Manufacturing Outlook - issue 2

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AIR INDUSTRIES GROUP

Assembling success in the aerospace industry

KAMSTRUP

Offering state-of-theart solutions for smart water metering

REGAL REXNORD AEROSPACE AND DEFENSE Establishing itself as the industry leader in aerospace bearings, seals, electrical components, and gears Bernie Quinn, Engineering Director and Partner at Premcar Pty Ltd, discusses helping global carmakers and their Australian importers create new cars that buyers really want

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Smooth cruising for European manufacturing

Behind the global tech powerhouse of the world’s Smartest City

The suite life of the hotel industry

World-class medical diagnostics for Africa

T R AV E L GUIDE

COCA-COLA SABCO MOZAMBIQUE Iconic and impactful brands and beverages

SYRAH RESOURCES LTD

Putting Mozambique on the map for global EV development

CYPRUS

GENIE ENERGY LTD

BATCHFIRE RESOURCES

Mediterranean escapism in the Land of Aphrodite

Advancing the solar generation

F E AT U R E

MOELLER AEROSPACE

PACTIV EVERGREEN

VAN MOER LOGISTICS

On a trajectory of expansion, Batchfire Resources is the low-fugitive emission energy coal producer pursuing plans for Net Zero

Sustainability and innovation in food and beverage packaging

Gideon Burger, CEO of Axiology Labs discusses providing top quality laboratory products for life science solutions across Africa

quality laboratory products for life science solutions across Africa Gideon Burger, CEO of Axiology Labs discusses providing top

Innoquest Diagnostics is moving forward as one in pursuit of transformative healthcare. Ginny Foo, CEO, gives us the details

Donavan Hutchinson, MD of SHI UK, tells us how how organisations are being empowered to adapt to changing business models and workplace strategies

LTD RESOURCES SYRAH

transformative healthcare. Ginny Foo, CEO, gives us the details Innoquest Diagnostics is moving forward as one in pursuit of

empowered to adapt to changing business models and workplace strategies Donavan Hutchinson, MD of SHI UK, tells us how how organisations are being

brands and beverages Iconic and impactful

MOZAMBIQUE SABCO COCA-COLA

RESOURCES BATCHFIRE

From quaint fishing village to bustling resort getaway

EVERGREEN PACTIV

AEROSPACE MOELLER

RE S US

We go Behind the Lens with culinary storyteller, Karolina Wiercigroch

VALLARTA PUERTO From quaint fishing village to bustling resort getaway

gas turbine technology discovery in air travel and industrial Ascending to new heights of

beverage packaging innovation in food and Sustainability and

TRAVEL GUIDE

PUERTO VALLARTA

We go Behind the Lens with culinary storyteller, Karolina Wiercigroch

of modern infrastructure investment Expert Eye, Amanda Li, discusses the unsustainable nature

LOGISTICS MOER VAN

pursuing plans for Net Zero is the low-fugitive emission energy coal producer On a trajectory of expansion, Batchfire Resources

Charting cleaner waters for the Adriatic

Expert Eye, Amanda Li, discusses the unsustainable nature of modern infrastructure investment

leading sustainable logistics in Belgium Founder and CEO, Jo Van Moer, discusses

EV development on the map for global Putting Mozambique

YACHTING’S SUSTAINABLE REVOLUTION

Ascending to new heights of discovery in air travel and industrial gas turbine technology

Founder and CEO, Jo Van Moer, discusses leading sustainable logistics in Belgium

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waters for the Adriatic Charting cleaner

REVOLUTION SUSTAINABLE YACHTING’S

GUIDE TRAVEL

F E AT U R E

solar generation Advancing the

Land of Aphrodite escapism in the Mediterranean

ENERGY LTD GENIE

CYPRUS GUIDE T R AV E L

diagnostics for Africa World-class medical

AFRICA LANCET CERBA

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WELCOME FROM THE EDITOR

EDITORIAL Head of Editorial: Jack Salter jack.salter@outlookpublishing.com Editor: Lucy Pilgrim lucy.pilgrim@outlookpublishing.com Editor: Ed Budds ed.budds@outlookpublishing.com Editor: Lily Sawyer lily.sawyer@outlookpublishing.com Junior Editor: Rachel Carr rachel.carr@outlookpublishing.com Junior Editor: Lauren Kania lauren.kania@outlookpublishing.com

PRODUCTION Art Director: Stephen Giles steve.giles@outlookpublishing.com Senior Designer: Devon Collins devon.collins@outlookpublishing.com Designer: Louisa Martin louisa.martin@outlookpublishing.com Production Manager: Alex James alex.james@outlookpublishing.com Digital Marketing Manager: Fox Tucker fox.tucker@outlookpublishing.com Web Editor: Oliver Shrouder oliver.shrouder@outlookpublishing.com Social Media Executive: Jake Crickmore jake.crickmore@outlookpublishing.com

BUSINESS CEO: Ben Weaver ben.weaver@outlookpublishing.com Managing Director: James Mitchell james.mitchell@outlookpublishing.com Chief Commercial Officer: Nick Norris nick.norris@outlookpublishing.com Regional Director: Joshua Mann joshua.mann@outlookpublishing.com

HEADS OF PROJECTS Callam Waller callam.waller@outlookpublishing.com Deane Anderton deane.anderton@outlookpublishing.com Eddie Clinton eddie.clinton@outlookpublishing.com Josh Hyland josh.hyland@outlookpublishing.com Ryan Gray ryan.gray@outlookpublishing.com BUSINESS DEVELOPMENT DIRECTOR Thomas Arnold thomas.arnold@outlookpublishing.com TRAINING & DEVELOPMENT MANAGER Marvin Iseghehi marvin.iseghehi@outlookpublishing.com SALES AND PARTNERSHIPS MANAGER Donovan Smith donovan.smith@outlookpublishing.com

PROJECT MANAGERS Cameron Lawrence cameron.lawrence@outlookpublishing.com Dennis Morales dennis.morales@outlookpublishing.com Jack Belton jack.belton@outlookpublishing.com Jordan Levey jordan.levey@outlookpublishing.com Kierron Rose kierron.rose@outlookpublishing.com Kyle Livingstone kyle.livingstone@outlookpublishing.com Liam Pye liam.pye@outlookpublishing.com Nicholas Kernan nicholas.kernan@outlookpublishing.com Poppi Burke poppi.burke@outlookpublishing.com Taylor Green taylor.green@outlookpublishing.com ADMINISTRATION Finance Director: Suzanne Welsh suzanne.welsh@outlookpublishing.com Finance Assistant: Suzie Kittle suzie.kittle@outlookpublishing.com Finance Assistant: Victoria McAllister victoria.mcallister@outlookpublishing.com

CONTACT Manufacturing Outlook Norvic House, 29-33 Chapelfield Road Norwich, NR2 1RP, United Kingdom Sales: +44 (0) 1603 363 631 Editorial: +44 (0) 1603 363 655 SUBSCRIPTIONS Tel: +44 (0) 1603 363 655 jack.salter@outlookpublishing.com www.mfg-outlook.com Like us on Facebook: facebook.com/manufacturingoutlook Follow us on Twitter: @outlookpublish

On Demand, In Demand Welcome to our second edition of Manufacturing Outlook.

In a post-COVID-19 pandemic environment, production demand has rebounded in the North American aerospace industry.

Headlining our latest issue is Regal Rexnord Aerospace and Defense, an established industry leader in aerospace bearings, seals, electrical components, and gears that has satisfied the needs and critical demands of the sector for more than 60 years.

Now increasingly providing vertically integrated electromechanical motion control solutions, we buckle up and explore the company’s evolving story.

The latest chapter includes an impressive new facility that will support Regal Rexnord Aerospace and Defense’s significant growth as a result of an increase in demand, as well as the overall recovery of the aerospace market.

“Our new facility was built with environmental sustainability in mind, evidenced by solar panel arrays, LED lighting, high-efficiency windows, and water conservation features,” excites Senior Director of Operations, Jamison Rediehs.

The concept of on-demand drinks chilling, meanwhile, has been around for many years, and several large companies have tried their hand at achieving success in this field.

V-Tex is driving major advances over traditional refrigeration methods, allowing users to chill beverages on demand while using less energy.

“Our breakthrough approach involves placing the beverage in a chamber filled with cold water and ice using forced convection,” explains Director, Colin Rodgers.

Equally, our Topical Focus highlights the opportunities of on-demand manufacturing, the technology behind it, and the obstacles it needs to overcome.

On-demand manufacturing is already a reality for industries where quick access to spare parts presents the opportunity to gain a potential competitive advantage.

With benefits ranging from de-risking supply chains to reducing waste and saving costs with digital inventories, on-demand manufacturing is changing the way that industries work.

Elsewhere in this edition, discover corporate stories spanning the manufacturing sector across the globe from the likes of Kamstrup, Sulzer South Africa, Premcar Pty Ltd, and more.

We hope that you enjoy your read.

Jack Salter Head of Editorial, Outlook Publishing Manufacturing Outlook Issue 2 | 3

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CONTENTS REGULARS

6 NEWS Around the manufacturing sector in seven stories

8 EXPERT EYE

8

Innovating for the reality of 1.5°C

B U S I N E SS I N S I G H TS

10

10 Maintaining a Chilled Approach Cool innovation, even cooler drinks

14 Machining Strategies in One Click Revolutionising automated manufacturing

TO P I C A L F O C U S

14

18

18 On Demand: The Future of Manufacturing Unlocking potential in the global supply chain

4 | Manufacturing Outlook Issue 2

MANUFACTURING OUTLOOK CONTENTS

F E AT U R E S

22 SHOWCASING LEADING COMPANIES

Tell us your story and we’ll tell the world

NO RT H AMERICA

24 Regal Rexnord Aerospace and Defense A Rich History of Flight Creating a better, energy-efficient tomorrow

34 Kamstrup Leaders in Water Meters Offering state-of-the-art solutions for smart water metering

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90

AS I A PAC I F I C

34

124 Premcar Pty Ltd Engineered, Enhanced, Electrified

46 Dayton Lamina Corporation

Hero cars and zero cars: engineered and built in Australia

Stamp of Approval

134 Mayfield Industries

The go-to partner for all things stamping

Sparking Success

56 Miller Industries Towing and Recovery Titans Vehicles that push the limits to recordbreaking success

66 CJB Companies

114 AFRICA

Focusing on the Future

90 Sulzer South Africa

The exceptional life sciences partner you deserve

Celebrating a Century of Heritage Solutions for sustainable flow management

74 Air Industries Group

104 UNICA Iron and Steel

Flying High

Setting a Solid Standard

Assembling success in the aerospace industry

Growth and production in South Africa

82 Piedmont National Inspiring Greatness in Packaging Signed, sealed, and safely delivered

104

Emerging opportunities and cutting-edge technologies

E U R O P E & MI DD L E E AST

144 Policolor-Orgachim Group Creating a Chemical Kaleidoscope Producing paint in a competitive market

114 Alu-Cab An Adventurous Pursuit A passion for overlanding and exploring the great outdoors

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Manufacturing Outlook Issue 2 | 5

NEWS

Around the manufacturing sector in seven stories…

SECTOR

Slashing Audit Times with Digital Transformation

Biodegradable Food Packaging

FLINTSHIRE-BASED COMPANY KINGSPAN Insulated Panels, a manufacturer of insulated building panels, has reduced the amount of time taken to perform a factory audit from three weeks to just three minutes by implementing a new business-wide Internet of Things (IoT) system.

Having worked with Amazon Web Services and Storm Reply to bring this intelligence to its network of factories, Kingspan Insulated Panels now has ‘IoT in a box’ to send alongside its physical production line, meaning that new factories can be up and running and online faster than ever before, ultimately unifying disparate data and control systems.

ECO-FRIENDLY FOOD PACKAGING firms 2M Group and Xampla have won the Innovate UK Smart Grant to manufacture packaging technology that has the potential to save millions of tonnes (t) of waste from being incinerated or dumped into landfills.

The biodegradable packaging material, Morro, has been designed to replace petroleum-based coatings used on single-use food packaging items and is not only plant-based but also home-compostable and safe for food contact.

The two chemical specialist companies claim that by 2031, Morro materials could replace up to 10,000t of single-use plastic coatings and one million kilometres (km) of plastic-coated paperboard.

Pharmaceutical Giant to Invest £200 Million AS PART OF its plans between 2023 and 2025, British pharmaceutical giant GSK is planning to invest £200 million in its UK manufacturing operations.

With global headquarters in Brentford, West London, GSK is focusing on utilising this investment 6 | Manufacturing Outlook Issue 2

SECTOR

to improve its various sites across the UK, including constructing new facilities and assembly lines.

This investment will help the company improve the production of the ingredients used to make a range of its medicines, along with furthering its commitment to continuous innovation in science, technology, and skills to deliver medicine faster and more efficiently.

SECTOR

SECTOR

Automation UK 2024 Doubling in Size THE FIRST-EVER AUTOMATION UK show in June 2023 proved to be a huge success, providing an opportunity for exhibitors to showcase their latest innovations in automation and robotics to a wide range of visitors.

Due to the substantial triumph and subsequent demand for more big brands and innovators, the show will not only return in 2024 but will double in exhibition space, taking place at the CBS Arena in Coventry.

2024 Manufacturing Industry Predictions PETER ROSS, FOUNDER and Managing Director of CP Cases, has provided his insight on what 2024 holds for the manufacturing industry.

Environmental concerns, rapid progress in technology, and political changes all mapped the manufacturing landscape last year.

As 2024 makes headway, and

Transforming Recruitment

Organised by the British Automation and Robot Association, the show has highlighted the tremendous appetite for an exhibition of this calibre in the UK, as it provides the opportunity to unite companies from all over the sector.

SECTOR

technology continues to advance, the manufacturing industry will be forced to rapidly change alongside it. Artificial intelligence (AI), IoT, and smart factories will make the manufacturing process more efficient and cost-effective.

Meanwhile, sustainability will remain a key priority as companies look to integrate greener choices into their operations as the year continues and new trends emerge.

AUTOMATION HAS UNDENIABLY become the way forward for a variety of businesses within the manufacturing industry.

Having impacted processes and workflows, resulting in increased efficiency, precision, and innovation, the sector is continuously advancing from all the benefits automation is providing.

Recruitment, an area which has been notoriously challenging over the past few years, is slowly being transformed by automation.

The goal is to not only utilise the advancement in automation to assist with skill shortages and training gaps, but to find candidates who are well-versed in current technologies and adaptable to emerging ones, focusing on the value of humanmachine collaboration.

SECTOR

The Desperate Plight of Garment Workers AFTER THE COVID-19 pandemic highlighted the reality of life in the clothing industry, activists and unions gained access to factories to fight for change. However, years later, abuse is still rife within the industry, which is only continuing to grow as a result of fast fashion trends.

Community project Fab-L, a workers’ advice bureau in Leicester, UK, has uncovered a catalogue of exploitative practices, including unpaid wages, unexplained dismissals, and punishing working hours.

Having paired with unions Unite and GMB, Fab-L is aiming to help garment workers understand and enforce their employee rights to ensure the ethical origins of the global textile and apparel manufacturing industry.

Manufacturing Outlook Issue 2 | 7

Responsible Manufacturing in 2024: Innovating for the Reality of 1.5°C

Professor Chris Harrop OBE, Chairman of Made in Britain, explores the feasibility of mitigating global temperature rises within the manufacturing industry, and the important role that manufacturers must play in a world increasingly focussed on sustainability and social responsibility Written by: Professor Chris Harrop OBE, Chairman, Made in Britain

P

ost-COP28, the world must now accept that the aim of keeping global temperature within 1.5°C above pre-industrial levels, as per the Paris Agreement, is dead in the water.

The reality is that a 1.5°C increase in global temperature is inevitable within the next decade. Experts, including the UN Intergovernmental Panel on Climate Change (IPCC), 8 | Manufacturing Outlook Issue 2

predict that this will happen in the early 2030s. Businesses need to ramp up their mitigation efforts, doing everything they can to decarbonise and cope with this new reality. It is a case of adapt or die.

New products will be needed, so manufacturers have a once-in-ageneration opportunity to lead the charge in preparing society for the

1.5°C future. It is they, the creators, and the makers, that will provide the innovations the world needs for the new era.

Here’s an outline of the four key areas of focus for manufacturers committed to responsible business in 2024 and beyond.

1. DECARBONISE: A TRANSFORMATIVE IMPERATIVE Decarbonisation is a transformative imperative for all responsible manufacturers. Where possible, manufacturing companies should be transitioning to cleaner energy sources; streamlining their supply chains; adopting circular economy principles; and continuously developing and building on their

EXPERT EYE MADE IN BRITAIN

2. INNOVATE: CREATE THE PRODUCTS OF THE FUTURE The 1.5°C future brings with it incontrovertible realities. These include more heat and floods, loss of biodiversity, and many more changes to the world around us. Manufacturers across the globe now have the opportunity to create and deliver for the new world.

By prioritising R&D, companies can develop new products that address the challenges posed by climate change, such as climateresilient infrastructure, sustainable energy solutions, and water-efficient technologies.

In this era of adaptation, collaboration is key. Manufacturers should actively seek partnerships with research institutions, government bodies, and fellow industry players to pool resources and expertise.

Shared knowledge and collaborative initiatives will accelerate the development and implementation of optimal solutions.

3. EMBRACE DIVERSITY OF THOUGHT sustainability practices.

Furthermore, manufacturers have another pivotal role to play – innovating to produce alternative products with lower product carbon footprints (PCFs) and embracing new technologies and processes that minimise environmental impact and enhance operational efficiency.

Made in Britain Impact Award winner, PUNCH Flybrid, is an inspiring example of what UK manufacturers can achieve in this area. The company uses flywheel energy storage technology developed for Formula 1 to provide a boost of power and allow users of dynamic equipment to reduce the size of generator they need – saving fuel and reducing CO2 emissions.

The only medium to long-term differentiator between businesses that are successful and those that are not, is people’s brains. It is humans that are the key driver of progress.

As such, responsible business is ultimately all about people.

While diversity of characteristics rightly garners attention, the power of diversity of thought should be at the forefront of our minds too.

Manufacturers should actively seek a broad spectrum of backgrounds, skills, and viewpoints. This not only enhances creativity and innovation but also ensures that solutions are robust, inclusive, and applicable to the diverse markets they will serve.

Harnessing the absolute best ideas means embracing diversity of thought as far as possible. Doing so is essential for driving innovation and problem

solving on a global scale. Thus, diversity of thought is far more than a box ticking exercise – it is a strategic imperative.

4. FORGET LABELS, FOCUS ON ACTION This is the time for tangible, measurable action. Let’s put complacency – and greenwashing – firmly in the past.

Rather than getting hung up on the noise around the many buzzwords and labels – “net zero”, “sustainability”, “carbon neutral” – manufacturers should focus on pragmatic actions that align with the broader goals of decarbonisation, adaptation, and progress.

The challenges posed by the 1.5°C future offer an unprecedented opportunity for manufacturers in the UK and across the world that are able to embrace the reality of this pivotal time.

Our world is entering a new era of manufacturing – this is the moment for responsibility, innovation, and transformative leadership.

The results will astound us.

ABOUT THE EXPERT Professor Chris Harrop OBE is ESG Strategy Director at Marshalls plc and has been at the heart of ESG and sustainability in business for almost 20 years.

He is Chairman of the non-executive board of directors at Made in Britain, the organisation uniting British manufacturers by their licensed use of the official Made in Britain collective mark, and a visiting professor at the University of Huddersfield Business School.

Manufacturing Outlook Issue 2 | 9

V-TEX FEATURE

Maintaining a

CHILLED Approach V-Tex is changing the way the world chills drinks.

We speak to Director, Colin Rodgers about the innovative technology company transforming the way we cool our beverages Writer: Ed Budds

L

aunched in 2010, V-Tex FP7 and Horizon 2020 grants,” is pioneering the drinks he enthuses. chilling industry with its These accolades have been groundbreaking ‘Chill then Go’ instrumental in evolving V-Tex’s technology. technology from a mere proof of Colin Rodgers November 2023 saw the official concept, transitioning successfully launch of the company’s rapid into a full array of commercially chilling solution that is transforming beverage viable products. service in various sectors, including retail, V-Tex’s market success is reflected in the hospitality, and events. continually increasing interest from potential “We’re driving major advances over partners and clients on a daily basis. traditional refrigeration methods, allowing In this way, the company maintains ongoing users to chill beverages on demand while conversations with venue designers, owners, using less energy,” introduces Director, Colin and distributors, actively seeking new opportuRodgers. nities to broaden its influence and reach.

“As a business, we’re deeply committed to addressing escalating global water and energy CONQUERING THE MARKET consumption, and our efforts have not gone The idea of on-demand drinks chilling has unnoticed. We’ve been honoured with the been around for many years, and several large European Commission’s ‘Seal of Excellence’ companies have tried to achieve success in and have received significant funding through this field.

10 | Manufacturing Outlook Issue 2

Manufacturing Outlook Issue 2 | 11

V-TEX FEATURE

“As a business, we’re deeply committed to addressing escalating global water and energy consumption, and our efforts have not gone unnoticed” – COLIN RODGERS, DIRECTOR, V-TEX

Historically, the challenge of drinks chilling has largely stemmed from the complexities involved in rapidly cooling liquids evenly, especially carbonated beverages. The key difficulty lies in achieving even cooling without disrupting the carbonation in fizzy drinks.

The experienced and innovative engineers at V-Tex have tackled these challenges.

“Our breakthrough approach involves placing the beverage in a chamber filled with cold water and ice using forced convection.

The real gamechanger in our technology is the creation of a Rankine vortex by rotating the beverage at a specific speed. This technique allows the carbonated liquid to mix without affecting the carbon dioxide bubbles,” explains Rodgers.

