Tyler Union opens $25M large diameter foundry expansion

Tyler Union celebrated the official opening of the facility’s new state-of-the-art, large-diameter foundry on April 11 with several community stakeholders and leaders. The 53,000-square-foot foundry expansion began construction in June 2023, costing approximately $25 million.

The expansion, which is projected to create 15 to 25 additional jobs, significantly reduces lead times and increases capacity for large diameter products, such as fittings and valves, enabling Tyler Union to better meet customer demand through greater efficiency and streamlined operations, including the ability to run multiple jobs simultaneously.

Among the highlights of the new foundry is the implementation of the VX400 3D sand printer, the largest system in the world for producing sand molds with a contiguous footprint of 4x2x1 meters. Developed by voxeljet, the printer will be used to print molds and cores, helping to reduce lead times for specialty request products or product specs for which the facility does not have the pattern or core box readily available. Another notable highlight is the large diameter foundry’s use of an induction melt furnace, yielding a more energy-efficient and well-controlled melting process, which is further complemented by dual baghouses as an essential component of the project’s infrastructure. Anniston-based Forsyth Building Company Inc. served as general contractor for the project.

Participants at the ribbon-cutting ceremony included Pollard, McWane, Inc. Chairman Phillip McWane, U.S. Rep. Mike Rogers (AL-03) and Calhoun County Economic Development Council Executive Director Don Hopper. Following the ribbon-cutting ceremony, attendees were offered a tour of the new space.

 “Today represents a milestone for Tyler Union and one that will carry this foundry forward for the next generation,” said McWane Anniston Operations Vice President Jon Pollard. “This plant has been a cornerstone in manufacturing across Calhoun County, and as one of the area’s largest employers, this latest investment is a testament of McWane’s commitment to the continued success of our operation and the economic viability of this area.”