The foundry industry is an integral part of engineering industry assisting in making machine parts, and structural components. It is energy intensive and produces enormous quantities of waste which is emitted into the atmosphere and into the waterbodies and landfills. In this study current casting processes available and their waste streams is conducted together with its long-term impact on society and the environment. Ways of improving material utilisation, lessen environmental impact and achieving compliance to pollution standards through analysis of available technology and processes and raw materials. A cost benefit analysis of continuous improvements in a casting environments and alternative manufacturing methods is conducted.