BOCAR to add more than 300 jobs in north Alabama, invest $115 million

HUNTSVILLE, Ala. (Nov. 16, 2017) – BOCAR, a Tier 1 automotive supplier, plans to invest $115 million in a new plant to be built in Huntsville in Limestone County. The company will hire more than 300 people, adding to the state’s booming automotive manufacturing sector.

BOCAR company leaders made the announcement on Thursday at the Huntsville/Madison County Chamber along with representatives of the City of Huntsville and Limestone County.

“We are glad to invest in Huntsville, Alabama, where good infrastructure, talented people and a host of excellent universities will develop our business while contributing positively to the social and economic development of this community,” said Gerd Dressler, CFO of BOCAR Group.

The plant will be built on a site strategically located on the northern side of Bibb Garrett Road, adjacent to Interstate 65. This will allow the company quick access to be able to ship parts to automotive companies north and south of the Tennessee Valley. Construction is scheduled to begin in the Spring of 2018 and production should begin two years later.

BOCAR is a German company with a presence in the United States, Germany, Mexico and Japan. It is a high-end technology and quality-driven automotive company with extensive experience producing high pressure aluminum die casting, plastics and machining for companies such as Nissan, Ford, GM and Toyota.

“Alabama is a premier destination for the automotive and automotive supplier industries, and we are proud to welcome BOCAR to our state,” Governor Kay Ivey said. “BOCAR choosing Alabama is another sign our state is moving in the right direction and doing all we can to attract good-paying jobs for all Alabamians.”

“BOCAR is highly praised for its attention to quality and excellence,” said Huntsville Mayor Tommy Battle. “And when a company like that puts its seal of approval on Huntsville, it is recognizing our pro-business climate and our highly skilled workforce.”

“We would like to welcome the BOCAR Group to Limestone County and we appreciate their confidence in our workforce,” said Limestone County Commission Chairman Mark Yarbrough. “We know that they will be a successful part of our future moving forward.”

“BOCAR is an innovative company that specializes in high quality precision parts and complex assemblies,” said Huntsville/Madison County Chamber President & CEO Chip Cherry. “They are highly regarded Tier 1 supplier to the automotive industry and we are proud that they selected Huntsville and Limestone County for their new advanced manufacturing facility!”


DETROIT  July 15, 2017 – The Engineering Society of Detroit (ESD) granted its 43rd annual Building and Construction  Award to FS&D for the Brembo North America Foundry

The Brembo North America gray iron foundry in Homer, MI, had been earning attention from metalcasters for several years prior to its opening last spring. When it announced the new capacity project in 2014, the brake specialist made clear its intention to be present in the region’s automotive supply chain, customizing its production capabilities in line with its own product and technologies standards. Those standards had previously been established with a new foundry project in Poland, and continue to be demonstrated by Brembo’s development of an aluminum foundry complex in Mexico.

But the Michigan project now has drawn recognition and praise of a different sort: The project was among a short list of honorees earning the Engineering Society of Detroit’s 43rd Annual ESD Construction & Design Award, with acknowledgement going equally to the new building’ owners, designers, and constructors, with credit for outstanding team achievements and innovative uses of technology.

In addition to Brembo North America, the ESD Construction & Design Award was presented to Foundry Solutions & Design, the engineering design group that conceived and planned the foundry operation; NSA Architects, Engineers, Planners, which handled the aesthetic and overall design, and The Christman Company, the project’s general contractor.

Mitigating the Effect of OSHA’s Silica Rule

The June, 2017 issue of Foundry Magazine features an article by Trent Blake which addresses the silica rule currently in effect.

The new standard, to be enforced starting on July 23, 2018, is half of the previous standard and “requires metal casters to prove that they have implemented all feasible engineering and work practice controls to reduce silica exposure to employees”.

KERAMIDA and Foundry Solutions & Design have formed a partnership to offer the industry a comprehensive resource to develop sampling methods resulting in a silica concentration map of the facility.

