Answer extracted from the Empowering Industry Podcast - A Production of Empowering Pumps & Equipment podcast — listen to the full episode below.
How has Mueller Water Products invested in manufacturing capabilities over the past decade?
Mueller Water Products has invested heavily in three foundries over the last 10 years, with employees actively engaged in those expansion efforts. The company now operates a lost-foam foundry that represents state-of-the-art technology not currently used by competitors in their market space.
A commitment to competitive manufacturing edge
The scale of Mueller's investment reflects a broader strategic commitment to manufacturing excellence. As Paul Gifford explains in the episode, the company's foundry upgrades over the past decade position Mueller with proprietary casting capabilities that differentiate it in the hydrant and valve market. This approach stands in contrast to relying solely on external suppliers or older casting methods.
The lost-foam casting technology deployed at Mueller represents a significant technical leap. This process enables higher precision in component manufacturing and allows for more complex geometries that traditional sand casting cannot achieve. The adoption of this technology demonstrates that Mueller is not simply maintaining its existing facilities—it is actively modernizing them to support future product innovation and reliability.
Employee enthusiasm about these manufacturing investments signals confidence in the company's direction. As one reflection of this commitment, the podcast explores how this foundry work supports Mueller's broader vision of serving the water utility industry for decades to come. The company, which has already operated for 160 years, explicitly targets another 160 years of operation—a longevity mindset that justifies sustained capital investment in manufacturing infrastructure.
"Never be satisfied with the way things are. There's always something better."
Paul Gifford — Product Management Group Representative, Mueller Water Products. Paul began his engineering career at a valve and hydrant company in Elmira, New York, working in foundry operations, product development, and quality management. After a circuitous career path, he returned to the hydrant and valve industry in Chattanooga, Tennessee at Mueller Water Products, where he identifies market opportunities and drives innovative solutions like the Hydrant Renewal program. His daughter also works as an engineer at Mueller Water Products.
For a deeper look at how this manufacturing philosophy translates into field results, the full episode details how Mueller's foundry network supports the Hydrant Renewal program, which can restore fire hydrants up to 75 years old—a testament to the durability of components manufactured with modern techniques.
See also
What are the maintenance advantages of proactive hydrant renewal compared to reactive failure management?
Proactive maintenance, similar to automotive oil changes every 3,000 to 4,000 miles, can help water distribution systems work better, last longer, and reduce unexpected failures in municipal infrastructure.
What is the average age of fire hydrants in municipal water distribution systems?
In a survey conducted at a trade show, utilities provided ages ranging from 10 years old to 40 or 50 years old. In a more detailed assessment, Paul Gifford found an average age of 50 years across 25 fire hydrants surveyed between his workplace and Highland Park.
How do water utilities currently use fire hydrants beyond firefighting purposes?
Water utilities primarily use fire hydrants for flushing water lines and for inspection of the pipeline system. Technicians can place cameras down through a hydrant connection to assess the internal condition of pipes and identify maintenance needs.
Key takeaways
- Mueller Water Products has invested in three foundries over the past decade as part of a long-term manufacturing strategy.
- The company operates a lost-foam casting foundry—a state-of-the-art technology that competitors are not yet using in this market segment.
- Manufacturing investment reflects Mueller's commitment to 160 more years of operations and supports product durability and innovation.
- Advanced foundry capabilities enable the production of complex hydrant components that support programs like Hydrant Renewal.