Through extensive testing, V-Tex discovered that cooling rates could be significantly improved by intermittently collapsing and recreating this vortex. This is then achieved through a pulsed rotation, which forms the core of the company’s patented V-Tex technology.

Today, this innovative approach allows the ability to chill drinks in just a few minutes, significantly faster than traditional methods, and offers crucial energy savings of 50 to 90 percent.

Additionally, V-Tex’s technology eliminates the need for the chemicals and glycol typically used in other cooling systems, further enhancing its eco-friendly credentials.

THE REFRIGERATION REVOLUTION V-Tex’s innovative technology allows for a dynamic approach to serving beverages.

Instead of maintaining a static, ready-toserve stockpile of drinks, V-Tex enables wines, beers, and mixers to be chilled on demand as they’re ordered.

The V-Tex unit is equipped with universal holders that can accommodate cans or bottles of any size, ranging from 150 millilitres 12 | Manufacturing Outlook Issue 2

to two litres. This impressive adaptability allows vendors to offer customers a wider variety of chilled beverages that can be served on demand for a fresher, more varied, and customised experience. The result is a significant enhancement in both the efficiency of service and the sustainability of operations.

Unlike traditional cooling systems that operate at a constant temperature, V-Tex’s technology also adapts to the specific cooling requirements of each bottle or can.

This precise temperature control elevates, enhances, and refines the customer’s drinking experience by ensuring that beverages like a fine Chablis or a can of beer are chilled to their ideal serving temperatures.

RESOLUTELY ENVIRONMENTALLY AWARE Across the globe in 2021, beverage companies emitted a staggering 3.8 percent of global CO2 emissions, and with an annual reduction of only 0.7 percent, the industry is increasingly falling behind both its 2030 and 2050 net zero goals.

Broadly, the refrigeration industry, which is traditionally reliant on large refrigerators operating around the clock, has struggled to find sustainable solutions to meet growing demands.

In most commercial settings, pre-packed beverages are kept cold continuously, resulting in significant energy consumption.

V-Tex’s technology, however, disrupts this norm by enabling venues to rapidly and perfectly chill beverages right at the point of sale or consumption, eliminating the need for drinks to be refrigerated 24/7.

In the short term, for venue owners or operators such as contract caterers, the ability to cool larger volumes of drinks using fewer refrigerators offers significant cost savings.

Parallel to this, in the long run, businesses and brands can now boast enhanced energy

V-TEX’S MISSION • To develop technology and products that rapidly and perfectly chill beverages at the point of sale or consumption.

• To develop an everlasting ice bucket to chill beverages, with the capacity to chill hundreds of bottles before changing the water.

• To reduce energy consumption and significantly lower carbon emissions by replacing energy inefficient commercial refrigerators with Enviro-Cool solutions.

REVOLUTIONISING MULTIPLE INDUSTRIES As the vast beverage industry faces yet more economic challenges and frequent closures, V-Tex’s ‘Chill then Go’ technology presents a promising solution to reduce costs and save substantial amounts of water and energy.

“These benefits resonate across the entire supply chain, especially drinks companies, by aligning with green initiatives and increasing sales through efficiently chilled beverages,” Rodgers tells us.

What’s more, this technology enables businesses to optimise space by reducing the need for large refrigeration units. This also means a wider range of products can be stored and chilled on demand, which is particularly advantageous for venues with limited space at their facility.

VIDEO: LIFE INSIDE MEDIA

savings that support greener operations and a move to net zero.

• Reduce the need for larger scale refrigeration • Reduce the quantity of pre-chilled stock • Ensure guests can enjoy a wider range of chilled drinks • Remove the risk that chilled drinks can run out

Now, in restaurants and bars, V-Tex’s fast cooling capabilities improve operational efficiency. As a result, staff can focus more on customer service rather than drinks preparation, enhancing the overall dining experience.

Moving forward, with new drinks being launched by brands and the massive rise in the popularity of non-alcoholic beverages, V-Tex presents the ability to cater for this increasing range of items, enhancing both consumer choice and satisfaction without making energy and environmental issues worse.

Overall, V-Tex is a gamechanging technology that will undoubtedly continue to transform the way businesses chill and serve their beverages. With its intuitive control panel, efficient cooling system, and premium design, V-Tex is a must-have for any business that wants to provide high-quality, chilled drinks to its customers.

For more information, visit v-tex.cool.

Manufacturing Outlook Issue 2 | 13

MACHINING S T R AT E G I E S I N ONE CLICK As the manufacturing industry sees the onset of more advanced technologies, artificial intelligence (AI) poses improvements to automation within the sector. Theo Saville, CEO of CloudNC, tells us more about the company’s use of AI in its precision manufacturing processes Writer: Lily Sawyer

CLOUDNC FEATURE

O

ver the years, the manufacturing industry has continued to see steady growth and an upward trajectory. Whilst this is a fantastic trend for expansion within the industry, the rate of production often struggles to keep pace with demand.

2023 saw AI evolve to influence our everyday lives. From ChatGPT and OpenAI for businesses and individuals, to operational optimisation for supply chains and factories, the onset of new AI technologies certainly increased societal productivity.

As such, the automation of the manufacturing sector has become a top priority going forward. Businesses and manufacturers alike recognise the benefits of AI and automated processes in their day-to-day activities, from optimising design and production functionalities to predictive maintenance and improving the speed of operations.

CloudNC, a UK manufacturing technology company, is a pioneer in this field, applying AI to the manufacturing process, allowing companies worldwide to programme the manufacture of parts and components more efficiently.

Theo Saville, CEO, discusses bringing one-click automation to computer numerical control (CNC) machining.

Manufacturing Outlook (MFG): How is CloudNC using AI to greatly accelerate the computer-aided manufacturing (CAM) programming of CNC machines?

Theo Saville, CEO (TS): CloudNC is a technology company reinventing precision manufacturing by automating CNC CAM programming, enabled by data and experience from our high-spec factory.

We’re backed by investors including Autodesk and Lockheed Martin, and we’re applying AI to accelerate global component manufacturing.

People think making parts and components is automatic, but it’s not. Almost everything that we use is made manually by experts – which requires considerable time, effort, and resources.

CloudNC’s technology accelerates and automates precision manufacturing and makes it more efficient, reliable, and accessible.

It completes much of the difficult, manual work involved with making a component – whether that’s programming a machine, creating a schedule for a factory to produce it, or selecting the correct tools for the job and how best to use them.

As a result, manufacturers become much more productive. Experts spend less hours on time-consuming chores, and instead add value by applying their knowledge to complex tasks.

Meanwhile, less-experienced workers receive a head

start, guided by advanced tools that help them to resolve new challenges.

These advances re-energise manufacturing sectors struggling with rising costs, ageing workforces, and competition from globalisation, keeping the costs of everything down for all.

What we are doing is an important step towards the manufacturing ideal, enabling products to be made with a single click.

MFG: When did you launch CAM Assist, and what has uptake been like since the software hit the market?

TS: We released CAM Assist in June 2023, and it’s now being adopted by hundreds of global users.

Currently available as a plug-in within Autodesk’s Fusion 360 software platform (but coming soon to other platforms), CAM Assist uses advanced computer science techniques to generate professional machining strategies for 3-axis parts in seconds, which could take CNC machine programmers hours or even days to manually create.

Manufacturing Outlook Issue 2 | 15

As a result, the amount of time it takes to programme a CNC machine to make a component – a bottleneck in many factories due to a global skills shortage – is greatly reduced compared to the previous manual programming process.

That gain enables manufacturers using CAM Assist to save hundreds of production hours and shorten lead times.

MFG: What advanced computer science techniques does CAM Assist use to generate these professional machining strategies?

TS: CAM Assist uses advanced computational optimisation and AI inference techniques to rapidly determine a professional strategy and the toolset needed to manufacture a part, along with the most appropriate cutting speeds and feeds from the user’s library.

As a result, a user today can upload a 3D model of a 3-axis component and the software determines the appropriate milling tools needed from those available, and how they will be used.

In seconds, CAM Assist drafts the code required to instruct a CNC machine how to make it, within the user’s existing CAM platform.

CLOUDNC FEATURE

“Essentially, we’re plugging the skills gap that exists within CNC machining (in fact, it’s a skills crisis!) with a smart application of cutting-edge coding that opens up enormous efficiency savings and gains.”

MFG: How will these advancements re-energise precision manufacturing companies struggling with rising costs and ageing workforces?

TS: Manufacturing in many parts of the world is a declining industry, threatened by rising costs as well as global competition from factories overseas that don’t face the same overheads. However, it remains vital, not least because it still makes everything we need today.

Most people don’t realise that manufacturing is still heavily reliant on experts, but it is, and they are getting old; about half of precision machinists will have retired in 10 years, and almost all of them will be retired in the next two decades.

CAM Assist fills that skills gap with smart technology that helps everyone in the CNC process, saving skilled programmers production hours and upskilling junior workers much faster.

Essentially, we’re plugging the skills gap that exists within CNC machining (in fact, it’s a skills crisis!) with a smart application of cutting-edge coding that opens up enormous efficiency savings and gains.

MFG: Finally, can you tell us about the beta testing for 3+2 axis machining?

TS: Yes! In addition to coming soon to platforms like Mastercam, Siemens NX, and Solid Edge, CAM Assist is currently in beta testing for 3+2 axis machining, which will greatly increase the utility of the AI and enable it to make much more complex parts.

If you want to see how CAM Assist can change CAM programming forever, simply go to our website and give it a try!

Manufacturing Outlook Issue 2 | 17

TOPICAL FOCUS ON-DEMAND MANUFACTURING

On-Demand: The Future of Manufacturing Gesa Schneider, Senior Territory Manager for Central Europe at Markforged, highlights the opportunities of ondemand manufacturing, the technology behind it, and the obstacles it needs to overcome Writer: Gesa Schneider, Senior Territory Manager for Central Europe, Markforged

O

n-demand manufacturing is already a reality for industries where quick access to spare parts presents the opportunity to gain a potential competitive advantage.

Sectors including rail, defence, and automotive are leading the way, making the most of technologies like additive manufacturing (AM) to localise production by printing spares, tooling, and products whenever and wherever they are needed.

With benefits ranging from de-risking supply chains to reducing waste and saving costs with digital

inventories – not to mention customising and creating bespoke products to suit customer needs – on-demand manufacturing is changing the way that industries work.

RESPONDING TO A CHANGING LANDSCAPE Where a global supply chain once meant greater access to the right materials and technology, current economic and geopolitical challenges have started to turn what were once deemed benefits into obstacles.

While working across borders still has huge benefits when it comes

to ideas and innovation, businesses have learned from the past few years that bringing a portion of their manufacturing closer to home can help speed up time-to-market.

With longer supply chains continuing to be vulnerable to delays and risks, on-demand manufacturing circumvents these issues time and time again – keeping things moving on the factory floors.

Companies like Deutsche Bahn (DB) have built on-demand manufacturing into their repair and maintenance cycles to speed up repairs, saving time, costs, and resources. The rail giant

produced its 100,000th 3D printed spare part in May 2023 and has a ‘digital warehouse’ containing virtual files of spare components, which DB plans to increase from 1,000 to 10,000 by 2030.

AM is making digital inventories a reality across a range of industries.

Technologies like The Digital Forge allow companies to print the parts they need according to demand. This not only helps to speed up repair cycles and response times, but can lower the high economic and environmental cost of long-distance shipping, as well as reduce waste and storage costs.

AGILE DESIGNS AND SUSTAINABILITY In addition to digital inventories and maintenance, on-demand manufacturing is also changing the way parts and products are designed.

Product design can be optimised with greater flexibility in mind – and thanks to AM, it allows for customisation to suit specific customer requirements.

It can also incorporate more complex geometries than traditional manufacturing methods, allowing for stronger, lighter structures, which are especially beneficial in industries such as automotive and airlines when it Manufacturing Outlook Issue 2 | 19

TOPICAL FOCUS ON-DEMAND MANUFACTURING

comes to reducing emissions.

Additionally, the localisation of production through on-demand manufacturing reduces transportation-related carbon footprints and waste, contributing to environmental sustainability.

The digital nature of on-demand manufacturing also encourages collaboration across departments, borders, and industries – enhancing designs and skills, and helping to create a more agile and flexible workforce.

It is thanks to this technology and collaboration that local automotive service centres printing parts on-demand to service cars, hospitals and surgeries creating custom prosthetics on-site, and innovations like bicycle tyres that never go flat, become a reality.

Industries like footwear are also

turning to on-demand to create custom designs as well as re-shore their manufacturing and reduce waste by creating fewer shoes – manufacturing for demand rather than stock.

ADDRESSING THE CHALLENGES It is important to note that while the possibilities and benefits of on-demand manufacturing are clear and far-reaching, it is not suitable for all means of production. Rather than

eliminating global supply chains, it serves to make them shorter and less vulnerable, whilst becoming more efficient and innovative.

However, on-demand manufacturing still has a long way to go before it reaches critical mass. Sharing success stories and innovations like those above play a big role in helping to overcome the uncertainty, fear of change, and inertia that slow the transformative power of nearly all new technologies.

“In addition to helping manufacturers save time and resources, and reducing waste and emissions, the true value of on-demand manufacturing lies in its ability to de-risk supply chains and solve problems closer to home” – GESA SCHNEIDER, SENIOR TERRITORY MANAGER FOR CENTRAL EUROPE, MARKFORGED

TOPICAL FOCUS ON-DEMAND MANUFACTURING

THE FUTURE OF ON-DEMAND MANUFACTURING

In addition to the challenges of behavioural change, there are still obstacles to overcome in the widespread adoption of on-demand manufacturing.

These are highlighted below, along with how technologies are helping to address them: Scalability and production capacity: On-demand manufacturing works well for smaller scale manufacturing and production, but as demand and volumes grow, it is crucial that their capacity, equipment, and workforce can handle larger orders as well as maintain and deliver consistent quality.

AM can help companies to scale their production volumes up and down, as well as incorporate quality assurance and repeatability.

Digital infrastructure, connectivity, and security: On-demand manufacturing heavily relies on digital technologies and connectivity.

Companies need efficient digital infrastructure, including robust computer-aided design (CAD) systems, digital communication platforms, and secure data transfer.

Government initiatives like Building Digital UK and the Digital Economy and Society Index (DESI) in Europe are helping to extend robust, highspeed broadband and infrastructure to ensure greater connectivity for individuals and businesses.

Emerging technologies like blockchain are helping to ensure the safe transfer of files across borders to protect proprietary data and intellectual property. As trust in this security grows, so will the adoption of technologies that power connectivity and facilitate collaboration between the designers, manufacturers, and customers required for on-demand manufacturing to thrive.

Quality control and certification: Product liability and certification need to be addressed before we can see the widespread adoption of on-demand manufacturing – especially when it comes to regulated industries. This requires collaboration between stakeholders, policymakers, and regulatory bodies.

Connected AM platforms like The Digital Forge are integrated with digital tools, including artificial intelligence (AI) powered validation and simulation to help enable a smooth digital workflow and repeatability that is vital for regulatory compliance.

Industries need to develop comprehensive frameworks that balance safety, innovation, intellectual property protection, and environmental sustainability.

Education: Knowledge is power, and while investment in digital skills is taking place, there is still a need for upskilling the manufacturing workforce. Engineers, product designers, and creatives need to collaborate and work across departments to drive innovation.

Industry and educational institutions need to continue to work together through facilities like Print City and iAero, providing the hands-on and business-level training needed to help on-demand manufacturing reach its potential.

As with any technology advancement, the cost of on-demand manufacturing will decrease as its adoption increases. Ultimately, its success lies in its ability to benefit end users.

In addition to helping manufacturers save time and resources, and reducing waste and emissions, the true value of on-demand manufacturing lies in its ability to de-risk supply chains and solve problems closer to home.

By bringing manufacturing nearer to the customers and markets it serves, on-demand means that products can be specifically developed and tailored to meet the needs of local markets, communities, and businesses.

Its widespread adoption will strengthen manufacturing as a whole, making it more relevant, responsive, and resilient when it comes to solving problems on a local and global level.

ABOUT THE AUTHOR Gesa Schneider has experience in the tech industry and has a determined passion for 3D printing, the circular economy, and sustainable manufacturing. Based in Berlin, she joined Markforged in March 2023, where she manages a team of staff and partners across 22 countries.

markforged.com

Manufacturing Outlook Issue 2 | 21

Tell us your story and we’ll tell the world MANUFACTURING OUTLOOK is a quarterly digital publication and media brand showcasing the latest innovations, industry insights and corporate stories from across the international manufacturing sector. Its world-class team collaborates with the biggest and most exciting brands to craft engaging and authoritative content for a global audience of industry players.

As manufacturing organisations worldwide confront unprecedented change, embracing technological innovations and incorporating critical environmental sustainability agendas, now more than ever is the time to showcase the strides being taken in this dynamic sector.

The expertise of our in-house design and production teams ensures delivery to the highest standards, as we look to promote the latest in engaging news, industry trends and success stories from the length and breadth of the global manufacturing sector.

As a multi-channel brand, Manufacturing Outlook reaches an international audience through various platforms, with exclusive content distributed through our website, online magazine, social media channels, and bi-weekly newsletter.

Through this compelling venture, we intend to foreground the movers and shakers of the industry. To participate as a featured company and join us in this exciting endeavour, contact one of our Project Managers or our Managing Director, James Mitchell, today.

FREE

D AY T O N L A M I N A C O R P O R AT I O N / M I L L E R I N D U S T R I E S

REGAL REXNORD AEROSPACE AND DEFENSE NORTH AMERICA

A RICH H I S TO RY O F

w w w. m f g - o u t l o o k . c o m

Marketi ng Oppo rtunity

FLIGHT

Issue 2

Regal Rexnord Aerospace and Defense, previously Rexnord Aerospace, long established as the industry leader in aerospace bearings, seals, electrical components, and gears, is now increasingly providing vertically integrated electromechanical motion control solutions. We buckle up and explore the company’s evolving story with Senior Director of Operations, Jamison Rediehs

AIR INDUSTRIES GROUP

Assembling success in the aerospace industry

Writer: Ed Budds | Project Manager: Kieron Harvey

KAMSTRUP

Offering state-of-theart solutions for smart water metering

A

cross North gear services for use all America, the over the world for original colossal aerospace equipment manufacturers industry finds itself in the (OEMs). midst of a very exciting As the premier leader period. in the supply of highly Jamison Rediehs Production demand engineered specialty has resolutely rebounded bearings and mechanical in a post-COVID-19 pandemic seals, Regal Rexnord products can environment, with the sector driving a be found in every aspect of the significant amount of innovation as it aerospace landscape, from engine strives for enhanced sustainability. systems and flight controls to landing Keeping aerospace applications gear and aircraft structures. moving for more than 60 years, Regal “Whether it’s the rudder of a plane Rexnord has satisfied the needs or landing gear, our products help and critical demands of the industry provide a smooth operation,” sets out with exceptional quality bearings, Jamison Rediehs, Senior Director of seals, electrical components, and Operations for the company.

REGAL REXNORD AEROSPACE AND DEFENSE Establishing itself as the industry leader in aerospace bearings, seals, electrical components, and gears 136 | Manufacturing Outlook Issue 2

Manufacturing Outlook Issue 2 | 137

Bernie Quinn, Engineering Director and Partner at Premcar Pty Ltd, discusses helping global carmakers and their Australian importers create new cars that buyers really want

www.mfg-outlook.com/work-with-us

R E G A L R E X N O R D A E R O S PAC E A N D D E F E N S E S U P P O R T I N G PA R T N E R S

24 | Manufacturing Outlook Issue 2

REGAL REXNORD AEROSPACE AND DEFENSE NORTH AMERICA

A RICH H I S TO RY O F

FLIGHT Regal Rexnord Aerospace and Defense, previously Rexnord Aerospace, long established as the industry leader in aerospace bearings, seals, electrical components, and gears, is now increasingly providing vertically integrated electromechanical motion control solutions. We buckle up and explore the company’s evolving story with Senior Director of Operations, Jamison Rediehs Writer: Ed Budds | Project Manager: Kieron Harvey

A

cross North gear services for use all America, the over the world for original colossal aerospace equipment manufacturers industry finds itself in the (OEMs). midst of a very exciting As the premier leader period. in the supply of highly Jamison Rediehs Production demand engineered specialty has resolutely rebounded bearings and mechanical in a post-COVID-19 pandemic seals, Regal Rexnord products can environment, with the sector driving a be found in every aspect of the significant amount of innovation as it aerospace landscape, from engine strives for enhanced sustainability. systems and flight controls to landing Keeping aerospace applications gear and aircraft structures. moving for more than 60 years, Regal “Whether it’s the rudder of a plane Rexnord has satisfied the needs or landing gear, our products help and critical demands of the industry provide a smooth operation,” sets out with exceptional quality bearings, Jamison Rediehs, Senior Director of seals, electrical components, and Operations for the company.

Manufacturing Outlook Issue 2 | 25

REGAL REXNORD AEROSPACE AND DEFENSE NORTH AMERICA

With an impressive global production footprint, Regal Rexnord provides highly engineered products and solutions to meet its customers’ needs.

Complementing this, the company’s sales professionals provide support as required and offer solutions tailored to meet client specifications.

Altogether, the Regal Rexnord team delivers on its promise to provide the lowest total cost of ownership and valuable expertise solutions that enhance the ease of doing business with the company.

“Our goal is to consistently create

superior value for our customers,” he adds.

Having been in the manufacturing sector his entire career, Rediehs has always been interested in all things mechanical and developed an initial fascination with flight when he was a child.

“I recall reading the story of the Wright brothers’ first flight over and over again and I marvelled at their ingenuity, so when given the opportunity to work in the aerospace industry I jumped at the chance,” he recalls fondly.

