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Figure 1: Sand Flows in the Queensland Foundry Industry

	The Queensland Foundry Industry
New Sand Purchased 48,700 tpa		Spent Sand 46,400 tpa
	Sand Lost (< 5% baghouse dust & general loss) 2,300 tpa	Landfill 85%   Beneficial Reuse 15%

As depicted in Figure 1, the average rate of internal sand reclamation for the Queensland foundry industry as a whole is currently 36%. Based on stated plans by several Queensland foundries, the industry average could potentially increase to 50% within the next two years.

Moving beyond 50% recovery will be relatively difficult. A further 5% may be gained if companies improve the efficiency of the current systems. Further gains will probably only be possible through the greater use of thermal reclamation, by improving moulding techniques to reduce the sand input, by changing to different casting processes or by identifying cost effective methods for sand reclamation at small foundries.

While significant work has already been undertake, most Queensland foundries recognise that there are many opportunities for continuous improvement in terms of by-product minimisation and for improving resource efficiency. Key areas identified by the sector include improved sand reclamation, metal yields, energy efficiency and the beneficial reuse of byproducts. All of these opportunities are discussed in further detail in this report.

Cleaner Production focuses on eliminating waste and inefficiency at their source, rather than finding ‘end-of-pipe’ solutions once the wastes have been generated. It involves rethinking conventional methods to achieve ‘smarter’ production processes and products to achieve sustainable production.

In adopting the Cleaner Production approach, try to consider how wastes can be avoided in the first place rather than focusing on how to manage or treat them once they have been generated.

Waste avoidance and reduction should be considered as the first options. Once all avoidance and reduction options have been eliminated, then options for on-site reuse and recycling can be considered. Only as a last resort should treatment and disposal options be considered. This approach is depicted in the Cleaner Production Hierarchy shown in Figure 2.

Cleaner Production has been the major environmental initiative for industries in the 1990’s. Thousands of manufacturing companies, including foundries have taken up Cleaner Production approaches to manufacturing.