This “mapping” strategy allows for an engineering solution to be implemented for reducing the silica at the source.

For additional information please click on the link below


Silica Exposure

Two of the most respected names in the foundry industry have partnered to provide the full range of services to assist our clients in compliance with the new OSHA Silica Regulations, as well as other Environmental, Health, Safety and Security Regulations.

FS&D and Keramida can assist with the following Respirable Silica Reduction Program:

  • Assembling and Documenting the Exposure Control Plan
  • Exposure Studies and Mapping
  • Evaluation of Existing Processes and Practices (Foundry Audit) to   Determine Source and Work Practice Reduction Opportunities
  • Reassess Respirable Silica Exposure Levels
  • Investigate and Recommend Ventilation / Air Pollution Control Improvements
  • Assistance with Process Control Improvement Implementation and Related   Services


Values are recorded by area on a plant layout image



A visual representation of silica loading is generated






OKLAHOMA CITY  September 15, 2016 – The state of Oklahoma and Star Pipe Products today announced that Star Pipe Products has acquired the assets of Jensen International, headquartered in Coffeyville, Kan., and its subsidiary, Jencast of South Coffeyville. Jensen International is a diversified manufacturer providing casting, machining, metal fabrication, assembly and production of customized cast iron and ductile iron products. The acquisition will allow Star Pipe to continue the operation of manufacturing domestically made cast iron and ductile iron products in South Coffeyville. The company intends to expand the existing facility in Oklahoma and install new and updated equipment.

The company will retain the current workforce and expects to create approximately 260 new jobs over the next five years. The direct investment is expected to be in excess of $40 million.

Foundry Solutions & Design has been chosen to provide the engineering service.

Brembo Celebrates First Pour at All-New Cast Iron Foundry in Homer, Michigan

Brembo, the world leader and acknowledged innovator of brake technology, conducted the first pour at its all-new cast iron foundry recently completed in Homer, Michigan. The first pour is a preliminary test of the facility that ensures all systems are functioning properly and is the first step before production ramp up begins.

During this test, the foundry’s furnaces were charged and the molten raw material from these furnaces was poured into a mold for the first time. All systems in Brembo’s new cast iron foundry performed as expected.

The Homer cast iron foundry is the fourth in Brembo’s worldwide foundry network and the first Brembo cast iron foundry in North America.The foundry is also the third manufacturing facility that Brembo has expanded or built at the Homer, Michigan manufacturing site.

“The startup of our new, state of the art foundry in Homer is further proof of Brembo’s commitment to Michigan and is a key component of Brembo’s continued global expansion”, said Matteo Tiraboschi, deputy executive chairman, Brembo S.p.A.  “The growth of our Homer operation exemplifies our commitment to the North American market, the top geographic market for Brembo worldwide.”

“Having our own dedicated foundry in the United States allows us to have maximum control over our process and costs. Our customers benefit by having a dedicated, fully integrated manufacturing process for their brake components,” added Dan Sandberg, president and chief executive officer, Brembo North America.


Construction on the 266,000 square foot foundry began in 2015. Brembo will begin production ramp up next month in May and the foundry is expected to be fully operational in 2017.The foundry is adjacent to Brembo’s 440,000 square foot facility that machines discs and drums for the original equipment market. Brembo also operates a caliper and corner module assembly facility at the same location. Since purchasing the Homer disc plant in 2007, as part of the acquisition of Hayes Lemmerz’s brake business, Brembo has continuously expanded its footprint in Michigan. Construction of Brembo’s North American headquarters and Research and Development Center, in Plymouth, Michigan, took place in 2009.The following year, the Homer caliper assembly building was constructed. Since 2009, the Homer disc plant has been expanded three times. Brembo invested $100 million into the Homer cast iron foundry. At full capacity, it will produce an annual output of 80,000 tons of brake disc castings. The foundry operations will cover an area of approximately 300,000 square feet and will create 250 jobs at the foundry and at Brembo’s North American Headquarters in nearby, Plymouth, Michigan.