“ O U R T E A M I S C O N S I S T E N T LY D E D I C AT E D T O I N V E S T I N G I N C U S T O M E R - D R I V E N I N N O VAT I O N , C O N T I N U O U S I M P R O V E M E N T, A N D I N C R E A S I N G P R O D U C T I O N C A PAC I T Y T O E N S U R E T H AT W E O F F E R T H E B E S T E X P E R I E N C E S A N D S U P P O R T TO O U R PA R T N E R S A L L A R O U N D T H E G LO B E ” – J A M I S O N R E D I E H S , S E N I O R D I R E C T O R O F O P E R AT I O N S , R E G A L R E X N O R D A E R O S PAC E A N D D E F E N S E

26 | Manufacturing Outlook Issue 2

FORGING A SUSTAINABLE FUTURE Regal Rexnord takes its corporate social responsibility (CSR) very seriously.

“We are driven by our purpose - to create a better tomorrow by energyefficiently converting power into motion. We live according to this purpose and it’s visible in the products and solutions we provide to our customers and in the manufacturing methods we deploy to produce them,” Rediehs enthuses.

As a corporation, Regal Rexnord has committed to achieving carbon emission neutrality across scopes 1 and 2 by 2032, and to improve this to net zero across all three scopes by 2050.

“We are also proud to share that these commitments have resulted in the company being recognized as one of America’s Greenest Companies in the 2024 ranking performed by Newsweek,” he shares proudly.

MW Components owns several brands which produce US-made critical components for aerospace, including metal bellows and assemblies, machined springs, and flexible shaft couplings. From a single prototype to full production runs, with MW Components you can be sure you’ll get the right part to the right specifications every time. To order stock and custom parts, visit mwcomponents.com.

Miniature Metal Bellows

Edge-Welded Bellows

Servometer produces miniature electrodeposited nickel bellows with diameters from 0.02 inches (0.5 millimeters) to eight inches in diameter. They are ideal for applications where reliability and long life are mission critical. We also design custom bellows for many stroke and pressure combinations.

As a premier manufacturer of high-quality, edge-welded bellows and assemblies, BellowsTech offers exceptional service and engineering support to produce optimized designs for prototyping and full production runs.

We offer various sizes, shapes, and specialty materials to customize the product you need.

Servometer products:

BellowsTech products:

• Miniature couplings and hermetic seals

• Accumulators, reservoirs and mechanical seals

• Pressure and temperature responsive devices

• Aneroids

• Electrical contacts

• Volume compensators

• Actuators

• Aneroids

Formed Bellows

Solutions to Simplify Assemblies

For 40+ years, Ameriflex has been a leader in metal bellows production for the vacuum electronics industry.

Our bellows and expansion joints are designed to absorb and reduce vibration and stress from extreme pressure, temperatures, and more.

AS9100D-certified and Nadcap welding accredited.

Helical Products produces custom machined springs, U-joints, and couplings for many applications unique to aerospace. Our flexible parts offer superior lifecycles, repeatability, and precision in extreme conditions.

Helical products are often found in flight controls, fluid and gas valves, and clutch assemblies.

Ameriflex products:

Helical products:

• Multi-ply and thin wall bellows

• Machined springs

• Expansion joints and other assemblies

• Flexible shaft couplings

• Flexible metal hose

• Custom spring solutions

• U-joints

704.837.0331 | mwcomponents.com

REGAL REXNORD AEROSPACE AND DEFENSE NORTH AMERICA

MANUFACTURING OUTLOOK: WHAT DIFFERENTIATES REGAL REXNORD FROM THE COMPETITION? Jamison Rediehs, Senior Director of Operations: “I believe the depth and breadth of our product portfolio is beyond any other company I can think of in our component supplier space. We have competitors in every product we make, but there is no other that designs and manufactures all the products that we do.

“In addition to our substantial product portfolio, we are also a very large organization that can produce products at scale. Because of our size and global footprint, we can supply development hardware for new technologies while also manufacturing products in high quantities with dedicated manufacturing cells.

“Lastly, we believe we have tremendous customer relationships as we have dedicated sales teams and application engineers that are available to support our customers at all times, partnering with them to develop the ultimate solutions for their technological challenges.”

This ranking reflects Regal Rexnord’s performance in reducing greenhouse gas (GHG) emissions, water usage, and waste generation, as well as its environmental commitments and disclosures.

Finally, Regal Rexnord encourages its teams to stay involved in their local communities. This commitment has been demonstrated through volunteering at food pantries, forest clean-ups, flag planting on Memorial Day, blood drives, Meals on Wheels initiatives, and local club support – to name just a few examples.

“Our goal is for our teams to engage directly in the communities where they live and work, and to make a positive impact on their local surroundings.”

STRENGTH IN COLLABORATION Across all industries and sectors, every successful supply chain is made

28 | Manufacturing Outlook Issue 2

up of the interconnected parts of a whole, all of which add up to a highquality final product that is bought by customers.

In this way, Regal Rexnord relies on critical supply chain partners for purchased components and services. From intricate machined componentry to special processes certified by the National Aerospace and Defense Contractors Accreditation Program (NADCAP), the company’s supply chain is vital to its ongoing success.

“Each component we manufacture relies on our supply chain partners to perform a service or provide a critical component of the assembly,” certifies Rediehs.

“Our best relationships are rooted in partnerships that have been forged through long-term collaboration that has enhanced our supply chain’s resilience,” he continues.

SPECIALTY STEEL AND ALLOYS FOR THE AEROSPACE INDUSTRY Michlin Metals excels in meeting unique demands and navigating complex supply chain issues with an unparalleled commitment to precision, quality and reliability. From valueadded processing to sourcing hard-to-find materials, we transform your challenges into opportunities with exceptional service and a commitment to supplying the correct material in a timely manner.

MICHLIN METALS WOMAN OWNED SMALL BUSINESS (WOSB) AS 9100D & ISO 9001

PRODUCTS Michlin Metals specializes in stainless steel, specialty steel, aluminum and specifically, alloys for the aerospace industry including: Aermet 100, Inconel, Monel, Hastelloy, Waspaloy, Kovar, Invar, Titanium and Tungsten.

Stainless Steel

Cold Finished and Alloy

Specialty Steel and Exotic

Aluminum

Brass, Copper, Bronze

APPROVED VENDOR Michlin Metals is an approved supplier for RTX companies, such as Pratt Whitney. In addition, Michlin works with many other large aerospace manufacturers including Sikorsky, NASA and the US Navy.

Call Us NOW for a Quote – Phone 847-272-3240 info@michlinmetals.com | www.michlinmetals.com

The foundation of this effective model of collaboration is open communication and transparent information sharing that fosters realtime problem-solving and continuous process improvement. In this manner, the company’s partners benefit from the extension of the Regal Rexnord Business System (RBS) that continuously drives improved process performance.

Equally crucial to Regal Rexnord’s prosperity is its expert team, which forms the backbone of its entire breadth of operation. Furthermore, empowering and recognizing the contributions of staff in a manufacturing environment is crucial for fostering a positive workplace culture, boosting associate engagement, and improving overall productivity.

“We try to empower our team with training and development opportunities and by involving them in decision-making and 30 | Manufacturing Outlook Issue 2

“ O U R G OA L I S FO R O U R T E A M S TO E N G AG E D I R E C T LY I N T H E C O M M U N I T I E S W H E R E T H E Y L I V E A N D WO R K A N D TO M A K E A P O S I T I V E I M PAC T O N T H E I R LO C A L S U R R O U N D I N G S ” – J A M I S O N R E D I E H S , S E N I O R D I R E C T O R O F O P E R AT I O N S , R E G A L R E X N O R D A E R O S PAC E A N D D E F E N S E

problem-solving through our continuous improvement efforts,” Rediehs tells us.

Regal Rexnord recognizes the outstanding efforts of its associates in a number of ways. First, the company stresses that its environment must operate safely and has created formal recognition programs for the bestsuggested safety improvements each month.

“We also promote the best problem-solving and process improvement efforts with regular awards and acknowledgment throughout the facility. We also hold

employee of the quarter awards every three months that include recognition at all-hands meetings. The bigger picture – the company is aggressively investing to grow its aerospace business, and a key focus of that investment is in its associates, ranging from skill and leadership development to offering a range of opportunities for career advancement.”

EXPANDING OPERATIONS As part of a thrilling new development, Regal Rexnord has begun the process of expanding its operations by opening a new

REGAL REXNORD AEROSPACE AND DEFENSE NORTH AMERICA

The largest precision job shop in the Midwest

(805) 584-2369 | libertyinspection.com

Our services include:

• ITAR reg and DLA certified • ISO 9001 and 13485 • 847-381-4405 • mail@SwissAutomation.com • swissautomation.com

• • • • • • •

Swiss Automation manufactures some of the smallest, most complex machine parts in the world Over 200 CNC Swiss and Multitasking lathes 12-axis Ø.005”-2.75” Space for 50 more machines

Liberty Inspection is an independent full service Non-Destructive Testing (NDT) Laboratory. We have been in business for over 40 years and have done work for many of the largest aircraft companies in the world, along with working with the petro-chemical and nuclear industries.

Broadened expertise with CNC milling and OD grinding

Our company has many major aerospace approvals and our facility is Nadcap approved for both non-destructive testing and chemical processing.

Dry Film Lube Dye Penetrant Magnetic Particle Inspection Radiographic (x-ray) Passivation Visual Inspection Level 3 Consulting

Manufacturing Outlook Issue 2 | 31

Khaite, New York

aerospace manufacturing production facility in Chihuahua, Mexico.

As demand has rebounded, Regal Rexnord recognized the need for additional capacity in the new environment with its trademark aerospace pedigree and a skilled workforce.

The new facility, which will bring an additional 125,000 square feet (sqft) to the company’s operations, will support the significant growth Regal Rexnord is currently experiencing as a result of an increase in product demand as well as the overall recovery of the aerospace market.

“Our new facility was built with environmental sustainability in mind, evidenced by solar panel arrays, LED lighting, high-efficiency windows, and water conservation features,” excites Rediehs.

The state-of-the-art facility keeps sustainability at the forefront by incorporating solar energy to support production needs and other 32 | Manufacturing Outlook Issue 2

Khaite, New York

energy-efficient features to drive the company’s net zero carbon footprint goals.

“The Chihuahua facility will increase our production capacity to better support the growth of our highly

valued customers. This will allow us to increase production, decrease lead times, and get products into our customers’ hands faster,” Rediehs shares.

With more hands on deck, the

REGAL REXNORD AEROSPACE AND DEFENSE NORTH AMERICA

company’s production-to-order process will become more efficient, making business with Regal Rexnord seamless.

“Our team is consistently dedicated to investing in customer-driven innovation, continuous improvement, and increasing production capacity to ensure that we offer the best experiences and support to our partners all around the globe – this new facility is just one way we are doing this,” he continues.

“Our targets for the coming year include leveraging our capacity investment in Chihuahua, to manufacture high-quality products to meet customer needs. The team in Mexico is highly skilled, motivated, and excited to be a part of the Regal Rexnord ecosystem and we will continue to expand our presence in the region throughout the year.”

FUTURE-PROOFING MERGERS Regal Rexnord recently acquired

leading power transmission and factory automation provider, Altra Industrial Motion. With nearly $2 billion in annual sales, the addition of Altra significantly enhances the Company’s capabilities in a range of strategic end markets – including aerospace. The Altra acquisition includes reputable brands such as Kollmorgen, Formsprag, Portescap, Boston Gear, and Thomson Linear to cover the entire range of electromechanical products.

Rediehs commented, “Through the combination of our legacy aerospace business with that of Altra, we have a more comprehensive product portfolio and a scalable global platform and footprint to expand from selling components to also providing vertically integrated electromechanical motion control solutions.”

This year also promises to bring exciting opportunities from a product development standpoint to vertically

integrate Regal Rexnord components into higher-level electro-mechanical actuators.

“We have multiple product lines and brands that design, manufacture, and test electro-mechanical actuators in industrial markets. Additionally, with the electrification of aircraft, and the emerging electric vertical take-off and landing (eVTOL) aircraft market, Regal Rexnord Aerospace & Defense is extremely well positioned.”

Rediehs concluded, “We are extremely excited about the opportunities in front of us at Regal Rexnord to serve our customers with many new, compelling products, and as we do so, to create many exciting opportunities for our associates.

Customer Care: 1-844-295-2376 www.aerospace.rexnord.com

Manufacturing Outlook Issue 2 | 33

KAMSTRUP NORTH AMERICA

LEADERS I N WAT E R METERS As a prominent and dominant force in the smart water metering industry, we speak to Kamstrup’s Country Manager and Vice President of North America, Bruce Bharat, about system solutions Writer: Rachel Carr | Project Manager: Ben Weaver

F

ounded in 1946, and with employees in more than 20 countries, Kamstrup is owned by Danish company OK. A world-leading manufacturer of advanced, solid-state, or static ultrasonic metering solutions for water utilities, Kamstrup also delivers network communications and software solutions for the water industry.

“In North America, we are primarily focused on water; in Canada, we are also engaged in the heating and cooling meter market,” opens Bruce Bharat, Country Manager and Vice President of North America at Kamstrup.

Kamstrup’s origin story revolves around vision, innovation, and perseverance. Since Olaf Kamstrup embarked on his journey as a selfemployed technician, the company has been driven by its late founder’s mantra – “there is always a better solution.

34 | Manufacturing Outlook Issue 2

“To this day, those words drive our people as we pioneer advancements in smart metering solutions through our values – inspire, lead, and deliver,” Bharat continues.

Some pivotal moments have required bold decision-making in keeping with Kamstrup’s vision and values. In 1991, for example, when Kamstrup was a small, agile company amidst a sea of bigger, more successful industry giants, the decision was made to invest in new technology based on the ultrasonic measuring principle over 20 years earlier than any other incumbent water meter provider.

As an early adopter of static ultrasonic technology, Kamstrup left mechanical metering behind over 30 years ago. Today, the company dominates the water industry – delivering the most ultrasonic meters in the market.

Manufacturing Outlook Issue 2 | 35

KAMSTRUP NORTH AMERICA

“We are the only metering provider in North America exclusively offering a full line of static ultrasonic meters, from residential to large commercial and industrial.

MANUFACTURING OUTLOOK: WHAT TYPE OF WORK CULTURE DOES KAMSTRUP HAVE, AND HOW IS IT REFLECTED IN CUSTOMER SATISFACTION? Bruce Bharat, Country Manager and Vice President of North America: “Culture starts with a purpose. At Kamstrup, we cultivate a work culture driven by a shared passion for water conversion, preventing water loss, and knowing that water is life. Our team is motivated by our noble mission of contributing to a sustainable future.

“We also have a very collaborative environment, and every individual’s contribution is valued. Committing to a purpose-driven culture translates into an exceptional dedication to our customers. This commitment is also reflected in our innovative smart water solutions and, in turn, high satisfaction from our utility customers.”

36 | Manufacturing Outlook Issue 2

“We are the company to watch in the water meter industry and are rapidly growing,” observes Bharat.

Kamstrup is widely considered one of the industry’s leading providers that helps utilities measure, manage, and analyze water consumption.

SOLID SOLUTIONS For decades, the water industry has been taught to manage and react. In contrast, Kamstrup has a different approach – it listens and learns.

“There is no such thing as innovation without understanding and empathy, and just like Olaf Kamstrup, we are relentless innovators,” reflects Bharat.

In the market, Kamstrup’s meters are an objective point of difference — their quality is unmatched. They are made of a composite material that resists cross-threading – this characteristic alone receives much attention.

“We also offer stainless steel options for customers concerned about ground shift. All of our commercial and industrial meters are stainless steel,” he adds.

Inside the meters and across its portfolio, Kamstrup embodies the future of water: focused, clean, and high-quality.

“In offering a portfolio exclusively focused on static meters, we offer only the future. We provide reliability, accuracy, and durability as we have the highest-quality meters in the water industry. Kamstrup’s return and customer satisfaction rates are unmatched,” outlines Bharat.

Indeed, Kamstrup’s state-of-the-art meters can identify leaks - known as “real losses” - 24 hours a day, seven days a week, on both the consumer and distribution side thanks to integrated acoustic leak detection.

In doing so, they enable utilities to “see” underground leaks within the distribution network, prioritize repairs, and help reduce the non-revenue water.

This is achieved simply by doing what water utilities have always done: installing meters without hardware or additional networks, like other commercially available solutions. It also adds a new, unique dimension to the traditional advanced metering infrastructure (AMI) business case, primarily focused on operational benefits, that help accelerate return on investment and create a more sustainable environment.

In one instance, a utility reduced water loss from 51 percent to 28 percent three months after deployment.

This was the case in Oneida,

Tennessee, a testament to the company’s technology and the team’s commitment to drastically reducing water loss.

“The easiest way to change customer expectations is to demonstrate Kamstrup in action, to install a meter in the ground, in a house, or other application. Similarly, our customers are our best advocates.

Their results and successes best explain the benefits we can offer,” Bharat highlights.

PROGRESSIVE PROJECT Along with moving to a new facility,

“THERE IS NO SUCH THING AS I N N O VAT I O N W I T H O U T U N D E R S TA N D I N G A N D E M P AT H Y, A N D J U S T L I K E O L A F K A M S T R U P, W E A R E R E L E N T L E S S I N N O VAT O R S ” – B R U C E B H A R AT, C O U N T R Y M A N A G E R A N D V I C E P R E S I D E N T O F NORTH AMERICA, KAMSTRUP

the company’s third North American expansion project in 12 years, Kamstrup is celebrating a milestone project win. El Paso Water is installing Kamstrup’s AMI system and software with meter-integrated acoustic leak detection across more than 220,000 homes and businesses in El Paso, Texas.

“It’s our largest project to date. It is a win for Kamstrup, El Paso, and our distributor partner, Ferguson,” Bharat comments.

The project began with a pilot in which El Paso Water installed several hundred meters across the street from a competitor’s product – half of these were manufactured by Kamstrup.

Manufacturing Outlook Issue 2 | 37

ETEC Services, Inc. (ETEC) provides robust and innovative solutions to our customers, allowing them to operate efficiently, increase production, improve overall system performance, and enhance customer satisfaction. We offer a variety of services to our customers providing them with the necessary services and support for sustainable success.

As an elite distributor of Kamstrup products, ETEC is actively involved in deploying and implementing Kamstrup solutions from start to finish. Our dedicated sales team is heavily involved throughout the entire sales process along with our project management team to ensure a seamless transition from sale to project to post-deployment services and maintenance.

Our experienced project management team has successfully deployed and implemented AMR, AMI, and ALD Kamstrup solutions throughout our territories. Our project management team is fully trained and certified on all Kamstrup software, infrastructure, and devices allowing us to successfully deploy, implement, and optimize Kamstrup solutions for our customers.

In addition, our post-deployment service offerings give our customers the option to have our experienced service and support team continue to provide ongoing professional services and support that will allow them to utilize their Kamstrup solution to its fullest capabilities maximizing their return on investment.

SERVICES AND SOLUTIONS

ETEC specializes in acoustic leak detection (ALD), advanced metering infrastructure (AMI), and automatic meter reading (AMR).

We provide services and support throughout all phases of a project, including pre-deployment, deployment, and post-deployment.

ADVISORY AND PLANNING

ETEC works with the utility’s staff and consultants to asses the current system, identify issues, and provide the best solution to meet the utility’s needs. We work with all stakeholders to develop a project implementation plan and schedule to meet the utility’s goals and expectations through system analysis, data analysis, planning and development, and scheduling.

PROJECT MANAGEMENT

We provide project management services throughout the duration of the project by managing and overseeing the entire deployment process. Our project management team is involved in all stages of the deployment process including planning, implementation, and optimization of Kamstrup solutions.

We coordinate with manufacturers, installation contractors, utility personnel, and consultants throughout the duration of the project. We also track and report progress, manage changes, and provide quality control assistance. ETEC’s project management team has the experience, skills, and expertise to provide the services and support that will ensure a successful project. This is through procurement, project controls, data management, software integration, inventory management, PROJECT HIGHLIGHTS City of Jackson, MS – ALD Water Meter Project: o

Kamstrup ALD Solution

o

74,000 Metering Points

City of Lake Charles, LA – ALD Water Meter Project: o

Kamstrup ALD Solution

o

36,000+ Metering Points

meter configuration, delivery coordination, quality control, and troubleshooting.

NETWORK MONITORING

Our team at ETEC provides AMI network monitoring services to ensure the system operates at peak performance. We continuously monitor and analyze network infrastructure health and system performance to identify any potential issues.

ETEC’s technical support team will identify, investigate, and troubleshoot performance issues involving the AMI network infrastructure and devices. All networking monitoring services are provided in routine reporting to the client.

This includes monitoring AMI network health and performance; remotely addressing AMI system issues; remotely addressing data issues; ensuring network performance standards are met; monitoring and track AMI alarms, system health reporting; KPI reporting; and field troubleshooting.

LEAK MONITORING

ETEC provides leak monitoring services and support to our customers utilizing Kamstrup’s ALD solution to reduce non-revenue water, lower operating costs, and increase revenue.

Our leak monitoring services allow utilities to efficiently identify, locate, and repair leaks on service lines and distribution mains. Our advanced analytics and reporting enable utilities to prioritize maintenance and repair efforts.

This includes monitoring acoustic noise data throughout the distribution network; analyzing and interpreting acoustic noise data; localizing potential leaks on service lines and distribution

mains; prioritizing and coordinating maintenance and repair efforts; work order management; and reporting.

SUPPORT

ETEC’s support team provides services and support to all of our customers, so they can utilize the Kamstrup solution to its fullest potential and maximize return on investment.

This includes IT support; an online help desk with service ticketing management, remote desktop support, and a knowledge base; a return merchandise authorization (RMA); and training for software, such as READy manager,

READy app, leak detector, metertool, labtool, and field procedures, such as READy mobile app and field troubleshooting.

