Bryce Kish, Senior Pattern Engineer, Michael Budworth, Senior Pattern Design Engineer, Brant Wilterdink, Staff Manufacturing Engineer“We have the resources and staying power to keep growing and supply premium products,” says Sean Wozniak, business development manager.
Differentiating Kohler is its ability to deliver consistent quality with fast turnaround, which bridges a critical gap for manufacturers and OEMs seeking reliable domestic suppliers. The focus on quality, efficient production and prompt delivery enables clients to stay on schedule, more than compensating for the lower costs often offered by overseas suppliers.
Kohler delivers a complete package of value-added solutions that meet diverse client needs. Leveraging a local network of foundries, machine shops, coating specialists and heat treaters, it coordinates machining, finishing and surface treatments to provide ready-to-use components for clients.
Building Long-Term Partnerships through Service-Driven Expertise
Kohler builds on the legacy of Kohler Company, which was founded in Wisconsin in the 1870s by an Austrian immigrant. He pioneered enamel-coated products and earned a reputation for craftsmanship and innovation.
In 1970, Kohler was established as a standalone division within the parent company and equipped with two automated molding lines. The expansion enabled the division to produce camshafts and flywheels for Kohler’s engine division while developing expertise in complex iron castings for various industries, including automotive, construction, rail, agriculture, and waterworks.
Customer referrals added momentum, and the division began to supply additional castings to external markets, gradually moving from passively filling extra capacity to a service-driven model by 1995. Backed by the expertise of its team and the stability of the parent company, Kohler continues to deliver castings that provide lasting value for clients across multiple sectors.
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As part of a larger company, we have the resources and staying power to keep growing and supply premium products.”
The HWS line can produce up to 240 molds per hour within a 42 by 32-inch envelope and handles castings ranging from 5 to 150 lbs. Production is further supported by five induction melting furnaces and three holding furnaces, ensuring efficiency and consistent quality across every project. Quality is treated as a standalone priority throughout the value stream, spanning melting, molding, grinding, cleaning and inspection. Kohler’s employees take pride in their workmanship and ownership of quality, creating premium products that consistently meet the highest standards.
Driving Down Costs, Maximizing Value
Kohler’s knowledgeable engineering team is focused on reducing the cost of its product. Tooling and pattern engineering teams strive to optimize manufacturability, which results in cost savings. The team’s long tenure and expertise enable them to understand precisely how to achieve cost reductions, whether that means reducing weight, simplifying weldments or consolidating assemblies into an as-cast state.
For a defense client, the team produced a very thin-walled casting weighing 8.6 pounds, which is significantly thinner than its typical ADI castings. The part required multiple cores to achieve its complex geometry. Within seven weeks, the team delivered prototypes and full production castings with an industry-leading turnaround time that accelerated the client’s project.
Sustainability is another core focus for Kohler, led by a sustainability officer and supported by multiple champions at various levels of the organization. Within the cast iron division, engineers actively lead projects and implement action items to advance sustainability across operations.
Transforming heavy casting challenges into dependable solutions, Kohler Industrial Castings is the go-to partner for manufacturers to meet demanding schedules with quality and cost-efficiency.
