During the past several years, the zircon market has experienced volatile periods of supply and demand with correlated pricing activity. These volatile periods were associated with a supply and demand imbalance that caused price spikes and material allocations, making it difficult for foundries to accurately plan production and price castings. Since mid-2010, we find ourselves in another volatile period that has caused foundries to re-evaluate their processes with a goal of reducing or eliminating zircon usage. By reducing dependence on zircon, foundries minimize or eliminate their exposure to this volatile market. This paper will discuss testing performed on different refractory material and binder systems to identify viable and economical zircon sand and flour substitutes.