SERVICE AND MAINTENANCE

ETEC provides ongoing post-development service and maintenance options that include monitoring and maintaining the AMI network infrastructure and devices.

Our ongoing service and maintenance allow the utility to lower operating costs, increase operational efficiency, and optimize system performance to ensure the maximum return on investment.

This includes network monitoring; IT support and troubleshooting; leak monitoring; analytics and reporting; customer service; RMA process management; field service and maintenance; and training.

ETEC also offers alternative funding options through strategic partnerships such as meteringas-a-service (MaaS), infrastructure-as-a-service (IaaS), and network-as-a-service (NaaS).

ETEC has in-depth knowledge and years of experience in municipal projects, and our professional staff has specific industrial expertise in such areas as pulp and paper, petrochemical, and poultry processing. Our depth of knowledge is matched by our team, which features eight outside salespersons, eight support staff, and six service technicians. With these resources our clients can feel confident they will be consistently provided with exceptional service and guidance they can trust.

Our service is what truly sets ETEC apart. We know this industry. We understand the challenges our clients face. We know what they need to ensure their projects are successful. ETEC consistently delivers on our promise of impeccable service through three distinct sectors: outside sales, contract administration, and field service.

BENEFITS •

Improve operational efficiency

•

Lower operating costs

•

Increase revenue

OTHER INDUSTRIES SERVED

•

Improve customer service

•

Water treatment

•

Reduce non-revenue water

•

Wastewater treatment

•

Future investment

•

Solids handling

•

Stormwater

WHY ETEC?

ETEC is an organization with expertise in equipment applications for water treatment, wastewater treatment, solids handling, and air emissions. By concentrating on these related areas, we offer an extensive collection of products, which allows us to present optimum solutions for our clients’ particular environmental problems.

We partner with a range of manufacturers to offer our clients the highest quality products for their environmental projects. In addition, we continue to seek manufacturers that not only produce stellar equipment, but are also technological leaders in their field.

www.etec-sales.com

KAMSTRUP NORTH AMERICA

“In a short period, it was clear that Kamstrup meters were measuring more accurately and pulling in more revenue than our competitors.

“Kamstrup’s solid state meter showed consistent and reliable performance. Kamstrup meters paid for themselves, and El Paso committed to a city-wide project in just over a year,” shares Bharat.

The project has many interesting aspects, but one of Bharat’s favorites is that Kamstrup was a uniting factor for the utility. In other words, Kamstrup meters delivered added value, satisfying concerns across the organization, from the meter shop to customer service teams, and from finance and operations to sustainability.

METERING-AS-A-SERVICE (MAAS) MaaS is a truly innovative solution that promises to change the water industry. It is a cooperative solution made possible by Sustainability Partners and Kamstrup that allows utilities to transform infrastructure and operations without upfront capital and zero risk.

Sustainability Partners is a public-benefit corporation offering usage-based infrastructure solutions. By necessity, it has rigorous standards for the meters used as part of MaaS. HOW MAAS WORKS: • It provides complete turnkey installation, maintenance, and troubleshooting, covered by a monthly fee. Once a meter is installed and is verified to be operational, 30 days later, a small monthly fee per installed meter is billed to the utility.

• Sustainability Partners and Kamstrup absorb the costs of deploying meters for a utility and take all the associated risks and accountability for performance.

• Sustainability Partners and Kamstrup resolve any meter issues at no additional cost to utilities, and monthly fees are waived until challenges are fixed and verified. Vendors are accountable for the installation, quality, and performance of water metering assets, end-to-end – a “lifetime warranty” for smart meters.

• MaaS delivers an instant return on investment and eliminates risk. In contrast to the traditional model, if the solution is not working as designed, with MaaS, the utility does not pay the monthly fee until the problem is resolved.

• Any maintenance and troubleshooting burden is shifted away from the utility and directs water utility resources toward proactive problem-solving, such as eliminating leaks in the distribution network.

42 | Manufacturing Outlook Issue 2

HURDLING BARRIERS Some projects undertaken

by Kamstrup have been more challenging, but the company has overcome many issues.

“I think about projects such as Milcrofton, Tennessee, where their legacy automatic meter reading (AMR) systems began to fail before they were expected to, increasing the operation cost to the utility. We brought in our product, and the crew’s first reaction was to dismiss it because it was different. They mistook our composite meter for plastic.

“The Milcrofton crew took one of our meters and tested it. They put a 24-inch pipe wrench on a vice with the meter and couldn’t misthread or break it. They admitted that the amount of torque applied would undoubtedly have damaged a brass meter,” Bharat declares.

Milcrofton went on to become Kamstrup’s first AMI customer in the US. Furthermore, Iredell County in North Carolina has a highly rural environment, which can be challenging for AMI technology.

We’ve got your back at every angle At Fortiline, our valued customers include small municipalities to large, multi-state corporations and everything in between.

Fortiline Waterworks is a leading supplier of underground water, sewer, and storm utility products in the United States. Founded in 1997, Fortiline distributes thousands of SKUs to a diverse base of contractors, developers, and municipal customers through our branch network across the U.S.

We have extensive experience with all water meters, AMR, and AMI systems on the market.

Fortiline can provide customized programs to evaluate the condition of your metering system, correct immediate problems, and keep it running smoothly for the long term.

From estimating and bid support before the project begins to expert procurement of the right products to project management and on-time delivery — we are with you every step of the way.

www.fortiline.com

KAMSTRUP NORTH AMERICA

“We were able to deploy the collector infrastructure to read meters remotely and cost-effectively, enabling Iredell Water to read meters across their entire 450-mile service territory at a success rate of over 98 percent,” Bharat divulges.

The revenue capture that Iredell Water received through low-flow accuracy with Kamstrup meters has delivered an increase of 10 million gallons from one year to the next.

“For nearly two decades, they carried mechanical meters and missed a lot of consumption.”

Additionally, a project in Jackson, Mississippi, presented challenges as the state capital was engaged in a lawsuit with a previous contractor over poor performance.

Therefore, Jackson was thrust into a simultaneous financial and water crisis.

44 | Manufacturing Outlook Issue 2

“They were losing significant amounts of water before delivery to citizens, the billing and receivables were at a low point, and the water quality was unstable, leaving the citizens of Jackson without safe, clean drinking water.

“Through our partnership with Sustainability Partners, we approached Jackson with MaaS, which enabled them to overhaul their infrastructure with no upfront capital investment or financial risk,” Bharat shares.

Jackson is now beginning to deliver safe, clean drinking water again, and receivables are increasing.

Kamstrup technology helps the city restore trust and generate revenue through accurate metering. Its meterintegrated acoustic leak detection also helps locate leaks within Jackson’s distribution system.

INNOVATIVE METERING INFRASTRUCTURE Not all AMI solutions are the same.

Kamstrup has elevated what is possible with AMI by integrating measurement and detection capabilities with communications inside the meter.

“There is a reason why Kamstrup boasts more ultrasonic installations than our competitors – our meters simply outperform the competition.

Once customers install our ultrasonic meter in the ground, they love the performance, quality, and fast return on investment.

“We are constantly innovating to deliver utility technology that meets their current needs and a solution that anticipates tomorrow’s operational demands. We are proud to be at the forefront of innovations and technological advances in the water

industry,” prides Bharat.

One of Kamstrup’s standout technologies is the flowIQ® 2200, a groundbreaking solution redefining residential water metering. The ultrasonic meter features acoustic leak detection integrated into the meter, enabling utilities to monitor their distribution systems for leaks.

It also features best-in-class lowflow detection that measures even the most minor consumption below 1/10th of a gallon per minute. It is a vast improvement over mechanical meters and better than any available static meters.

“Our meters minimize the amount of water that goes undetected. The term we’ve coined in our business is, ‘life happens at 1/8th of a gallon’. Most meters in North America today will not capture water flow at such a low rate, where life happens,” he notes.

The meters have no moving parts, so the performance does not degrade over time. For utilities, such measurement sensitivity and durability can amount to significant, even transformational, revenue recovery.

The flowIQ® 2200 is the most accurate residential meter in the industry and the only one capable of listening bi-directionally, on the consumer and the distribution side, for leaks.

“In 2022, we extended all our ultrasonic meter and flow benefits to large six-to-12-inch commercial and industrial meters with the flowIQ® 4200 line. It combines the nondegrading accuracy and enhanced low-flow measurement of ultrasonic technology with a field-replaceable battery for easy maintenance to increase water revenues, maximizing the return on investment for water utilities.

“Kamstrup’s flowIQ® 4200 is designed for commercial and industrial applications, but the 10-inch version can detect a toilet flush! No other meter of that size can detect

flows that low. With that type of low-flow capture in a large meter application, the return on investment is very rapid.” exclaims Bharat.

FACILITIES OF THE FUTURE A new state-of-the-art, advanced manufacturing facility in Cumming, Georgia, complete with robotic automation, is on the horizon for Kamstrup. It will also house the company’s corporate offices, innovation center, and North American headquarters, which it moved into in mid-December 2023, with production slated to begin transitioning in early February.

When the transition to the new manufacturing facility is complete, Kamstrup will be the only water metering company manufacturing static meters inside the US. Most incumbents, even ones producing mechanical meters, have moved manufacturing operations outside of the country.

“We moved into our new manufacturing facility in December last year, and we will mark the occasion with a grand opening celebration planned for March 21st, 2024,” Bharat reveals.

The site totals over 150,000 square feet (sqft) and will be able to support over three million meters annually.

“We expect the first meters to come out of the new manufacturing facility in early February. We are excited about welcoming our partners, customers, and community leaders to the opening,” excites Bharat.

Moreover, regional expansion is already underway. Kamstrup boasts the largest AMI network deployment in Mexico and looks forward to delivering value to water utilities in Canada and the Caribbean.

Looking towards the future, Kamstrup continues building an unrivaled sales team and distribution network – focusing on small and mid-sized customers and explicitly centering on the larger water utilities

in North America.

“We focus more on marketing and creating brand awareness around our innovative technology through targeted campaigns, content, and education. We love our utility customers and look forward to highlighting their success stories even more as we grow together.”

Kamstrup is helping many cities and utilities operate more efficiently, and it aims to educate communities, ensuring they can leverage the best water technologies in the marketplace and ultimately conserve more water.

“We are bringing our new facility online to manufacture more meters to serve our customers in the US, Canada, Mexico, and the Caribbean.

Optimizing our organization means we will continue to deliver better services and technology. Our product roadmap is exciting, and we are poised to add even more innovation and value to the market in 2024 and beyond,” Bharat closes.

KAMSTRUP +1 (404) 835-6716 info-us@kamstrup.com www.kamstrup.com Manufacturing Outlook Issue 2 | 45

DAYTON LAMINA CORPORATION NORTH AMERICA

46 | Manufacturing Outlook Issue 2

S TA M P O F A P P R OVA L Dayton Lamina Corporation continues to be the go-to partner for all things stamping, with its combination of a rich legacy and a pioneering, forward-thinking spirit ensuring it stays ahead of the chasing pack.

We find out more with Rick Hern, Vice President of Sales and Marketing Writer: Tom Wadlow | Project Manager: Callam Waller

S

ometimes the most traditional ways of doing things are the best.

When it comes to stamping, the saying ‘to stand the test of time’ certainly resonates – a manufacturing process that has been around for well over a century, with origins dating back even further depending on your interpretation of history.

It remains highly relevant today in large part due to its simplicity. In short, it is a process used to convert flat or coiled metal sheets into various shapes using forming techniques and tools such as preset dies.

However, like many manufacturing techniques and industrial processes, new ways of doing things will inevitably emerge to challenge orthodoxy, no matter how long an incumbent has been dominant.

Rick Hern is Vice President of Sales and Marketing at Dayton Lamina Corporation (Dayton Lamina), a US-born company that has deep roots in the stamping trade.

Asked for his take on the sector

Rick Hern

dynamics at present, he refers to the need to keep pace with the rate of change that has emerged from competing parties challenging the status quo.

“It can be difficult due to the numerous ways that stamping is being challenged from the likes of laser, waterjet, 3D printing, and casting,” he says.

Manufacturing Outlook Issue 2 | 47

DAYTON LAMINA CORPORATION NORTH AMERICA

“I also think that we don’t put enough effort, as an industry, into developing new methods, faster processes and cycle times, along with product development. These areas, in addition to marketing and training materials, are serious needs.”

Hern knows what he is talking

A GLOBAL PRESENCE Dayton Lamina operates a network of manufacturing and engineering facilities throughout various regions of the world.

Specifically, the organization operates production facilities in the following countries: • US • Canada • China • Czech Republic • France

about. His entire career has been spent in the world of cutting tools and computer numerical control (CNC), a manufacturing method that automates the control, movement, and precision of machine tools through the use of pre-programmed, embedded software.

And while he acknowledges that there are challenges ahead, there is equal cause for optimism and excitement.

“For me, this part of manufacturing, stamping, is the opportunity to take a century-old application and make it cool again,” Hern adds.

“Like CNC, there are so many things that get bent, stamped, pressed, folded… it would be amazing if the everyday consumer understood the impact of the stamping business and Dayton Lamina’s impact.”

This, ultimately, is part of Hern’s mission – to get the message out there about just how impactful stamping is and continues to be on many aspects of business, and people’s lives.

• Germany • Japan • Mexico • Portugal • Spain • UK The products made at these sites are sold through more than 500 distributor representatives. Dayton Lamina maintains close-knit relations with all of its distributor partners, offering them the technical support they need to provide the added value their customers have come to expect.

Meanwhile, in Asia, the firm has partnerships with licensees that both sell and manufacture its products.

48 | Manufacturing Outlook Issue 2

As for Dayton Lamina, there is no better organization through which that mission can be undertaken. Its origins date back to the early 20th century, with the current enterprise coming into being in 2012 when Japanese firm Misumi entered the North American market and acquired several brands. Now, it is a

truly global entity with presence all around the world.

STANDING OUT AND STAYING IN FRONT A key reason Dayton Lamina stands proud as a leader in the field is due to its ability to serve as a onestop supplier shop to many of its

Dayton Lamina brand video

customers across various industries.

The firm has a diverse customer base spanning many applications and industries – these include automotive, beverage can tooling, appliances, mandrels, nuclear fuels tooling, compaction tooling, performance racing components, ammunition, die components, and

electronics, among others.

“We offer the largest, most complete assortment from a single supplier,” Hern adds. “Our capabilities to manufacture and source die components, catalog, configured and special punch tooling, as well as high precision steel of any shape, tolerance, and finish, is what sets us

apart.

“For decades we have set the standard of the industry in our quick deliveries, outstanding quality, and technical expertise.

This is why most automakers and other stamping companies refer to Dayton Lamina products as the trusted, specified tooling to use.”

Manufacturing Outlook Issue 2 | 49

T O O L S F O R T H E S TA M P I N G I N D U S T RY S I N C E 1980

Steel Die Components:

Nitrogen Gas Springs:

Dayton Progress

Kaller

Carbide Die Components:

Spring Plungers:

Hyson

American Carbide Tooling

Vlier

Die Sets:

Feeds & Coil Handling:

Anchor Danly

PA Industries

Guide Components & Die Supplies: Danly IEM

Lamina

Drill Bushings: Steel & Carbide Lempco

Royal

Boneham Metal Products

Phone: 1-800-972-4040 | Fax: 203-878-9085 Harmac@live.com | www.harmacllc.com

Endurance Carbide

Supporting your production requirements Har/Mac & Dayton Lamina bring a wealth of knowledge, experience, and skills to each and every job. We can deliver the precision die details, the tightest tolerances, the right configurations, and the quick turnaround you need to manufacture the best quality, most cost-effective end products.

Danly IEM:

Dayton Progress:

Lamina:

Lempco:

• • • • • •

• Punches, Die Buttons, & Retainers (Inch & Metric) • Die Springs • FDS® (Firm Delivery Schedule) • DAYSet® Compound Tooling Solution • Posi-Strip™ Self-contained punch stripping system • DAYStrip® Punch stripping system for flat or shaped surface • DAYLube™ NanoCeramic Lubricating Grease • Urethane Products • EVERLAST® • In-house Metallurgical Lab

• • • • • • • • • •

• Accu-BendTM Rotary Benders • Guide Posts & Bushings • Springs

Accu-BendTM Rotary Benders Cams Diemakers’ Supplies Guide Posts & Bushings In-Die Tapping Springs

• Wear Product

Cams Die Accessories Guide Posts & Bushings Hydraulics In-Die Tapping Lamina-Bronze Components Mold Components Springs Wear Product Posi-BendTM Rotary Benders

Phone: 1-800-972-4040 | Fax: 203-878-9085 | Harmac@live.com | www.harmacllc.com

HAR/MAC LLC Proudly representing the highest quality, worldclass name-brand suppliers, Har/Mac LLC has 50+ years of experience providing products to the metal stamping and forming industries.

Integrity, reliability, and resourcefulness are central to Har/Mac LLC’s success, and the team’s knowledge remains unmatched.

As a viable and responsible supplier to manufacturers ranging from small to large, Har/ Mac LLC is here to assist with looking for those hard-to-find items, streamlining your company’s supply base, or help to improve tool life.

Stamping tools vary due to the complexitiy of the part being produced, but Har/Mac LLC has a wide range of products that are the backbone of metal forming industries. Therefore, whatever your metal stamping needs are, Har/Mac LLC has you covered.

OTHER OFFERINGS Brand and product catalogs are available as PDFs to download or print on the Har/Mac LLC website. Alongside catalog standards, the custom machining of individual details is also offered, delivering precision tooling, the tightest tolerances, the right configurations, and the quick turnaround you need to manufacture the best quality and most cost-effective end products, which includes die sections, blade style punches, retainers, and swedging mandrels.

Technical resources of downloadable guides include Dayton’s Engineered Clearance, Tool Steels, Problem Solving Guide, Form Shapes, High-Performance Treatment & Coatings, with a technical assistance request form also available.

BRANDS CARRIED BY HAR/MAC LLC • DaytonProgress® – Steel punches and dies, specials to print, die springs, urethane • ACT™ (American Carbide Tooling) – Carbide components, both standard and special to print • Anchor Danly™ – Die sets • Lamina® – Guide components (die and mold), wear products, springs/urethane, hydraulic equipment • Danly® IEM® – Guide components, springs/ urethane, die accessories, in-die tapping • Lempco® – Guide components • Kaller® – Nitrogen gas springs • Misumi – Metric die components • Endurance Carbide – Drill brushings (carbide) • BMP (Boneham Metal Products) - Drill brushings (steel) • Vlier® – Spring plungers • PA Industries – Feeds, scrap choppers, coil handling equipment • Dieco® – Springs, die accessories, die sets, guide components • Hyson – Nitrogen gas springs

Phone: 1-800-972-4040 | Fax: 203-878-9085 | Harmac@live.com | www.harmacllc.com

Die Sets

Both catalog and custom machined to print.

MACHINED AND CUT & GROUND PLATE • Steel plate in 0.25” to 15” thicknesses (grades include hot rolled typeA36/44W/50W mild steel and 1045 & 4140 specialty steel) • Flame cutting and plasma cutting • In-house stress relieving, heat treating and shot blasting • Blanchard grinding 144” diameters • CNC machining up to 138” x 320” • High-quality Adapter & Boster plates - Quick Die Change (QDC) plate is also available

Proudly Representing Anchor Danly Since, 1980

Contact us for more information: Phone: 1-800-972-4040 Fax: 203-878-9085 Harmac@live.com www.harmacllc.com

Har/Mac “Di-Ton” Style Spring Retainers for High Production Dies • • • • • •

Offered in Hex & Round Style Fast removal of Stripper Plate Less Possibility of Damage to Punches & Perforators Quick Access to Punch Holders Easy Retro-fitting to Existing Tools Easy to adjust Pre-load on Springs

Contact Har/Mac for Pricing and Availability 1-800-972-4040 Harmac@Live.com

DAYTON LAMINA CORPORATION NORTH AMERICA

Put simply, the company can be trusted for quality and service, a combination that sees customers coming back time after time, even those that may venture further afield seeking a cheaper alternative.

“As with many other industries and applications in B2B and B2C, customers are always looking to save a penny and find other low-cost countries or knock-off products,” Hern continues. “But they often end up coming back to Dayton Lamina because those companies stop production, cause time delays, and are inconsistent.”

A culture of continuous improvement and refinement has also been key. As Dayton Lamina has grown and added new machines and processes to produce a larger variety of parts, the operating environment naturally becomes more complex.

Recognizing this, the company has rejigged its state-of-the-art site in Michigan to ensure an optimized 54 | Manufacturing Outlook Issue 2

“ F O R M E , T H I S PA R T O F M A N U FA C T U R I N G , S TA M P I N G , I S T H E O P P O R T U N I T Y T O TA K E A C E N T U R YO L D A P P L I C AT I O N A N D M A K E I T C O O L AG A I N ” – RICK HERN, VICE PRESIDENT OF SALES AND MARKETING, D AY T O N L A M I N A C O R P O R AT I O N

production flow. “In some cases, we were seeing a part traveling a mile by the time it was complete,” Hern says.

“Now, we’ll be able to cut that to 20 percent of what it was.”

MOVING WITH THE TIMES Continuous improvement also means investing in technology to augment the vast depth of human experience and knowhow contained within the organization.

“For decades, we have relied upon operator skill to hold tight tolerances running multiple machines at once

and CNC tooling with manual load and unload – this is mostly due to keeping costs down, and the fact that the manufacturing processes is proven, and operators know the parts,” adds Hern.

“In today’s environment we are addressing ever changing needs to be more cost effective, use less manpower, and operate overnight and at weekends unmanned. Automation also enables us to run several parts with little to no setup changes, and reduce lead times, costs, and human intervention.”

