Covia’s Troy Grove Resin Plant: Innovation, Safety, and Quality in Manufacturing
Nestled among the fields near the quiet village of Troy Grove, Illinois, stands a Covia facility that plays an outsized role in supporting the company’s foundry and industrial markets.
Though modest in size, the Troy Grove Resin Plant is far from ordinary. Inside, science and skill intersect as a close-knit team applies advanced thermodynamics to create resin-coated sand products used by manufacturers across many industries. Like other Covia sites, Troy Grove’s story is one of perseverance, innovation, and pride in craftsmanship.
A Team with Deep Roots
Covia has managed operations at Troy Grove for more than three decades, but the facility’s history stretches back much further. What truly sets it apart is the tenure of its employees. Many of the 17 team members have been with the plant since Covia’s acquisition in the 1990s, and one member’s career reaches back over half a century.
“Jose Sanchez was here long before Covia took over and just marked 51 years of service this June,” said Operations Manager Jennifer Perry. “He’s a living archive of the plant’s history and a powerful example of long-term dedication.”
Built on trust, teamwork, and years of expertise, the Troy Grove team embodies stability and collaboration.
The Science Behind Resin-Coated Sand
So, what happens inside the plant? The answer lies in the careful balance of heat, chemistry, and precision.
The process begins by heating sand to the proper temperature before moving it into a pug mill. Resin and crosslinker are added, triggering a chemical reaction that is then halted with water. After drying, additives can be introduced to customize the product to meet each customer’s specifications. With equipment designed to handle a wide variety of formulations, Troy Grove regularly produces numerous grades tailored for different uses.
Once production is complete, the sand is screened, cooled, and packaged in bulk bags weighing between 2,000 and 4,000 pounds. The facility produces coated sands across a wide fineness range — from 30 GFN to 100 — all while maintaining strict quality standards.
“Our SCADA system ensures temperature control within five degrees, regardless of whether it’s -30 or 100 outside,” Perry noted. “Customers count on us for consistency, and that’s exactly what we deliver.”
Safety as a Core Value
While heat is essential to the process, safety is equally critical — and for this team, it’s personal.
“Safety starts with us,” Perry explained. “Most of these employees have worked side by side for decades. They look out for one another as much as for themselves.”
This culture of care has led to impressive results: the plant is nearing a decade without a lost-time incident, underscoring the team’s shared responsibility and commitment to one another’s wellbeing.
Building for the Future
With strong processes and a relentless focus on quality, Troy Grove Resin continues to meet customer needs for reliable resin-coated sand products. But the team is not stopping there — they’re also looking to expand into new markets and broaden their capabilities.
“Every day we come in, we’re stronger than before — stronger than we were five years ago,” Perry said. “We’re committed to diversifying what we do and improving continuously.”
From its Illinois roots, this small yet highly capable Covia plant keeps setting higher standards — one batch at a time.
Though modest in size, the Troy Grove Resin Plant is far from ordinary. Inside, science and skill intersect as a close-knit team applies advanced thermodynamics to create resin-coated sand products used by manufacturers across many industries. Like other Covia sites, Troy Grove’s story is one of perseverance, innovation, and pride in craftsmanship.
A Team with Deep Roots
Covia has managed operations at Troy Grove for more than three decades, but the facility’s history stretches back much further. What truly sets it apart is the tenure of its employees. Many of the 17 team members have been with the plant since Covia’s acquisition in the 1990s, and one member’s career reaches back over half a century.
“Jose Sanchez was here long before Covia took over and just marked 51 years of service this June,” said Operations Manager Jennifer Perry. “He’s a living archive of the plant’s history and a powerful example of long-term dedication.”
Built on trust, teamwork, and years of expertise, the Troy Grove team embodies stability and collaboration.
The Science Behind Resin-Coated Sand
So, what happens inside the plant? The answer lies in the careful balance of heat, chemistry, and precision.
The process begins by heating sand to the proper temperature before moving it into a pug mill. Resin and crosslinker are added, triggering a chemical reaction that is then halted with water. After drying, additives can be introduced to customize the product to meet each customer’s specifications. With equipment designed to handle a wide variety of formulations, Troy Grove regularly produces numerous grades tailored for different uses.
Once production is complete, the sand is screened, cooled, and packaged in bulk bags weighing between 2,000 and 4,000 pounds. The facility produces coated sands across a wide fineness range — from 30 GFN to 100 — all while maintaining strict quality standards.
“Our SCADA system ensures temperature control within five degrees, regardless of whether it’s -30 or 100 outside,” Perry noted. “Customers count on us for consistency, and that’s exactly what we deliver.”
Safety as a Core Value
While heat is essential to the process, safety is equally critical — and for this team, it’s personal.
“Safety starts with us,” Perry explained. “Most of these employees have worked side by side for decades. They look out for one another as much as for themselves.”
This culture of care has led to impressive results: the plant is nearing a decade without a lost-time incident, underscoring the team’s shared responsibility and commitment to one another’s wellbeing.
Building for the Future
With strong processes and a relentless focus on quality, Troy Grove Resin continues to meet customer needs for reliable resin-coated sand products. But the team is not stopping there — they’re also looking to expand into new markets and broaden their capabilities.
“Every day we come in, we’re stronger than before — stronger than we were five years ago,” Perry said. “We’re committed to diversifying what we do and improving continuously.”
From its Illinois roots, this small yet highly capable Covia plant keeps setting higher standards — one batch at a time.
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