Protect Your Foundry from Staffing Fluctuations with Electromagnetic Pumps
As 2025 begins, a number of uncertainties continue to swirl around the state and future of manufacturing in the U.S. Questions about inflation, the cost of raw materials, and inconsistent demand abound. Amid these unknowns, one challenge remains clear: workforce shortages show no sign of easing in the coming year.
Across industries, manufacturers have seen sharp decreases in the labor supply. Two primary factors are driving this trend:
- Older workers are aging out: A significant percentage of the foundry workforce has either recently retired or is preparing to do so in the coming years
- Younger workers are spurning manufacturing careers: Stigmas about manufacturing work being dangerous, low paying, and inflexible persist among Millennials and Gen-Z workers
While many manufacturers have been forced to contend with the dwindling workforce, the foundry industry, in particular, has struggled. 30% of respondents to the American Foundry Society’s 2024 Q4 Survey reported that “labor shortages” were one of their top three concerns.
If you manage a foundry, these statistics aren’t abstract – they’re your reality. And while no miracle solution exists, automation is the closest thing to a silver bullet. Automated solutions don’t just help foundries ensure continuity amid labor fluctuations – many can also make foundries safer and more worker friendly. Electromagnetic (EM) pumps, in particular, are a salve to retention and recruitment struggles because they move workers away from the most dangerous and punishing workflow: casting.
Here’s a deeper look at how EM pumps can help your foundry retain current workers, recruit new ones, and ensure continuity while the labor pool is in flux.
EM Pump Basics
EM pumps are an advanced form of casting automation that use electromagnetism – and no moving parts – to move molten metal. Pumps, which are fully enclosed systems installed inside furnaces, eliminate the need for hand ladling. As a result, EM pumps:
- Reduce the risk of hard-to-heal burns
- Save workers from overexertion, heat stroke and burnout
- Increase productivity while minimizing the burdens placed on workers
- Make foundries more appealing to new recruits
Retain Current Employees with Improved Safety & Ergonomics
A study by the National Association of Manufacturers found that, as of 2017, nearly 25% of the manufacturing sector’s workforce is either at or approaching retirement age. That means the current shortage of workers is likely to intensify in coming years.
In addition to depleting the workforce, the mass exodus of aging workers has resulted in a secondary problem: brain drain. As experienced workers leave en masse, their institutional knowledge leaves along with them – and younger workers don’t have the opportunity to learn from them. This, in turn, creates a skills gap that can be extremely challenging to rectify.
EM pumps can help alleviate these issues. They move workers away from the most dangerous part of the foundry and allow them to be repurposed to other, safer – and potentially higher paying – roles. Because of this, foundries that use EM pumps have an easier time retaining employees – and can incentivize workers approaching retirement age to remain for a few years to mentor new workers.
Attract New Workers with Technology-Forward Roles
Foundries that rely on manual processes have a reputation for being unsafe and demanding – and often struggle to fill open positions. This struggle has led some to believe that younger workers are simply unwilling to work in foundries. And, while it can be challenging to compete with safer industries with equivalent pay, foundries are actually incredibly well-positioned to attract younger workers – if only they are willing to invest in technology.
According to recent research from McKinsey, Gen-Z workers are “open to the idea of working in manufacturing” but seek roles that offer “career development and advancement” opportunities – even if the starting salary is slightly lower.
This is excellent news for foundries. While traditional foundry work – like hand ladling – is unlikely to offer the opportunities for advancement that Gen-Z desires, roles that leverage learnable technology – like EM pumps – do. When workers use EM pumps, they gain technical and marketable skills that will allow them to advance their careers – and position them to assume higher wage positions down the line.
Ensure Continuity Amid Labor Fluctuations
EM pumps can solve recruitment and retention issues – but not overnight. As generational labor reshuffling continues, fluctuations to the workforce will, inevitably, persist. Luckily, EM pumps ensure continuity – in productivity and quality – despite ebbs and flows in the labor pool.
Future-Proof Your Foundry with Casting Automation
Since its founding in 1981, CMI Novacast has supplied foundries with EM pumps and related systems, including heated launders, preheat ovens and control systems, to alleviate common casting problems. Implemented alone, or in conjunction with other automation equipment, CMI Novacast EM pumps supercharge production, improve the quality and finish of metal, and help foundries retain and recruit employees.
For more information about EM pumps or foundry automation, speak with a CMI Novacast factory expert or download our guide, A Guide to Automating Your Foundry & Casting Process.
