At Meloon Foundries, we believe that excellence is never a destination—it’s a continuous journey. That philosophy drives every upgrade, every process refinement, and every product we cast. Today, we’re excited to spotlight one of our latest improvements: a major upgrade to our sand delivery system at our Syracuse, NY facility.

Why Sand Delivery Matters

Sand is the foundation of every high-quality sand casting. It’s not just filler—it’s precision material. The quality, consistency, and handling of sand directly influence casting surface finish, dimensional accuracy, and repeatability. By upgrading our sand delivery system, we’ve taken direct aim at these key performance drivers.

The results?

• Minimized downtime

• Reduced material waste

• Tighter tolerances and repeatable quality

Continuous Improvement, the Meloon Way

This enhancement isn’t just about better equipment—it’s part of our ongoing, kaizen-inspired commitment to continuous improvement. From the melt deck to the finishing line, we’ve implemented a range of operational improvements over the years that reduce cycle time, cut costs, and deliver better results to our customers.

Industry data backs up this approach. According to the National Association of Manufacturers, manufacturers who implement continuous improvement strategies see:

• Up to 30% higher productivity

• 20% improvement in lead time reliability

• Reduced scrap and rework by as much as 50%

Every incremental improvement compounds. And with this sand system upgrade, we’re seeing substantial gains in casting consistency, throughput, and overall efficiency.

100% USA-Made. Always.

This upgrade is proudly 100% sourced and built in the USA—from the piping to the precision control systems. That’s not just a detail; it’s a principle. As a family-owned business since 1938, Meloon Foundries has long stood for local manufacturing and American craftsmanship.

By sourcing domestically:

• We reduce supply chain risk

• Ensure top-tier quality control

• Support American jobs at every step

With a 60,000 sq ft facility right here in Syracuse, we are doubling down on American manufacturing strength—built to serve industries that demand reliability, from infrastructure to defense to transportation.

What This Means for Our Customers

This sand delivery system upgrade directly enhances what we deliver to our partners:

• Greater consistency in every aluminum and copper-based casting

• Increased production capacity to meet growing demand

• Lower waste, supporting leaner, greener manufacturing

These aren’t just technical wins—they’re competitive advantages for every client who chooses Meloon Foundries.

Forging Ahead

In a global environment where quality and resilience matter more than ever, Meloon Foundries continues to invest in the systems, people, and processes that deliver both. This sand system upgrade is just one of many steps we’re taking to reinforce our reputation as a trusted American manufacturer.

We’re proud of what our team has accomplished—and we’re excited for what’s next.

Learn more about our capabilities and legacy of quality: Meloon Foundries – 100% American Manufacturing Since 1938