ONE COMPANY, FOUR LEADING BRANDS With roots dating back well over a century, Dayton Lamina has developed into a worldwide and renowned specialist in the production of catalog and special punches, die components, die details, punch blanks, metal stamping tools, and more.

The organization trades through four brands, each with their own niche and unique offering to customers around the world: LEMPCO – Established in 1917, Lempco is the oldest of the four brands under the Dayton Lamina umbrella. Its die set guiding components are manufactured at state-of-the-art facilities in Michigan and Wisconsin, providing customers with the highest precision level available in the metal stamping industry.

DANLY IEM – In operation for more than 100 years, Danly IEM produces components and innovation-enabling tools which are used in the stamping, molding, and machine building industries. Key product lines include DieMax springs, die accessories, formathane urethane, and IDT in-die tapping.

LAMINA – A highly specialist producer of die components, Lamina also produces is products out of the enterprise’s facilities in Michigan and Wisconsin. Products include rotary benders, ball-bearing solutions, guided retainers, hydraulics, cams, and springs.

DAYTON PROGRESS – Known for its high quality and competitively priced punches, die buttons, retainers, and other tooling products, metal fabricators have been relying on Dayton Progress since the end of the Second World War. Today, it operates multiple manufacturing and engineering facilities in North America, Europe, and the Pacific Rim.

Such investments are being made at several sites. In Bellaire, new robotic part changers are being installed. At Dayton, new CNC grinders are about to come online. Meanwhile, the Beaver Dam facility is about to benefit from the introduction of a new spring manufacturing machine.

Coming back to Hern’s remit as Vice President of Sales and Marketing, a key recent priority has involved Dayton Lamina’s brand refresh – another sign that the organization continues to move with the times.

That said, the tried and tested product range is not being touched.

Rather, the rebrand is designed to bring cohesiveness to the portfolio as a whole, the ultimate aim being for Dayton Lamina to have its own identity as the complete solution provider and technical leader.

A smarter, more intuitive website is central to this endeavor.

“We’re adding more info, more access, and more tools,” Hern says.

“This new system connects directly to our manufacturing capabilities as well as our ERP system to show specific customer orders, history, pricing, and inventory levels.

“It will enable our customers and distributors to manage their orders, search for products and 3D CAD drawings which we’re introducing.

Historically, we’ve had a limited amount of products with CAD drawings, so this will be a big and positive change.”

This feeds into Hern’s key goal for the year ahead, which is to make the ordering process as seamless as possible for Dayton Lamina customers. It is a transition which will also require training and development with internal teams, as well as continued investment in technology behind the scenes – all crucial steps in the journey ahead.

DAYTON LAMINA CORPORATION (800) 652-6462 www.daytonlamina.com Manufacturing Outlook Issue 2 | 55

TOW I N G A N D R E C OV E RY T I TA N S

With the largest portfolio of towing, recovery, and transport vehicles in the world, Miller Industries is triumphant in spearheading the global towing and recovery sector. President, Will Miller, tells us more Writer: Lucy Pilgrim | Project Manager: Kieron Harvey

M

iller Industries’ resounding success in the North American manufacturing industry stems from a founding mission of perseverance and dedication to being first in class.

The company was first founded in 1990 by current Chairman, William Miller, who had the ardent belief that to be successful, a business must 56 | Manufacturing Outlook Issue 2

have the best people, products, and distribution network.

William’s philosophy was vital for the consolidation of the towing and recovery industry in North America, dictated by abundant distribution.

This is evidenced by the swift expansion of the company’s network, as within the first year of business, William streamlined the number of

North American distributors from over 450 to 125.

“My father’s belief was that distributors are the key to our success; having the best and most profitable, solid distributors for our products makes Miller Industries successful as a whole,” opens Will Miller, son of William and President of the business.

Following the completion of

MILLER INDUSTRIES NORTH AMERICA

distributor consolidation in 1994, Will has gone one step further in reducing the number of Miller Industries’ distributor locations to approximately 225 worldwide, harnessing the capabilities to export to 67 different countries.

THE BIGGEST AND THE BEST The company is proud to manufacture the largest portfolio of towing,

recovery, and transport vehicles in the world. This includes anything from 8,000 pounds (lbs) of lightduty wreckers up to 100,000 and 200,000 lbs of its largest trucks.

Its diverse network is invaluable for facilitating the company’s enviable global reach. Miller Industries boasts six world-class manufacturing facilities across three countries, with

four facilities in the US and one a piece in the UK and France.

The organization is positioned at the forefront of innovation in the towing and recovery industry, thanks to its vast product range and services that consistently break the boundaries of manufacturing.

As part of its portfolio, the company produces light, medium, Manufacturing Outlook Issue 2 | 57

MILLER INDUSTRIES NORTH AMERICA

highly advantageous 25-ton recovery boom and 25,000 lbs winches for a vast range of recovery and lifting applications.

Another highly significant component of Miller Industries is its rotator product, Century 1150. Seen as an industry staple, the 50-ton rotator is ideal for daily recovery tasks or more complex needs, with 360-degree continuous boom rotation.

and heavy-duty wreckers, as well as rotators.

Its light-duty wreckers, known as the Vulcan 812 and the Century Express 312, are utilized throughout the industry for private property, repossession, and cater to commercial towers.

Despite the products’ trusted use throughout the field, Miller Industries is consistently improving its product designs to achieve maximum efficiency for its customers. This can be seen in its light duty lineup where it increased the rear visibility between the boom and the tailboard

that facilitates greater hook-up ability, the recently introduced hose tracking system for longer life and easier maintenance, along with giving customers more choices with several hand-held controllers and other options available.

Also notable is the Century 5130, Miller Industries’ best-performing heavy-duty wrecker with 128 inches of underlift reach. This gives users of the wrecker the ability to tow the majority of vehicles without sacrificing the maneuverability of a single axle or tandem axle unit. The product also affords customers a

The company is the only manufacturer of recovery equipment capable of meeting tower needs and safety, making it a highly sought-after resource in the towing and recovery sector. The rotator is also ideal for the quick clearance of congested railways, ensuring the swift recovery of vehicles.

MANUFACTURING OUTLOOK: CAN YOU TELL US MORE ABOUT THE IMPORTANCE OF A STABLE SUPPLY CHAIN TO THE BUSINESS? Will Miller, President: “As most manufacturers have learned over the last two to three years, relationships are super important to ensure that your company isn’t just a sales order number.

“Since we are operating within a relatively small global industry, building generational relationships with our distribution and retail customers is essential.

“Our customers, distributors, and even our employees are in their second or third generation, and we want to ensure that these relationships are passed down.

“By maintaining these relationships over the years, Miller Industries has more than doubled our number of key suppliers for key components, particularly in the hydraulic and electrical space.”

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Thirdly, Miller Industries is also an industry leader in the production of light, medium, and heavy-duty carriers.

To date, it operates the largest dedicated carrier platform, comprising over 200,000 square feet (sqft), solely committed to building carriers that keep up with the demands of the industry.

One example is the 12 Series LCG™ (low center of gravity) carrier. Through a specialized patented design, it lowers by a much greater degree than conventional carriers used by competitors, whilst also offering greater stability in the transportation of taller loads.

LEADERS IN INDUSTRY INNOVATION Whilst Miller Industries thrives with the largest and most successful distribution network in North America, what differentiates the

company globally is its unmatched product quality, reputable aftersales service, and history of recordbreaking vehicles.

The notion of continuous tradition is ingrained in the company, as Miller Industries is the product of a diverse and forward-thinking sector that has cultivated some of the most wellknown machinery and vehicles of the modern era, such as the Model T Ford.

Following this, the car manufacturing sector progressed from body-on-frame construction to unibody construction in the 1960s, which can still be seen in many passenger vehicles today.

Also known as chassis frames, bodyon-frame construction is used primarily in commercial vehicles, pick-up trucks, and sports utility vehicles (SUVs), whilst most other vehicles are transferred to unibody construction.

“ O U R M OT TO I S TO T H I N K L I K E T H E C U STO M E R , TO P R OV I D E A Q U A L I T Y P R O D U C T T H AT C A N W O R K E F F I C I E N T LY E V E R Y D AY FO R T H E G E N E R A L M OTO R I N G P U B L I C I N A T I M E O F N E E D ” – W I L L M I L L E R , P R E S I D E N T, M I L L E R I N D U S T R I E S

When it matters, choose At Collins, our philosophies and priorities revolve around adding value to our customers, the industry, and our team.

We seek to enrich the M.M Hassell -- 1930’s on Route 66 communities around us through safety, quality, advanced designs, personal customer service, and doing what’s right. In our nearly 40-year association with Miller Industries, we have sought to support the towing industry by providing state-of-the-art towing equipment like the Hi-Speed®Dolly, the Carrier Dolly System, truck organization and towing accessories.

The history of Collins commenced with M.M. Hassell, the

father of Collins Hassell, who settled his family of eight in the small village of Bluewater, New Mexico. As a certified mechanic in the early 1930’s, Hassell senior was sought after to work on the famous Route 66 that ran 2,448 miles through eight states, (including New Mexico), from Santa Monica, California to Chicago, Illinois. Throughout his career, he was always involved in heavy equipment, logging, or trucking--in one form or another--from repairing them, to operating them, to driving them.

As was customary of the time, fathers typically passed their vocation onto their sons. All four of Hassell’s sons eventually centered their livelihoods around heavy equipment, logging, manufacturing, and long-haul trucking.

Collins Hassell was extensively involved in all of these.

Having logged with their father for many years in Colorado,

Tunnel Tool Boxes

Hi-Speed Dollies staged for shipping

New Mexico, Arizona, and Oregon, Collins and his younger brother Ray Hassell identified a need for improved logging equipment. The humble beginnings of Hassell Fabrication started in 1954, in a barn behind Collins’ Ashland residence.

The fledgling operation was later moved across from Ashland’s airport in Oregon, where it continues to operate today. Throughout the 1950s and 60’s, the two brothers produced advanced stakes and log bunks for the 1952 Collins’ First tandem-axle Truck Northwest timber

industry. It was during this time that Collins left the company to his brother Ray to start another manufacturing business.

Collins Manufacturing was founded in August of 1972 when Charlie Nowell partnered with Collins Hassell to develop the world’s first articulating tow-truck dolly. It had four 8” pneumatic Goodyear tires on 5” wheels, which lifted each vehicle tire off the ground. The Collins Dolly acted as both jack and dolly by means of simple leverage. By adjusting the dolly to fit around the vehicle tire with the telescopic dolly frame, a person could then use their own weight as leverage on the end of a 5’ pry bar to quickly lift a vehicle with the dolly itself. A dolly tow could be ready to go in less than a minute. In the early 1970’s, all of this was quite revolutionary.

By introducing an articulating dolly that both lifted and hauled vehicles, Collins changed the towing industry forever.

That first-generation dolly set the stage that would see the design, development, and manufacturing of the first SelfLoading (SL) dollies just three years later, after which Charlie would leave for other ventures. Collins Hassell continued innovating. His years of experience in trucking, designing, and manufacturing equipment that required the hauling of tens of thousands of pounds long distances, from forest-to-mill, across rough logging roads -- was the same DNA for creating the future Collins Hi-Speed®Dolly.

Loaded Log Truck outfitted with Hassell Stakes and Bunks

Collins Hassell -- Final Dolly Build March 1984

Now, towed vehicles could be moved safer, easier and further with the Collins Hi-Speed®Dolly, which in the 50-plus years since, has been the preferred choice of towing professionals. As vehicles today advance in design and technology, (EVs, hybrids, all-wheel drive, electronic parking brake systems), Collins Dollies are still a critical tool that helps support and enhance the essential work that professional towing and recovery operators do to safely and effectively tow or recover vehicles.

Collins Dollies support and honor these professional operators who, because of the nature of the job, often do what others can’t and go where others won’t.

“The goal is to have all our products at the highest level, in terms of safety, quality, functionality, and aesthetics. Safety truly is first and foremost ahead of everything else we do in our product designs.”

Curtis Collins Hassell, CEO & President.

Collins G7 Hi-Speed®Dolly

Hi-Speed®Dolly - The Collins Hi-Speed®Dolly has evolved significantly from the first generation in 1972 to it’s seventh generation 50 years later in 2022. Distinct features of the Collins Hi-Speed®Dolly: 1) Secondary Safety features; 2) Freeway approved--rated for both long distance and freeway/highway speeds; 3) Requires only one truck and driver to safely transport the vehicle; 4) Lightest in weight with the greatest load capacity; 5) Quickest and easiest to use with automatic locking features; 6) Widest cross rail span for larger vehicles up to 104” and a true, positivecamber center; 7) Two-Tone zinc-plated finish as standard for additional corrosion protection. The new 7th-generation G7 Hi-Speed®Dolly adds 36 advancements.

Carrier Dolly - The Collins Carrier Dolly, (though similar in appearance to the 1st-generation highway dolly), serves a slightly different purpose. It is used on carrier or flatbed tow trucks to load and unload vehicles without risking damage by allowing the vehicle to roll on and off the deck. Prior to this, vehicles would have to be skated or dragged up onto the truck by the winch hook connected somewhere on the vehicle with a greater potential for damage, difficulty and concerned customers. In contrast, the winch hook connects to the Collins Carrier Dolly and the vehicle rides on the dollies. This also simplifies and standardizes the loading and unloading procedure no matter the vehicle—especially EVs, hybrids, vehicles with all wheel drive, and those locked up with the electronic parking brakes. The same Carrier Dolly unit, set up in a different configuration, can also be used for quickly loading and unloading motorcycles by a single operator and again, with less risk of damage to the motorcycle.

Truck Boxes - For over 30 years, Collins has designed and built an array of truck boxes: Tunnel boxes, to expand the available storage on a wrecker body, and Underbody boxes for

Collins Tunnel Boxes--Designed and Custom Built Since 1992

essential storage on a flatbed/carrier tow truck.

These boxes have ranged in size, door styles, and materials (steel or aluminum). In each case, careful attention is given to create a robust box that holds up to the rigors of towing while refined in style to compliment the truck and body itself. The latest box project is a joint development with Jeff Cross to revamp his Streamliner Box — first made popular over 10 years ago — and is quickly recognized as the best underbody box ever built.

As a manufacturer and supply partner with Miller Industries for over 40 years, Collins is committed to continuing to improve, develop, and advance our products, enhance the user experience, and keep pace with growing demand.

Today, Collins Manufacturing utilizes state-of the-art equipment and cutting-edge techniques, including CNC Fiber Laser cutting, CNC tube cutting, CNC high-precision press brakes, CNC multi-axis milling, CNC multi-axis lathe turning, automatic drilling, and machining. Our skilled craftsman in manual welding take pride in ensuring quality, while our precise repeatability in robotic welding, in-house powder coating, and world-class designs are unrivaled.

Collins Carrier Dollies for both Vehicles and Motorcycles

We have participated in historical and industry-recognized testing to ensure the efficacy of our products, such as the HORIBA MIRA proving grounds in the UK, the GM proving grounds in the US, as well as decades of successful in-house, and grueling real-world field testing. Collins’ partnership with Miller Industries continues across a global market with Collins supplying dealers on almost every continent, with self-loading dollies found on Miller Industries light-duty wrecker and car-carrier trucks.

“We appreciate our partners and customers and wouldn’t be around for this long without them. With our excellent team at Collins Manufacturing, who are also putting their names into a great product, we plan to be here many more decades serving our customers.”

Chris Usher, General Manager.

collinsdollies.com

MILLER INDUSTRIES NORTH AMERICA

Over the years, the company has proactively reacted to changes and innovations in the sector, as it had to alter the way in which it recovers and tows a vehicle in order to stay on top of industry changes and to ensure the safety of products.

For example, Miller Industries navigated the shift in the 1990s from lightduty recovery vehicles and wreckers to car carriers and platforms by building its first dedicated carrier manufacturing facility in 1994 in Hermitage, Pennsylvania, making multiple additions to the factory over time.

Furthermore, there was a noticeable shift in light-duty wreckers from conventional wreckers of the early 2000s to auto loads – low profile crossbars that go under a vehicle to grab it by its front tires rather than using a chassis frame.

“These wreckers have hydraulic claws that reach around the tires so you can pick up half the vehicle singularly by the front or back wheels, showing a serious evolution,” Will explains.

Regarding heavy-duty products, large over-road-chassis have gotten lower to the ground and more aerodynamic as the industry has progressed, resulting in better fuel economy. Consequently, the company reduced the height of the crossbar device that comes into contact with the vehicle.

“We’ve had to make it increasingly thinner whilst retaining its strength.

The crossbar is now down to five inches in height so they can

MILLER INDUSTRIES IN NUMBERS 75 distributor locations in the US 225 distributor locations worldwide 1,600 employees globally 45 innovative engineers

64 | Manufacturing Outlook Issue 2

fit underneath the bumpers of commercial vehicles easily.

“This also means that we can still tow vehicles without damaging their dynamic fairings and underbody,” he adds.

Another aspect Miller Industries pays close attention to is weight.

It wants to ensure that its vehicles comply with all road safety standards and do not exceed the maximum weight allowance of public roads, whilst still being strong enough to efficiently tow the desired vehicle.

ACHIEVING VERTICAL INTEGRATION With continuous improvement as a hallmark of the business, the company has invested over $100 million in its manufacturing facilities globally in just over a decade, particularly in its paint capabilities and robotics, as well as developing a dedicated R&D center.

Miller Industries specifically focused on vertical integration during the COVID-19 pandemic in 2020, at a time when a lot of its competitors were slowing down production and letting staff go.

During this period, the company invested in a state-of-the-art fabrication equipment facility to begin the production of its own steel parts, growing its in-house capabilities.

Meanwhile, staff whose work had stagnated due to the decreased demand were given the opportunity to go to training centers to learn how to operate computer numerical control (CNC) machines, as well as control lasers, press brakes, plasmas, and lay mills. This contributed to the wider goal of having a functioning workforce that can efficiently operate new, highly automated, world-class fabrication equipment.

The company’s vertical integration process also included the introduction of an enterprise resource planning (ERP) system in 2019, which allowed Miller Industries to succinctly run all its worldwide facilities, streamlining

MILLER INDUSTRIES NORTH AMERICA

“ M Y FAT H E R ’ S B E L I E F WA S T H AT D I ST R I B U TO R S A R E T H E K E Y TO O U R S U C C E S S ; H AV I N G T H E B E S T A N D M O S T P R O F I TA B L E , S O L I D D I S T R I B U T O R S FOR OUR PRODUCTS MAKES MILLER INDUSTRIES SUCCESSFUL AS A WHOLE” – W I L L M I L L E R , P R E S I D E N T, M I L L E R I N D U S T R I E S

operations in manufacturing, human resources (HR), accounting, and engineering.

The ERP system comprises a cloud-based piece of software called CloudSuite Automotive, created by Infor, which enabled the company to handle over a billion dollars of revenue in preparation for 2024.

“As a manufacturing organization, a solid software system allows us to expand organically and harness additional acquisitions and the future growth of Miller Industries,” Will highlights.

The company’s second phase of vertical integration in Q2 2023 witnessed the acquisition of Southern Hydraulics Cylinder (SHC). The entity had previously been a supplier; therefore, the acquisition was a natural step to progress Miller Industries into the wider manufacturing space, having more control over certain supply chain issues.

DIVERSE, FAIR, AND ENGAGED At the heart of the company lies Miller Industries’ staff base, who are continuously valued across the organization. Considered a profitsharing company, it has a strict bonus structure applicable to all employees so that each team member can take home a percentage of net profit.

Alongside company-wide financial incentivization, Miller Industries also invests in human capital and the health and safety of its employees. These standards include

climate-controlled facilities, LED lighting, and overall enhancement in the work environment.

As of last year, the company also introduced an employee family scholarship fund, into which each of the executives commits to putting $5,000 per year, a figure that the wider company then matches.

This generosity is used to facilitate 14 higher education scholarships for either the children or grandchildren of employees.

This is compounded further by the Frontline Leadership Academy, which provides tuition reimbursement to further the education of its employees. Additionally, Miller Industries also possesses an in-house welding academy where high school students and former military personnel can become skilled welders to further the productivity of its facilities.

In accordance with its commitment to employee well-being and personal development, the business strives to create an environment that is inclusive, diverse, fair, and engaged.

To meet these high standards, the company has implemented a specific diversity, equality, and inclusion (DEI) program that is consistently monitored to see how it could be improved. For example, in 2022, Miller Industries introduced an antiharassment and anti-discrimination policy as part of the program.

On top of this, the company also regularly monitors DEI metrics to

develop its minority representation, as well as having a proactive hiring process that welcomes veterans, women, and underrepresented minority groups.

BREAKING BARRIERS At the forefront of the towing and recovery sector’s innovation, Miller Industries is immensely proud to have developed and created the Century M100 100-ton rotator. The product came into ideation in 2017 after the company identified a greater market demand for a higher capacity product.

Consequently, Miller Industries proactively created a dedicated team of engineers to develop the world’s largest rotator, setting a precedent in size and capability. Following years of testing, working to strict deadlines, and intricate efficiency and detail, the team combined all the best aspects of its most successful products, with cutting and production completed in-house.

Eventually, testing proved that the product could pick up over 200,000 lbs, marking a major turning point in the industry and cementing Miller Industries as a towing and recovery titan.

With innovation at the core of the company’s resilience, Will cites Miller Industries’ success as a simple formula.

“Our motto is to think like the customer, to provide a quality product that can work efficiently every day for the general motoring public in a time of need. This also applies to our employees, who are to focus from the top down, helping them realize they have a critical part to play in the success of the company,” he closes.

800-292-0330 sales@millerind.com millerind.com Manufacturing Outlook Issue 2 | 65

CJB COMPANIES NORTH AMERICA

FOCUSING ON THE FUTURE From start-ups to multinationals, CJB Companies uses chemistry to connect with businesses.

