ replacement parts in stock and nationwide field crews, IAC keeps your systems running with minimal downtime.
- Commitment to Compliance & Safety – Every solution is designed to meet stringent environmental regulations, protect worker health, and safeguard your investment.
By choosing IAC, foundries gain a trusted partner dedicated to emissions compliance, operational efficiency, and long-term performance.
Request More Information
Industries
Foundries Industry Solutions For more than 35 years, IAC has partnered with foundries across North America and globally to solve critical challenges in emissions control, material handling, and plant performance. […]
Read More
about Foundries Industry Solutions
Turnkey EPC & OEM Solutions for Industrial Metals Processing The metals and materials industries are the backbone of global manufacturing and infrastructure, driving everything from construction and automotive production to […]
Read More
about Metals Production & Processing