We speak to Clinton Beeland, President and CEO of CJB Companies, about its pioneering roles from contract chemical manufacturing and development to commercializing advanced detection technologies Writer: Lauren Kania | Project Manager: Callam Waller

H

aving been fascinated by building things and understanding the intricacies of how they work from a young age, Clinton Beeland, President and CEO of CJB Companies (CJB), may not have known the specifics of becoming a chemical engineer but possessed the innate curiosity and hands-on nature of such a career.

In the 25 years since forming CJB as an intimate start-up, with one small building and a repair and assembly contract in Valdosta, Georgia, Beeland’s passion for engineering and chemical orchestration has continued to inspire him and allowed the company to find significant growth while making a difference across a

variety of industries.

Despite this incredible growth, CJB remains a family-run business at heart and keeps this intimate origin at the center of every decision made.

“As a family-owned company, we are grounded in the values of respect, integrity, trust, excellence, and stewardship (RITES), which guide us every day in our interactions with customers, employees, suppliers, business partners, and the community,” opens Beeland.

It’s these principles ingrained in the company’s DNA that have allowed CJB to consistently and organically evolve, now boasting a team of approximately 200 people at six locations throughout Valdosta.

Manufacturing Outlook Issue 2 | 67

CJB COMPANIES NORTH AMERICA

MANUFACTURING OUTLOOK: WHAT PROJECTS ARE EACH OF CJB’S SUBSIDIARIES CURRENTLY WORKING ON? Clinton Beeland, President and CEO: “At CJB Industries, the Gil Harbin Plant is currently under expansion with a new lab and expanded processing and material handling areas. The total investment is more than $10 million and will expand our capabilities and footprint.

“For CJB Applied Technologies, we are working on a myriad exciting projects from sustainable formulations for environmental remediation to novel biologicals for use in agriculture. Our recent patent on benzyl alcohol is currently moving to field trials, with several companies interested in licensing the technology.

“At Salvus, we are adding staff and completing lab and pilot plant build-outs to accelerate the ability to create assays and receptors for the Salvus Detection Technology device. Food safety is an important area for Salvus, and we recently worked with Georgia Tech on detecting peracetic acid (PAA) in poultry processing.”

Since its initial inception, CJB has developed into the parent company of three separate organizations – CJB Industries, CJB Applied Technologies, and Salvus.

“We started CJB Industries as a contract manufacturer supporting agricultural chemical companies, working with start-ups and multinationals to produce products primarily in the agricultural or life sciences space, along with supplying

companies within the industrial, automotive, and other chemicalbased sectors,” expands Beeland.

CJB Applied Technologies, meanwhile, was formed in 2015 after the discovery that some companies needed help with, or additional capacity for, developing products – from creating and testing formulations within high-tech labs and on-site greenhouses to packaging and generating small-batch

formulations in a pilot plant.

Finally, Salvus came to fruition in 2018 after the agricultural industry was faced with drift challenges caused by dicamba herbicide.

“We saw the need for detection and approached Georgia Tech, who had been working on interferometric detection technology, and we were able to engage with them to help develop it for use within multiple industries – from agriculture and food to water management and healthcare,” notes Beeland.

Through the company’s valuedriven innovation and an unwavering commitment to providing the best customer service in the industry, CJB has grown into an unparalleled life sciences partner of choice.

A CHEMICAL RENAISSANCE “I see chemical manufacturing, or its most basic form, chemistry, and the problems it solves as going through an evolution and perhaps even a renaissance,” comments Beeland.

With the many developments that are making a rapid appearance, the chemical manufacturing industry is an undeniably exciting place to be in.

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CJB COMPANIES NORTH AMERICA

“ W E H AV E A N D C O N T I N U E T O I N V E S T I N O U R P E O P L E , FA C I L I T I E S , A N D T E C H N O LO G I E S TO E N S U R E W E ’ R E A B L E TO M E E T T H E N E E DS O F O U R C U S T O M E R S T O D AY A N D I N T H E FUTURE” – C L I N TO N B E E L A N D, P R E S I D E N T A N D C E O, C J B C O M PA N I E S

One such advancement that is making a prominent appearance across many industries is the drive toward sustainability.

“From a formulation development perspective, the move toward more sustainable or biological-based products is extremely tricky,” remarks Beeland.

“These types of products are more sensitive, so the formulations can turn bad faster if they’re not made, stored, or applied properly. There is also the 70 | Manufacturing Outlook Issue 2

challenge of making them robust enough for customer use.”

Nevertheless, the drive to safely and confidently produce such products is making headway throughout the industry, connecting both customers and businesses alike toward a cleaner future.

Alongside this collective push towards sustainability, technology is also making a transition within the life sciences industry. Specifically, CJB has observed the need to rapidly

and accurately detect substances at the point of use to help speed up decision-making.

“We are working to deploy our Salvus Detection Technology at the point of use in aquatics, agriculture, food safety, and other areas where waiting on results from a lab can be costly in both time lost and delayed action,” explains Beeland.

Providing accuracy, specificity, and sensitivity all within an adaptable device, Salvus is poised to flip the detection market on its head.

Such new technologies provide the subsidiaries of CJB with the opportunity to constantly challenge themselves and remain engaged in an ever-evolving industry, whilst showcasing how the group is focused on the future with every decision made.

CJB COMPANIES NORTH AMERICA

“ T H E O P P O R T U N I T Y T O C R E AT E S U S TA I N A B L E S O L U T I O N S FOR CURRENT CHALLENGES IN THE ENERGY AND THE FOOD S Y S T E M , M A N A G E FA C T O R S C O N T R I B U T I N G T O C L I M AT E C H A N G E , O R M A K E T H E WO R L D A B E T T E R P L AC E M A K E S I T A V E R Y E X C I T I N G T I M E T O B E I N V O LV E D I N C H E M I C A L M A N U FA C T U R I N G ” – C L I N TO N B E E L A N D, P R E S I D E N T A N D C E O, C J B C O M PA N I E S

GROWING THROUGH SERVICE AND INNOVATION As the future of chemical manufacturing continues to progress with every new scientific development, CJB is at the forefront of these industry-leading advancements with its consistent mindset toward innovation and working with those at the top of the

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field.

Looking ahead to 2024, the company is prioritizing growth through partnerships with new and existing customers along with developing its already highly adept workforce.

At CJB Industries, this entails enhancing current capabilities, developing talent, and applying

analytics to data extracted from the company’s new data historian to ensure a smoother process for everyone involved.

Equally, at CJB Applied Technologies, it means hiring new talent and developing its capabilities in formulations, not only in agriculture but also other outside areas that require such expertise.

CJB COMPANIES NORTH AMERICA

CJB’S PRODUCTS AND MARKETS CJB INDUSTRIES provides contract chemical and toll manufacturing for the following markets: • Agriculture chemicals and crop protection – CJB works with a number of agricultural chemical companies to manufacture pesticides, fungicides, insecticides, and herbicides, as well as plant growth regulators, micronutrients, biologicals, biostimulants, and other specialty products.

• Industrial and specialty – Working with customers to solve their challenges in industrial, specialty, and niche markets, all with various requirements.

• Turf and ornamental – CJB’s flexible manufacturing processes and ability to handle small production campaigns are particularly significant to the turf and ornamental industry.

• Pest control operators – CJB manufactures products for pest control operators, meeting their unique requirements with highly flexible and capable processing and packaging operations.

• Automotive – Consistingly meeting the industry’s rigorous demands for reliability and supply chain management that keep original equipment manufacturer (OEM) production lines running smoothly.

• Biocides and antimicrobials – CJB meets all of the stringent environmental and safety regulations for manufacturing biocide and antimicrobial products.

• Coatings and adhesives – CJB has the expertise essential for handling highviscosity and moisture-sensitive products and meeting customers’ specialized needs.

CJB APPLIED TECHNOLOGIES specializes in formulation and product development solutions in crop protection, specialty chemicals, biologicals, and other industrial markets.

SALVUS addresses chemical and biological detection needs for a variety of markets, including water management, food safety, animal health, production agriculture, human health, and industrial.

Finally, at Salvus, the future includes the commercial launch of new technology, thus bringing in new channel partners and increasing the speed of commercial detection assays.

“The key to any business is the people within it, and we are no different. However, what does make us different is our focus on culture, the intentional acquisition of talent, the further development of that talent, and the constant desire across our organization to successfully apply our

skills,” enthuses Beeland.

In addition to these business objectives, CJB places a priority on its corporate social responsibility (CSR) practices and the impact it has on the local community.

“We take our role in creating a better community and environment seriously,” notes Beeland.

“We value our position in helping start-up companies realize success and also recognize the importance of education by supporting efforts from elementary schools through college.

‘‘Knowledgeable students are the foundation of our future workforce, so we’re committed to helping them understand the variety of careers available to them.”

Working with students of all ages, CJB has invested in programs including the Valdosta Children’s Imagination Center and the STEAM Center for Applied Creativity and Innovation at Valdosta State University, alongside many other opportunities such as sponsoring scholarships for those looking to obtain a degree in STEM. Through both chemical manufacturing advancements and the investment in those who will encompass the future of the industry, CJB strives to continue its vision of working together to improve today for a better world tomorrow, furthering its reputation as one of the most respected chemical companies in the world.

CJB COMPANIES Tel: 229.293.0800 Manufacturing Outlook Issue 2 | 73

AIR INDUSTRIES GROUP NORTH AMERICA

F LY I N G HIGH In the face of rapid change, many companies are seeking ways to remain at the forefront of the US aerospace industry. Lou Melluzzo, CEO of Air Industries Group, shares how his company continues to stay competitive, relevant, and successful Writer: Lily Sawyer | Project Manager: Kieron Harvey

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Combustor Case

Submarine Valve

T

he US aerospace industry has witnessed considerable advancements in a short period, from the pioneering work of the Wright brothers to the inception of Boeing, alongside the development of state-of-the-art military aircraft, and the modern-day drone.

Air Industries Group (Air Industries), a manufacturer of precision assemblies and components for mission-critical aerospace and defense applications, seeks to stay abreast of a rapidly evolving aerospace industry.

“It’s a fast-paced sector, and a very exciting space to be in. The technology changes so quickly that you’ve got to stay on top of your game; it keeps you young,” opens Lou Melluzzo, CEO of Air Industries.

Melluzzo has been involved in the aerospace field since the mid-1980s when he studied as a design engineer. Driven by a passion for mechanical engineering, a creative imagination, and a desire to enhance and improve mechanics, he quickly climbed the ranks of several US engine component companies.

“I’ve always been a very critical

thinker and I continuously strive to build a better tool. For as long as I can remember, my passion has been taking things apart and putting them back together, so the mechanical aspect of the aerospace industry is really attractive to me,” he reflects.

Headquartered in Long Island, and with manufacturing facilities in both New York and Connecticut, Air Industries is a small public company, occupying 200,000 square feet of manufacturing space. Much of the organization’s work is concentrated on military fixed wing landing gear and arresting gear, actuators, rotorcraft components, turbine engines cases, rotating engine seals, and submarine valves.

The company is also licensed on aftermarket military spares programs, thus supporting out-ofproduction parts that the original equipment manufacturer (OEM) no longer makes.

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AIR INDUSTRIES GROUP NORTH AMERICA

The company views itself as not only a manufacturer, but as an integrator and assembly house.

A one-stop shop for engineered aerospace components and assemblies. Air Industries seeks to provide a smooth, tailored customer experience.

“We favorably differentiate ourselves from other manufacturers by our ability to engineer, machine, and assemble from start to finish,” informs Melluzzo.

AIR INDUSTRIES’ GOALS 1. WORLD-CLASS SERVICE Air Industries wishes to continue to offer customers world-class service in a responsible, proactive, and timely manner.

2. CONTINUOUS IMPROVEMENT Air Industries wants to continue to improve the life of its employees through flexibility and understanding. The company recognizes that employees have children and families and wishes to provide them with a healthy worklife balance.

3. MAXIMIZE SHAREHOLDER VALUE Being a public company, Air Industries wishes to maximize shareholder value following considerable market disruption in the aftermath of the COVID-19 pandemic. The company wants to ensure that its shareholders get the payback that they expect.

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STAND-OUT SERVICES Since the onset of the COVID-19 pandemic in the US, supply chain operations across the country have been compromised from both a procurement and personnel standpoint. Notably, Air Industries has utilized this as an opportunity for growth.

Part of the company’s unique offering is a comprehensive in-house service, which mitigates the necessity for customers to outsource parts, labor, or supplies, and streamlines the entire experience.

“Customers don’t have to shop around to a dozen different places to achieve their goal. They can outsource

their complete requirements to us, and we will integrate it, manage the supply chain, and oversee its total lifecycle,” Melluzzo enthuses.

Subsequently, many of the agreements and partnerships that Air Industries enters into are not standalone spot buys. Oftentimes, multiyear agreements are successfully arranged with clients, which Melluzzo attributes to a client-centric ethos.

“When we look at a partnership, we’re looking at what we can offer the client to make their life easier, and we see it as an opportunity to provide the total package. We tell them what it’s going to cost today, next year, and the year after that.

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We specialize in tool crib management and vendor managed inventory, providing state-of-the-art Auto Crib equipment. Blue Point’s in-house sales staff are knowledgeable and experienced in the product needs of our customers.

Our Tooling and Applications Specialists will help your business achieve greater productivity and reduce downtime. We can handle all of your shop needs, offering more than just expert advice for your tool and supply purchases, call us today.

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This service is only offered in the New York, tristate area and includes refractometer readings, maintenance schedules and product recommendations in order to maintain optimum coolant performance.

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AIR INDUSTRIES GROUP NORTH AMERICA

“We have a very dedicated and experienced team internally. We don’t just produce the component; we produce the entire finished assembly.

That’s our first and foremost criterion,” he explains.

To facilitate Air Industries’ objective of self-sufficiency, the company has internalized several of its secondary operations.

“Most aerospace alloys require special processing. Heat treating, shot peening, non-destructive testing, chemical coatings, and painting are just a few common ones.

Since COVID-19, we’ve started to integrate secondary operations into our facilities, like painting the parts in-house,” he exemplifies.

In addition, Air Industries is setting up a flash-welding department, to support some of its primary product lines. In the past, these processes were outsourced.

“Our plan is to insource a process or two each year, focusing on those that have historically impacted lead time, risk, or throughput. Managing what’s outside our walls is as critical as managing what’s inside,” Melluzzo reveals.

Furthermore, the company offers design integration services to every customer. This means expertly advising on potential design improvements or mechanical engineering queries.

“If a client is having a problem with a mechanical component in their fabrication, we can suggest how to design it differently to yield better results. We have that ability in-house,” explains Melluzzo.

EXCITING PROJECTS Historically, Air Industries has been involved with a host of OEMs. Of note, the company’s work with the UH-60 Black Hawk helicopter (Black Hawk) over the past 40 years has made up a sizable chunk of its business.

“Approximately 25 percent of our business is conducted for or through

Black Hawk,” Melluzzo states.

Air Industries has produced an array of structural components for the helicopter, whilst elements such as the main flight controls, throttle quadrants, mixers, and transmission mounts demonstrate the company’s mechanical versatility.

Black Hawk is one of the most successful US military aerospace programs of its time, with over 5,000 designated UH-60 units in the field.

Some UH-60 models have expanded beyond military use.

“Many municipalities are now using the Black Hawk for a variety of applications. California, for example, has several operational helicopters to put out fires, as it’s such a reliable platform.”

Additionally, Air Industries has manufactured vibration dampeners for Black Hawk, specifically tuned to counter vibration transmission within the aircraft, along with push rods and tail cone assemblies.

“The Black Hawk program is near and dear to us. With around 5,000

“ I T ’ S A FA S T- P A C E D S E C T O R , A N D A V E R Y E XC I T I N G S PAC E TO B E I N . T H E T E C H N O L O G Y C H A N G E S S O Q U I C K LY T H AT Y O U ’ V E G O T T O S TAY O N T O P O F YO U R G A M E ” – LOU MELLUZZO, CEO, AIR INDUSTRIES GROUP

helicopters in the field overall, the amount of spare parts required is incredible. We service this need through the OEM, and directly with the US government as required,” states Melluzzo.

Although fixed wing military jets are considered the bread and butter of Air Industries’ output and have always provided a stable foundation for steady growth, the company’s rotorcraft business has seen exponential growth of late.

In the past two and a half years, Air Industries has invested nearly

$12 million into new equipment to support the expansion of rotorcraft, whilst an expansion of the company’s Connecticut facility could see it spending another $15 million in the next several years.

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MANUFACTURING OUTLOOK: WHAT SOCIAL AND CORPORATE RESPONSIBILITIES DOES AIR INDUSTRIES HAVE IN PLACE? Lou Melluzzo, CEO: “Being a public company, social responsibility is at our forefront. We’re on the board of an organization in New York called ADDAPT, a non-profit organization aimed at nurturing the aerospace industry and bringing younger people into the business.

“We work with local universities, conduct shop tours, and attend trade shows to attract young people to learn about the aerospace business. We endeavor to promote this industry and ensure that it is as vibrant in 50 years as it is now.

“We also donate to local charities and are actively involved in our community. All of our employees live within close proximity to the plant. We have 200 employees and their families counting on us to be successful.

“COVID-19 was not friendly to anybody, but Air Industries did not let any staff go. We are a team, and we protect each other.”

“ W E H AV E T H E A B I L I T Y, E Q U I P M E N T, PEOPLE, KNOWH O W, A N D ENGINEERING E X P E R T I S E TO FA B R I C AT E T H E W H O L E A S S E M B LY F R O M S TA R T T O FINISH” – LOU MELLUZZO, CEO, AIR INDUSTRIES GROUP

“We’ve got the latest and the greatest machinery. We’ve increased the quantity and the overall size envelope of our five-axis milling and turning equipment, and increased the number of our state-of-the-art computer-aided design (CAD) seats (CATIA and Siemens NX). Given the cost and lead time associated with raw material, we simulate the complete manufacturing process before we ever cut a piece of metal.

We don’t produce a part until we know that our processes and our computer-aided manufacturing (CAM) programs have been proven.

“It’s now a matter of creating the additional space and continuing to increase our staff in order to support the growth spurt we’re seeing,” informs Melluzzo.

POWERFUL PARTNERSHIPS Over the years, Air Industries has developed a sturdy and reliable relationship with the US government.

Due to the company’s comprehensive repertoire of military aviation parts, it has proven itself as a trusted supplier to the Department of Defense (DOD).

Through Source Approval Requests (SARs), which are used to demonstrate a company’s ability to manufacture a critical product, Air

Industries proves its worth to the US government.

“What these packages prove, is that we can produce the part they’re looking to purchase either through prior experience with the same, or demonstrably similar items,” comments Melluzzo.

For a typical manufacturer, acquiring a direct government contract can prove very difficult to navigate due to the vast amounts of associated paperwork.

“This paperwork is almost as complex as the making of the parts themselves. We have an entire team dedicated to making sure that the paperwork is correct every step of the way. Smaller companies may not be willing to invest this time or manpower,” he shares.

In addition to its longstanding relationship with the US government, Air Industries has recently developed a partnership with a large European OEM following this year’s Paris Air Show.

Melluzzo is confident that Air Industries’ engagement with the European OEM will lead to a beneficial business relationship.

“We had a booth at the show, and were fortunate enough to have the right person stop by and ask the right questions. Within a very short period of time, this relationship started to mature,” excites Melluzzo.

This newfound partnership will not only extend Air Industries’ reach across the Atlantic and into the European aerospace market, but also contribute to increased commercial work.

“Just that one contact made the entire show worth attending,” he concludes.

AIR INDUSTRIES GROUP Tel: +1 631 968 5000 www.airindustriesgroup.com Manufacturing Outlook Issue 2 | 81

Jeffrey and Gary Marx

PIEDMONT NATIONAL NORTH AMERICA

INSPIRING G R E AT N E S S I N PAC K AG I N G Piedmont National has attained remarkable success in the packaging industry by exceeding the expectations of its myriad customers through high-quality service and state-of-the-art products. CEO, Gary Marx tells us more Writer: Ed Budds | Project Manager: Kieron Harvey

I

n 1950, at the age of 52, Hugh Marx decided to take a risk and launch Piedmont National (Piedmont) from his house with his wife’s help.

The formula they envisioned was simple – provide quality products, prompt delivery, and first-class service for the packaging industry.

Subsequently, their children and grandchildren have built on this enduring legacy by continuing to honor the core business values that were originally established over 70 years ago, as the corporation remains 100 percent family-owned and operated today.

With its headquarters in Atlanta, Georgia, Piedmont boasts vast distribution capabilities, comprising 17 company owned warehouse facilities, several third-party logistics (3PL) providers, and the company’s own array of delivery assets and drivers.

Thorough knowledge and industry experience remain paramount to

retention and personalized service,” remarks Gary Marx, CEO of Piedmont.

“For over 73 years, our solid values and unwavering commitment to customers have created lasting relationships. We supply packaging products, automation, technology, and tailored solutions to customers nationwide, with an emphasis currently on the southeast,” he continues.

DEDICATION TO EXCELLENCE

Piedmont’s long-standing reputation for excellence, and the company’s executive team continues to provide a sincere commitment to customer support and service while inspiring greatness throughout every faction of the business.

“We take great pride in being an accessible, family-run business with an unsurpassed record for customer

For the past seven decades, Piedmont has placed vital emphasis on providing premium service for its customers, employees, and communities. The company focuses on social responsibility and corporate citizenship by encouraging its team to inspire greatness through serving in their local communities.

“We use our expertise in packaging to aid charitable organizations whenever possible, as I have always believed there is more satisfaction in giving than receiving,” acclaims Marx.

Manufacturing Outlook Issue 2 | 83

INDUSTRIES SERVED

BY PIEDMONT Piedmont serves a variety of industries to help its clients achieve their packaging and automation needs.

AEROSPACE – The aerospace industry can face difficult shipping challenges due to the large, fragile parts that need to be delivered both locally and internationally.

Every component that an aerospace company needs to fulfill its daily tasks is shipped according to the industry’s stringent safety standards to ensure safe shipments.

APPAREL – The apparel industry benefits most from an efficient and reliable packaging system, built to handle a large volume of products that are either shipped to retail stores or directly to the consumer.

AUTOMOTIVE – One of the most

“ F O R O V E R 7 3 Y E A R S , O U R S O L I D VA L U E S A N D U N WAV E R I N G C O M M I T M E N T T O C U S T O M E R S H AV E C R E AT E D L A S T I N G R E L AT I O N S H I P S ” – G A R Y M A R X , C E O , P I E D M O N T N AT I O N A L

valuable aspects of automotive packaging revolves around protecting high-value components necessary for the assembly of automotive products.

COLD STORAGE – Piedmont understands that product integrity comes from superior protection during long shipments with tough, leak-proof, food-safe packaging.

Other industries served by Piedmont include: • E-commerce • Electronics • Flooring • Food and beverage • Health and beauty • Healthcare • Manufacturing • Pharmaceuticals

84 | Manufacturing Outlook Issue 2

As his grandfather started the company in 1950, Marx grew up entrenched in the business from an early age.

“I worked at Piedmont during my summers in high school, so I really did grow up fully involved in the company.

I think it’s a great business within a fascinating industry,” he enthuses.

Packaging has evolved throughout Marx’s career and has arrived at the forefront of manufacturing in the last 20 to 30 years with the advent of numerous technological innovations, such as the meteoric rise of e-commerce.

During the COVID-19 pandemic, packaging became a vital industry as companies needed to rise to the challenge of increased demand, while dealing with a shortfall of resources and disruptions in the supply chain.

“As a society, we don’t often take too much time to think about the important role that the average packaging company plays in the economy, let alone our daily lives.

However, packaging companies such as Piedmont hold an integral place in the worldwide supply chain.

“I think packaging is still a very relevant business and I fully expect it to be around for many more years,” he shares.

Furthermore, the key to staying relevant and prosperous within the packaging industry is having a dedicated and supportive technical services team, which is integral to a facility’s success. Piedmont’s service technicians are factory-trained and certified to help its clients’ businesses achieve the ultimate level of success.

“Improving packaging processes

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One of Piedmont’s latest projects involved helping a local, family-owned e-commerce company save over $600,000.

What started as an ordinary customer in Suwanee, Georgia, has evolved into an opportunity to gain the customer’s trust through packaging spend, labor reallocation, automation, and shipping execution.

“Like many direct-to-consumer (D2C) companies, this e-commerce business specializing in pest control experienced tremendous growth in 2020 – but as a family-owned and operated company, they recognized the need to implement automation to keep up with demand,” Marx recalls.

“Shortly after sharing what we do best – through our people and automated solutions – we were able to discuss both packaging needs and operational pain points.”

The strategy brought forward by Piedmont involved increasing throughput for the client’s growing customer demand, alleviating an expensive labor force, eliminating costly human errors, and combating the increasing cost of small parcels.

Manufacturing Outlook Issue 2 | 85

New office in Dallas

Not only did Piedmont prove to be a trusted, consultative packaging solutions provider, but the company also saved the client a substantial amount of money and allowed them to grow at an exponential rate.

With customers across nearly every vertical, from food and beverage to e-commerce fulfillment, retail, automotive parts, and manufacturing, Piedmont always has exciting projects in the works.

“We can manage your inventory, optimize your production line, recommend alternative solutions, consolidate vendors, free up valuable warehouse space and working capital, as well as perform audits to ensure the most effective packaging is being used to protect your products,” Marx acclaims.

CHAMPIONING SUSTAINABILITY Piedmont is committed to supporting a more sustainable environment.

“Our goal is to implement reusable, 86 | Manufacturing Outlook Issue 2

PIEDMONT MISSION AND VALUES MISSION – To be the market leader in supply chain solutions, automation, and technology.

VALUES • Piedmont is all one family • Win together • Deliver success • Get stuff done • Make quality personal • Listen first, then listen more • Have fun

recyclable, and responsible initiatives both internally and through proactive consultation with our customers. We have taken strides towards the pursuit

of long-term sustainability through several strategic initiatives,” Marx tells us.

As a corporation, Piedmont continually makes efforts to contribute to the environmentallyfriendly development of society through its business, as well as to pursue the realization of its mission to inspire greatness in packaging, a proud company promise since its establishment in 1950.

“As a distributor, we have implemented various corporate social responsibility (CSR) and environmental, social, and governance (ESG) requirements towards our suppliers. Our supplier guidelines have been used as the protocol to contribute to a more responsible and sustainable economy,” he adds.

Piedmont is committed to having all company cars upgraded to electric or hybrid by 2030, conducting sustainability audits to educate customers on eco-friendly packaging

PIEDMONT NATIONAL NORTH AMERICA

“ W E U S E O U R E X P E R T I S E I N PAC K AG I N G T O A I D C H A R I TA B L E O R G A N I Z AT I O N S W H E N E V E R P O S S I B L E , A S I H AV E A LWAY S B E L I E V E D T H E R E I S M O R E S AT I S FA C T I O N I N GIVING THAN RECEIVING” – G A R Y M A R X , C E O , P I E D M O N T N AT I O N A L

solutions, and continuing to achieve the company’s goal of 100 percent recyclability on all products utilized internally.

Alongside this, Piedmont is striving to reduce its energy usage by implementing LED lightbulbs and motion-activated lights in all offices and warehouses, and all outbound pallets are now wrapped in a stretch film that bio-assimilates into an environmentally-friendly food source.

INSPIRING GREATNESS As part of Piedmont’s mission to inspire greatness in the packaging

industry, the company believes collaboration is one of its most impactful actions.

“We value a set of shared commitments and know that environmental and social issues are too big to solve on our own. In order to pursue compliant partners, we are dedicated to purchasing from responsibly sourced suppliers and do so by ensuring we uphold CSR and ESG principles with all suppliers and manufacturing partners,” Marx divulges.

As such, Piedmont-distributed products are produced in an

ESG-compliant environment, and manufactured in a safe, respectful workplace that has a zero-tolerance policy towards non-compliance.

Piedmont’s facilities also monitor their own environmental impact regarding emissions, circularity, recycling, waste, and more.

As Piedmont continues to prioritize collaboration and endeavors to uphold its commitment to responsible processes, the future of packaging looks both sustainable and rewarding for the company.

PIEDMONT NATIONAL Tel: 404-351-6130 info@pncorp.com www.piedmontnational.com Manufacturing Outlook Issue 2 | 87

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KOMATSU

Australia’s leading oil and gas exporter

Facilitating the rapid expansion of digital infrastructure in East Africa

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New cars that buyers really want

Driving the acceleration of the South African construction industry, we speak to the Managing Directors of the four pillars that have cemented the division as the frontrunner in road construction for nearly 50 years

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Treating complex cancer cases from across Brazil

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Assembling success in the aerospace industry

Championing the voices of its members, communicating the industry’s needs, and highlighting the importance of renewable infrastructure

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RAUBEX ROADS AND EARTHWORKS

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REA:

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Dr. Jeffrey Kuvin and Dr. Alan Hartman talk about how working together with the community is raising the standard of healthcare one patient at a time

Establishing itself as the industry leader in aerospace bearings, seals, electrical components, and gears

Adama Soro, President of the Burkina Faso Chamber of Mines, unpacks the challenges facing the Burkinabe mining industry as a key driver of the country’s socioeconomic development

Chris Ware, General Manager of Mayfield Industries, shares how his company contributes to the growth of Australian electrical infrastructure

Michael Peither, CIO and co-Founder of VoltStorage GmbH, reveals the company’s innovative battery storage solutions spearheading the renewable power sector

Bruce Bharat, Kamstrup’s Country Manager and Vice President of North America, talks about his company’s dominant force in smart water metering

Michal Jezioro, President and Managing Director, highlights how DMC Mining Services continuously puts performance first

Moog Medical is having a direct impact on the lives of patients, says Vice President and General Manager, Mike Henderson

Bernie Quinn, Engineering Director and Partner at Premcar Pty Ltd, discusses helping global carmakers and their Australian importers create new cars that buyers really want

the Burkinabe mining industry as a key driver of the country’s socioeconomic development Adama Soro, President of the Burkina Faso Chamber of Mines, unpacks the challenges facing

company contributes to the growth of Australian electrical infrastructure Chris Ware, General Manager of Mayfield Industries, shares how his

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America, talks about his company’s dominant force in smart water metering Bruce Bharat, Kamstrup’s Country Manager and Vice President of North

how DMC Mining Services continuously puts performance first Michal Jezioro, President and Managing Director, highlights

says Vice President and General Manager, Mike Henderson Moog Medical is having a direct impact on the lives of patients,

global carmakers and their Australian importers create new cars that buyers really want Bernie Quinn, Engineering Director and Partner at Premcar Pty Ltd, discusses helping

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growth, sustainability and prosperity mining and rehabilitation company, that drives BUMA Australia has a vision to build a modern

buyers really want New cars that

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in East Africa digital infrastructure rapid expansion of Facilitating the

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CORPORATION WESTSIDE

together and planet thrive people, business, A future where

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innovation standard in conservation and Complex setting the global The world-class Olive Downs

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& DEFENSE AEROSPACE REXNORD REGAL

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of healthcare one patient at a time the community is raising the standard talk about how working together with Dr. Jeffrey Kuvin and Dr. Alan Hartman

HOSPITAL UNIVERSITY NORTH SHORE

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TECHNOLOGY ENERGY AND CLEAN FOR RENEWABLE ASSOCIATION

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GROUP INDUSTRIES AIR

CANCER CENTER A.C.CAMARGO

one mission Five divisions,

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industry in the aerospace Assembling success

cases from across Brazil Treating complex cancer

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a legacy of excellence in a busy and exciting industry With over 75-years’ experience, KMC Mining boasts

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C E L E B R AT I N G A C E N T U RY O F H E R I TAG E Comprehensively supporting customers, Sulzer South Africa is dedicated to improving pumping processes, operational reliability, and the high performance of industrial rotating machinery. We discuss all this and more with Managing Director, Henry Craukamp Writer: Ed Budds | Project Manager: Poppi Burke

90 | Manufacturing Outlook Issue 2

SULZER SOUTH AFRICA AFRICA

T

here is often a tendency to label Africa as one market or industry, but it’s important to remember that the continent is made up of 54 distinct nations, each with their own unique opportunities and challenges.

Several noteworthy trends are shaping the current landscape, as despite the enduring challenges posed by the COVID-19 pandemic, many African companies are steadfastly maintaining their focus on pivotal trends, including digitalisation and sustainability.

It is no secret that Africa is simultaneously experiencing an

increase in urbanisation, leading to an upturn in the need for water and electricity. The global requirement for natural resources also continues to boost investments in the mining industry, as the demand for raw materials is still a powerful factor in continued investments in the vast African mining sector. Meanwhile, across a plethora of African industries, the intense competition for talent acquisition remains an ongoing and pressing concern for businesses.

Expertly navigating these numerous challenges is Sulzer South Africa (Sulzer), established in

1922, who has intricately built a rich company legacy rooted in the region’s industrial growth.

“Our evolution from diesel engines and boilers to comprehensive electrical services marked the early stages of our diverse portfolio,” introduces Henry Craukamp, Managing Director of Sulzer.

“Over the years, we have expanded our offerings to include solutions beyond pumps, catering to industries such as water treatment, chemical solutions, transportation, food processing, and power generation,” he expands.

Manufacturing Outlook Issue 2 | 91

SULZER SOUTH AFRICA AFRICA

At Sulzer, we are more than just a product supplier; we aspire to be true partners in delivering substantial value to our customers.”

A HISTORY OF EXCELLENCE

MANUFACTURING OUTLOOK: HOW DID YOUR CAREER JOURNEY BRING YOU TO YOUR CURRENT ROLE? Henry Craukamp, Managing Director: “My career journey began as a technician in the South African heavy industries. As a young engineer, I quickly realised that service excellence and maintaining close contact with customers were fundamental.

“In order to provide service excellence in these industries, it is important to have a profound understanding of how electrical and mechanical equipment works and impacts various processes. As a result of this realisation, I developed a passion for understanding the intricate details of electrical and mechanical systems.

“My professional journey was founded on this realisation, emphasising the critical intersection of technical expertise and a strong commitment to customer satisfaction.”

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Craukamp is a seasoned business leader with a wealth of experience in various aspects of the industrial and engineering sectors. As of 2022, he serves as the Managing Director and Compliance and Information Officer at Sulzer, where he oversees the entire business, assuming responsibility for sales and operations within the region.

With approximately 300 employees, the company’s operational region currently serves customers in 10 countries from within South Africa, based out of two major service locations, Johannesburg and Welkom. Sulzer’s overarching mission as a full-service provider is to adapt continuously to meet the country’s evolving needs.

Throughout Sulzer’s history in South Africa, it has accumulated extensive experience in navigating the complexities of investing, divesting, and reinvesting in a variety of countries and industries.

“Our experience has enabled us to adapt and evolve as the landscape changes, and we find that difficulties like these are truly inspiring,” Craukamp tells us.

“By transforming challenges into opportunities, we can provide solutions that directly meet the specific needs of our customers.

The roots of Sulzer’s history lie in the development of a range of pumps used in diverse applications where fluids are treated, pumped, or mixed.

“We can stand out from the competition in this market because of our facilities, manufacturing and engineering capabilities, and the level of service we provide our customers,” Craukamp acclaims.

A great example of Sulzer’s engineering capabilities is its ability to design equipment for a variety of industries and applications.

“We have crafted a team of seven engineers, with backgrounds in turbine and hydrodynamic design, who are not only involved in local projects but also in global R&D efforts,” he elaborates.

Because of this, Sulzer is more competitive than other pump manufacturers with centralised engineering activities. Moreover, the company has developed reverse engineering capabilities, so it can provide solutions for mechanical rotating equipment, high-speed gearboxes, hydrodynamic couplings, and electromechanical systems. In addition, customers can also benefit from Sulzer’s global network of expertise and know-how.

With specialised requirements and a limited number of experienced service engineers in the industry, Sulzer values experience and knowledge. Throughout the organisation, the company invests a lot of time and effort in training and developing its employees.

“With one engineer working with us for over 25 years, we have a seasoned, experienced engineering team and value their contributions highly.”

With respect to Sulzer’s specialised capabilities, it boasts two service

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SULZER SOUTH AFRICA AFRICA

centres in Elandsfontein and Welkom that provide pump, rotating equipment, and electromechanical services.

Additionally, the company offers in-house full-performance testing for pump systems, allowing the customer to feel confident when installing the equipment and reduce commissioning time.

EXCEPTIONAL SOLUTIONS AND SERVICE Sulzer has played a pivotal role over the last century by delivering exceptional solutions through its comprehensive engineering expertise, industry-specific product range, and customer-centric services.

“While we are often recognised as the preferred pump company, our offerings go far beyond pumps and pump-related services. Our journey in South Africa traces back to the early 1900s when we were involved with diesel engines and boilers, preceding our formal establishment in 1922,” Craukamp shares.

The company then seamlessly diversified into electrical services 94 | Manufacturing Outlook Issue 2

“ O U R E VO LU T I O N F R O M D I E S E L E N G I N E S A N D B O I L E R S TO CO M P R E H E N S I V E E L E C T R I C A L S E R V I C E S M A R K E D T H E E A R LY S TA G E S O F O U R D I V E R S E P O R T F O L I O ” – H E N RY C R AU K A M P, M A N AG I N G D I R E C TO R , S U L Z E R S O U T H A F R I C A

Engineering machine workshop Specialising in the refurbishing of old and new pumps of any variety including HPH, HPL, BKN, PJ250, and MSJs pumps Fedpump, founded in 1991 by Ermindo da Cunha, is a engineering machine workshop dedicated to the refurbishing of a variety of pumps including HPH, HPL, BKN, PJ250 and MSJs. With a strong focus on quality, precision, and customer satisfaction, we have established ourselves as a trusted provider of pump refurbishment services in the industry.

Our experienced team of engineers and technicians possess extensive knowledge and expertise in handling a wide range of pumps, ensuring optimal performance and longevity.

Our Expertise: At Fedpump we specialise in the refurbishment of a variety of pumps including HPH, HPL, BKN, PJ250 and MSJs, covering both old and new models. Our team of skilled engineers and technicians possess in-depth knowledge of various pump types, designs, and manufacturers. We have successfully refurbished pumps from renowned brands and can work with different materials, such as cast iron, stainless steel, and exotic alloys.

Our expertise extends to: 1. Pump Inspection and Assessment: We conduct a thorough inspection of pumps to identify the root cause of any performance issues or failures. Our team utilises advanced diagnostic techniques and equipment to assess the condition of various components, including casings, impellers, bearings, seals, and shafts.

2. Repair and Replacement: Based on the inspection findings, we develop a comprehensive repair plan. Our technicians are proficient in repairing or replacing damaged or worn-out components, ensuring that the pumps meet or exceed original specifications. We source high-quality parts from trusted suppliers to ensure durability and performance.

Quality and Customer Satisfaction: At Fedpump, we are committed to delivering high-quality services and exceeding customer expectations.

We prioritise the following: - Quality assurance: Our workshop adheres to rigorous quality assurance processes and follows industry best practices. We maintain strict quality control standards throughout the refurbishment process to ensure consistent and reliable results.

- Timely delivery: We understand the importance of minimising downtime for our customers. Our team is dedicated to completing projects within agreed timelines, ensuring prompt delivery of refurbished pumps.

- Customer collaboration: We value open communication and collaboration with our clients. We work closely with them to understand their specific requirements, provide regular updates on project progress, and address any concerns promptly.

Fedpump is a trusted engineering machine workshop specialising in the refurbishment of a variety of pumps including HPH, HPL, BKN, PJ250 and MSJs. With our expertise, we have dedication to quality.

Contact us: Tel: (011) 894-3658 | Cell: 0605324233 Email: sonia.dacunha@yahoo.com

SULZER SOUTH AFRICA AFRICA

“ BY T R A N S FO R M I N G C H A L L E N G E S I N TO O P P O RT U N I T I E S , W E C A N P R OV I D E S O L U T I O N S T H AT D I R E C T LY M E E T T H E S P E C I F I C N E E DS O F O U R C U STO M E R S ” – H E N R Y C R AU K A M P, M A N AG I N G D I R E C TO R , S U L Z E R S O U T H A F R I C A

96 | Manufacturing Outlook Issue 2

in 1925, before opening a pump reconditioning service centre in Jeppestown in 1936 to cater to the thriving gold industry of the 1940s.

“To further support South Africa’s growth, we inaugurated a pump factory in 1951. During this period, we played a vital role in advancing the power, mining, and water sectors,” he adds.

However, as the late 1960s approached, Sulzer anticipated a decline in demand for mine dewatering pumps, prompting a shift towards the power generation market and the increasing public need for water supply.

In 1976, the company established a purpose-built pump manufacturing facility in Elandsfontein, which not only produced world-class pumps but also provided a comprehensive range of spare parts. This marked the inception of Sulzer’s journey as a combined supplier of new pumping assets and a service provider for rotating equipment.

Furthermore, in 1979, a dedicated workshop for rotating equipment

SULZER SOUTH AFRICA AFRICA

was introduced, aligning with the aging equipment in South Africa, proving to be a prudent move for both the company and its customers.

Collaborations with original equipment manufacturers (OEMs) to manufacture approved spare parts further solidified Sulzer’s offering.

“While the 1980s witnessed the era of big hair and power dressing across the world, Sulzer was busy evolving into a leading independent service provider (ISP) in South Africa.”

This impressive transformation was facilitated by the establishment of a new engineering department in 1984,

and by the end of the decade, Sulzer had become a fully-fledged ISP for rotating equipment for nearly any brand.

Staying true to its heritage of adapting to customer needs, in 2023, Sulzer opened a state-of-the-art electromechanical services facility in Elandsfontein. This facility aligns with the company’s commitment to not only enhance its customers’ pump performance, but also optimise the entire associated drivetrain.

The facility further bolsters Sulzer’s capabilities in refurbishing motors, gearboxes, and generators, offering customers in South Africa a comprehensive one-stop shop for their rotating equipment needs. Additionally, when necessary, customers can access Sulzer’s global network of over 100 service centres for comprehensive maintenance and repair works.

CSR PROJECTS Sulzer not only cares for its customers, but also for the communities where it operates.

98 | Manufacturing Outlook Issue 2

POWERING SUSTAINABILITY, POWERING SUSTAINABILITY, POWERING SUSTAINABILITY, POWERING SUSTAINABILITY, MAXIMIZING RELIABILITY MAXIMIZING RELIABILITY MAXIMIZING RELIABILITY MAXIMIZING RELIABILITY

John Crane is a global leader in mission-critical technologies for the energy and process industries and an innovator in rotating equipment, encompassing mechanical seals, couplings, filtration systems and cutting-edge asset management and digital diagnostics solutions.

Blending a rich legacy of innovation with a commitment to service excellence, we’ve enabled our customer’s reliable and sustainable operations for over a century. While recognizing the role of • Packing traditional energy, we are pioneering solutions that enable cleaner alternatives, crafting a vision for a sustainable energy future. Our extensive global presence underscores our promise to • Mechanical seals customers, with over 200 service centers in 50 countries. With more than £1 billion in • Split seals revenue in fiscal year 2023, we are an integral pillar of Smiths Group plc, an FTSE 100 listed company dedicated to improving our•world smarter engineering.

Sealthrough face technologies

GLOBAL PRODUCTS GLOBAL PRODUCTS GLOBAL PRODUCTS GLOBAL PRODUCTS • Packing • Packing

• Packing • Mechanical • Mechanical sealsseals • Mechanical seals • Split • Split sealsseals • Split seals •South Seal face technologies John• Crane in Africa, established in 1967, has service centers throughout Seal face technologies • Upstream Pumping South Africa that provide a full range of products, services, and solutions, with • Seal face technologies maintenance and repair capabilities throughout all our facilities in Springs, • Upstream Pumping • John Crane Diamond® • Upstream Pumping Durban, Cape Town, Sasolburg, and Secunda. Our application-specific • tailored Upstream Pumping • Couplings approach and service offering provide the right solution for every • John Crane Diamond® • John Crane Diamond® situation.

• Filtration ••John Crane Diamond® The South African business is a Broad-Based Black Economic Empowerment Couplings • Couplings (B-BBEE) Level 3 contributor following a successful partnership with Bunengi Couplings LOCAL Group, a• 100% women-owned investment andSERVICES services group, who • Black Filtration GLOBAL PRODUCTS Filtration share•our aspirations to enable underprivileged women to enter Science, • Maintenance and repair services • Filtration • Packing Technology, Engineering and Mathematics (STEM) careers.

POWERING SUSTAINABILITY, MAXIMIZING RELIABILITY

LOCAL SERVICES LOCAL SERVICES LOCAL SERVICES • Maintenance and repair services • Maintenance and repair services

• Mechanical seal reliability programs Further supportingseals John Crane’s commitment to invest in South Africa, our • Mechanical global gland packing production has now been consolidated in South Africa, with • Gas seal management programs • Split seals our Springs facility upgraded to a center of excellence, producing products to •various Assetkey management solutions support our local and global demand in the industries including mining.

• Seal face technologies

POWERING SUSTAINABILITY, • Maintenance and repair services • Mechanical reliability programs • Five service centers in South Africa POWERING SUSTAINABILITY, • Mechanical seal seal reliability programs • Upstream Pumping • Mechanical seal reliability programs • Consignment stock agreements MAXIMIZING RELIABILITY • Gas seal management programs • John Crane Diamond® • Gas seal management programs MAXIMIZING RELIABILITY • Service exchange • Gas sealmanagement managementsolutions programsagreements • Couplings • Asset Supporting the broader economy through inclusive and equitable business practices aligns with the core values that define how we work with our partners, customers, vendors and suppliers.

• Asset management solutions

• Filtration • Asset management solutions

INDUSTRIES SERVEDAfrica GLOBAL PRODUCTS • Five service centers in South • Five service centers in South Africa GLOBAL PRODUCTS • Oil and Gas / Petrochemical • Packing • Five service centers in South Africa LOCAL SERVICES • Packing• Consignment stock agreements

• Consignment stock•agreements Mining • • Mechanical Maintenanceseals and repair services • Consignment stock agreements • Mechanical seals • Service exchange agreements • Pulp and Paper • seals • Service exchange agreements • Split Mechanical seal reliability programs • Split • seals Service exchange agreements • Chemical • Seal face technologies • Gas seal management programs • Seal face technologies Upstream Pumpingsolutions• Power Generation • •Asset management • Upstream Pumping •Africa Pharmaceutical • John Crane Diamond® • Five service in South •and Oilcenters and Gas / Petrochemical • Oil Gas / Petrochemical • John Crane Diamond® • General industries • • Couplings Consignment stock agreements • Oil and Gas / Petrochemical • Mining • Couplings • Mining • Filtration • Service exchange agreements • Mining • Filtration • Pulp and Paper

INDUSTRIES SERVED INDUSTRIES SERVED INDUSTRIES SERVED

Explore and discover the John Crane product or service that fits your needs

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• Oil and Gas / Petrochemical • Maintenance and repair services • Chemical • seal reliability programs • Power Generation • Mechanical Mining Explore and discover • Power Generation Explore and discover the the • Mechanical seal reliability programs • Gas seal management programs • Power Generation Explore and discover • Pulp and Paper John Crane product orthe service • Pharmaceutical John Crane product or service • Gas seal management programs • Pharmaceutical • Asset management solutions • Chemical John Crane product or service that fits your needs Pharmaceutical that fits your needs • Asset•management solutions • General industries • General industries • Five service centers in South Africa • Power Generation that fits your needs Explore and discover the • Five service centers in South Africa • General industries • Consignment stock agreements John Crane product or service • Pharmaceutical • Consignment stock agreements Learn that fits your needs • Service exchange Learn MoreMore • General industriesagreements • Service B-BBEE exchangeLevel agreements 3 Contributor - South Africa Learn More

B-BBEE Level 3 Contributor - South Africa

INDUSTRIES SERVED B-BBEE Level 3 Contributor - South Africa INDUSTRIES • Oil and GasSERVED Petrochemical B-BBEE Level 3 /Contributor - South Africa • Oil and Gas / Petrochemical • Mining • Mining

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SULZER SOUTH AFRICA AFRICA

“This is part of our identity, our vision, and deeply rooted in our employees’ DNA. Our sense of care binds us together even more,” Craukamp exudes.

In 2021, the company introduced the Sulzer Scholarship for Women in Science and Engineering. This scholarship is targeted at female students pursuing degrees in engineering, technology, and science, with the ultimate goal of increasing female participation in the engineering industry.

As part of Sulzer’s commitment to the communities in which it operates, the company is actively collaborating with universities in South Africa to establish and promote these scholarships, reflecting its presence and business needs in the region.

Sulzer further demonstrates its commitment to education by providing financial support to 10 students from Volksrus Primary School on an annual basis.

“Furthermore, in 2023, we embarked on a two-year restoration project for Primrose Primary School.

This project not only aims to provide 100 | Manufacturing Outlook Issue 2

SULZER SOUTH AFRICA AFRICA

DRIVEN BY PURPOSE MISSION

CORE VALUES

Consistently deliver innovative solutions reinforced by responsive client service and a commitment to quality and excellence.

We invest in our people. At Pro-Industrial, we constantly enhance our professional knowledge and skills by staying abreast of the dynamic changes and technological advancements utilised by our clients and the industry.

We believe in partnering with our clients to help ensure their success. We are consistently driven to contribute to our clients’ ability to reach their VISION business goals. After all, we succeed when our Be recognised by our clients clients succeed. as their partner in the development, delivery, and We never compromise on our commitment management of engineering to quality. The core of what we do is ensuring engineering and design integrity. This defines products to samples and drawings as per customer’s who we are and our commitment to excellence.

We are committed to diversity. The richness of requirements. our relationships and the success of our pursuits, individually or collectively, are influenced by the extent to which we respect, listen to, and appreciate one another irrespective of differences. In fact, diversity, in all of its forms, is the cornerstone of creativity and innovation.

(+27 11) 613 6971/72 | 082 921 9686 | proindgasket@mweb.co.za | stevenpillay@mweb.co.za

We pursue an unrelenting quest for excellence, continual improvement and cutting-edge modernisation of our machinery, technology and staff training.

Guia Engineering’s core business is manufacturing a full range of precision machined components, on the latest CNC machines.

Our Services: •

Precision Component Manufacture

•

CNC Turning, Milling, Drilling

•

Precision Grinding

•

ISO 9001:2015 Accredited

•

1-100 000 Part Capacity

•

Prototyping

•

Light Fabrication

•

Replacement Parts

Guia Engineering serves all manufacturing plant sectors, particularly the mining, pharmaceutical, FMCG, electrical and packaging industries.

40 years and going strong Manufacturing Outlook Issue 2 | 101

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students with a school to take pride in, but also to create a safe and conducive learning environment, especially for students from the local informal settlement,” he adds.

STRATEGISING FOR A BRIGHT FUTURE Sulzer aims to be a responsible corporate citizen and endeavours to harness the power of fluid engineering to make life better, safer, and more sustainable.

“Our sustainability strategy is composed of three pillars – minimising our carbon footprint, enabling a

Sulzer Johannesburg service centre

102 | Manufacturing Outlook Issue 2

low-carbon society, and engaging our employees and communities to build a more inclusive and sustainable future,” Craukamp offers.

The three pillars are supported by Sulzer’s commitment to the principles of good corporate governance, which ensure a sound balance of power and support the company in creating sustainable value for its various stakeholders.

Sulzer actively engages with its customers to address pump-related challenges, such as failures and evolving specification issues. Sulzer is also heavily investing in R&D for

leading engineering solutions to address these issues.

“For example, we are working on utilising additive manufacturing for pump repairs and retrofits.

This approach underscores our commitment to environmentallyresponsible practices, reducing the need for equipment disposal or extensive remanufacturing, thus aligning with our dedication to minimising our carbon footprint and advancing a low-carbon society.”

Looking ahead, Sulzer’s key priorities include further enhancing its engineering capabilities, expanding its local footprint, and investing in advanced technologies.

“We aim to position Sulzer as a leader in innovative solutions, ensuring our services align with evolving industry needs. Our focus on customer satisfaction, sustainability, and continuous improvement drives our strategic vision,” Craukamp sets out.

“While specific targets are confidential, our overarching goal is to achieve sustainable growth, offer unparalleled customer experiences, and contribute meaningfully to the communities and industries we serve,” he excites.

To summarise, Sulzer continues to expertly provide a comprehensive range of solutions to its customers.

It is the company’s robust engineering capabilities and facilities in close proximity to its customers that set it apart from various competitors. Investing in continuous learning and development for its employees allows Sulzer to guarantee its services meet the highest standards, and will ensure that the company remains a leading fullservice provider in the market.

SULZER SOUTH AFRICA www.sulzer.com

SULZER SOUTH MANUFACTURING AFRICA

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Manufacturing Outlook Issue 2 | 103

104 | Manufacturing Outlook Issue 2

UNICA IRON AND STEEL AFRICA

SETTING A SOLID S TA N DA R D E

As proud pioneers of secondary metals manufacturing, UNICA Iron and Steel is successfully forging a path in South Africa.

Managing Director, Mohammed Asif Qasim, tells us more about the industry Writer: Rachel Carr Project Manager: Poppi Burke

stablished in 2007, UNICA Iron and Steel (UNICA) is the first in South Africa (SA) to feature a fully integrated mini-steel plant that produces light to medium structural steel.

“We are growing with the pace of demand, and our market share increases daily. We are currently installing a new melting furnace to increase our capacity from 120,000 tonnes per annum (tpa) to 240,000 tpa,” opens Mohammed Asif Qasim, Managing Director of UNICA. Qasim began his career as an entrepreneur and retail shop owner.

He developed an interest in the manufacturing industry as an industrialist in 1998 when UNICA Plastics, as it was then known, started in Pretoria.

Subsequently, a steel fabrication shop was incepted in 2000, and following that, the company evolved into UNICA Iron and Steel, where Qasim became the Managing Director, co-Founder, and a shareholder.

Alongside the melting furnace, Qasim proudly tells us of other projects in the pipeline for UNICA. For example, in an effort to optimise its production capacity, the company added argon oxygen decarburisation (AOD) and oxygen plants to its production processes.

UNICA IRON AND STEEL AFRICA

“We are installing two oxygen plants and one AOD unit, which will allow us to improve our quality further and supply different market sectors,” Qasim tells us.

AOD is a chemical process where oxygen is introduced in a vessel to create an exothermic reaction, hence, UNICA installed oxygen plants alongside it. As a result, the plant produces oxygen and nitrogen necessary for decarburising and refining the steel.

“We have invested over R450 million since the COVID-19 pandemic and are continuing to do so. Once all the expansions are completed, we may be at the level of R550 million,” Qasim notes.

PROCESSES AND PLANTS The company uses processed scrap as a raw material to produce steel using an induction furnace, in a process known as secondary steel making. The resultant billets are then processed

in the rolling mills to produce light to medium steel sections such as angle iron, round bars, and window sections.

“Focusing on this niche, UNICA has managed to grow its share substantially and has become a benchmark operation for many who have followed its success,” Qasim reveals.

“The company is the first 100 percent Bureau of Energy Efficiency (BEE) rated metal waste recycle plant in the small and medium-sized enterprises (SME) space.”

“FOCUSING ON THIS NICHE, UNICA H AS M A N AG E D TO G R OW I TS S H A R E S U B S TA N T I A L LY A N D H A S B E C O M E A B E N C H M A R K O P E R AT I O N F O R M A N Y W H O H AV E F O L L O W E D I T S S U C C E S S ” – M O H A M M E D AS I F Q AS I M , M A N AG I N G D I R E C TO R , UNICA IRON AND STEEL

106 | Manufacturing Outlook Issue 2

Manufacturing Outlook: Could you talk about UNICA’s supply chain operations and what the company procures locally?

Mohammed Asif Qasim, Managing Director: “Since we are secondary steel producers, meaning we are metal recyclers, our major input is scrap, which we procure locally.

“We have to procure certain consumables from India and China, as the plant is still new to SA, and there aren’t many producers of consumables in the country currently. However, manufacturing may start locally in the near future, but until then, we will rely on imports. Aside from that, 85 percent of our procurement is local.”

Indeed, UNICA has much to celebrate, and its success is partly down to the 900 people it employs from the rural Hammanskraal area in Gauteng Province. The workforce operates in rolling mills to produce over 100 different sections from billets created in an induction furnace and castes in a continuous caster.

“When the plant was established, it was able to produce only 12,000 tpa, whereas in the space of 14 years, it has already reached the levels of 15,000 tpa and is expanding further, so we are hoping to reach up to 24,000 tpa by Q3 in 2024.

“Next year, the process involving melting scrap to liquid metal and casting it to billets, which are then reheated and rolled from light to medium,” Qasim informs us.

Before 2007, only six major steel-making plants existed in the country, which were

dominating the sector, particularly since there were only two major plants in the long products market.

“That is where we saw a gap; therefore, we decided to adopt the Asian mini steel plant. Our success followed, with five or six more plants established after us,” continues Qasim.

A strategic hands-on approach gives

MPHO MOOFE TRADING ENTERPRISE the competitive advantage Mpho Moofe Trading Enterprise CC started operations in 2008. The Company was founded by its current Director, Stanley Sello Molele. Its main objective, to develop and provide good quality services in the following key areas: • Project Management • Operations • Construction • Technical Support • Engineering Services • Maintenance • Supply, distribution and other related services, reflecting its clients’ demands

Mpho Moofe Trading Enterprise CC’s products and services are always in demand because its engineering, project management skills and technical background is more diverse than that of its competitors.

Mpho Moofe Trading Enterprise CC as a company, is 100% black owned and controlled, and is therefore well structured to supply excellent quality services to satisfy its broad range of clients and customers.

HEAD OFFICE (LIMPOPO): P.O Box 702, Rozano, 0723

GAUTENG OFFICE: 201 Maletswai Section, Ramotse, Hamm

Fax No: 012 345 6789 | Cell No: 079 967 0233

Fax No: 012 345 6789 | Cell No: 079 967 0233

Alternative No:078 686 0063

Alternative No:078 686 0063

E CC PLANT EQUIPMENT The company owns some construction plants list below: • 1x water tank 12000 litres • 1x TLB • 2x Bakkie • 1x Diesel bowser • 15x Welding machines • 15x Generators

OUR MISSION Empowerment of our employees and stakeholders is our mission.

This will be achieved through continuous development within the communities and organisations we serve.

manskraal, 0400

stanleymolele@yahoo.com

UNICA IRON AND STEEL AFRICA

STRENGTHENING COMMUNITIES “One of the reasons that UNICA is growing and successfully capturing the market is due to our dedicated, motivated, and welltrained workforce. Our experienced executive, senior, middle, and junior management in particular are key reasons for our prosperity,” Qasim sets out.

As UNICA is a first-of-its-kind project in SA, most of its staff had no first-hand experience in the demands of secondary steel manufacturing.

To address this, the company’s HR department provides on-the-job training.

“ T H E C O M PA N Y I S T H E F I R S T 1 0 0 PERCENT BUREAU OF ENERGY E F F I C I E N C Y R AT E D M E TA L WA S T E R E C YC L E P L A N T I N T H E S M A L L A N D M E D I U M - S I Z E D E N T E R P R I S E S S PAC E ” – M O H A M M E D AS I F Q AS I M , M A N AG I N G D I R E C TO R , UNICA IRON AND STEEL

“We also provide ample training and opportunities for career growth by encouraging our employees to work smart,” he adds.

Over the years, the company has consistently improved staff conditions, and now it is the highestpaying employer in the country.

Furthermore, it distributes annual bonuses, long service awards, and production incentives. Employees of the month and year are just some of the initiatives that make UNICA the workplace of choice.

As part of UNICA’s mission, vision, and values, it is also deeply committed to making a difference in the community through its corporate social responsibility (CSR) programmes.

“We provide economic and equal opportunities to our immediate community by offering direct jobs to citizens in surrounding areas. We ensure that we also extend a helping hand to widows and orphans.”

Other programmes include rehabilitating drug users and educating communities on drug abuse as well as the prevention of violence against women.

Allied Mineral Products South Africa (AMSA) would like to extend our deepest congratulations to Unica Iron and Steel for the ongoing partnership we have developed over the years. Best wishes for continued prosperity and growth.

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UNICA IRON AND STEEL AFRICA

“Sporting activities are also one of our key principles. As such, we sponsor local sports events and kits for teams,” acknowledges Qasim.

As corporate citizens, UNICA believes its impact on the local communities and surrounding environment must be positive. To that end, the company encourages a culture of care, supporting multiple projects to uplift the disadvantaged and assist those less fortunate.

UNICA Environmental Objectives The company has set goals to become a sustainable operation and green steel manufacturer by 2025 by: • Migrating to clean energy, including solar and compressed natural gas (CNG).

• Recycling at least 2,500 kilogrammes (kg) of general waste (paper, plastic, etc.) and at least 5,000 litres of used oil per annum.

• Training 80 percent of employees on different topics under environmental management.

• Ensuring that it does not exceed the allowed amount for dust monitoring more than twice a year.

• Reducing water usage by five percent compared to the previous year.

• Installing a waste processing plant to make waste useable for the construction industry.

• Generating power.

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UNICA UPGRADES As the plant is the first of its kind in SA, it is unique in its totality.

“We have adapted many different methods in billet-making and rolling processes to innovate our profile. We produce and offer better commercial benefits to our market; for example, we are the first in the country to master and successfully produce light angles of 2 millimetres (mm) gauges.

“Similarly, we have produced a special window section, which is light in weight but still does not lose strength due to its innovative design,” Qasim enthuses.

The steel industry is one sector that the government has focused on, especially since the COVID-19 pandemic.

More aggressive steps have been taken by the current administration,

having who has developed a master plan for the industry, encouraging even greater growth for UNICA. Moreover, the localisation drive and protection of regional products has played an important role in UNICA’s growth after the devastation caused by the COVID-19 pandemic.

“During 2020, we completed a new rolling mill, which has allowed us to

expand our billet-making capabilities.

Subsequently, the second expansion since the COVID-19 pandemic is underway. This growth is a direct result of our continuous hard work, R&D, and customer-orientated attitude, by providing clients with flexibility and easy access to our ordering and delivery systems,” he details.

All expansions are carried out with calculations and market surveys, demonstrating how UNICA sets realistic targets and achieves them to the maximum extent.

“Our current goal is to cross the 24,000-tonne figure by the end of 2024. We are well on course, and I believe we will get there,” Qasim closes.

UNICA IRON AND STEEL Tel: 012 719 9736 info@unica.co.za ironandsteel.unica.co.za Manufacturing Outlook Issue 2 | 113

AN A DV E N T U R O U S PURSUIT

Born out of a passion for overlanding and exploring the great outdoors, Alu-Cab has transformed from a Cape Town start-up to a global supplier of adventure vehicle accessories, as CEO, Warwick Leslie tells us Writer: Tom Wadlow | Project Manager: Poppi Burke

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ALU-CAB AFRICA

To be successful, you have to have your heart in your business, and your business in your heart.”

Coined by Thomas Watson, the entrepreneur whose 40 years at IBM propelled it into the largest manufacturer of data-processing equipment in the world, this statement captures perfectly the story of Alu-Cab. Like Watson and IBM, this is a story of passion. In this case, Founder and COB Jeremy Bergh’s heart was in overlanding – a hobby centred around a combination of remote travel, offroading, and camping that is fuelled by a spirit of adventure and a desire to seek off-piste, unspoiled destinations.

Manufacturing Outlook Issue 2 | 115

The same can be said of Managing Director, Warwick Leslie, whose love of mechanical engineering (and fishing) brought him into the Alu-Cab fold.

“I’ve been interested in anything mechanical my whole life,” he says.

“When I finished school, I studied mechanical engineering and during that time got involved in circuit racing, building and modifying road cars for the track. At the same time, I also got very involved in fishing and that’s when I decided that I needed a more practical vehicle to get to the areas I wanted to get to.

“The natural choice was a fourwheel drive and, being a tinkerer and someone that can’t leave things alone, that vehicle didn’t remain standard spec for very long. It was in this modifying journey that I met Jeremy.

This was in the very early days of AluCab and together, we did quite a lot of work on the vehicle.”

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Back then, Warwick was working in the food processing industry, an endeavour which, by his own admission, was not motivated by a

ALU-CAB AT A GLANCE Alu-Cab has grown from a Cape Town start-up to a fullyfledged manufacturer and global distributor of vehicle accessories for overlanding adventurers.

•

Founded in 2000

•

Pioneer of the first-ever aluminium adventure canopy

•

620 employees

•

450 sellable products

•

Products sold in 70+ countries

passion for pursuing a career in the sector.

“Jeremy offered me an opportunity to work at Alu-Cab,” he continues. “It was, at the time, a very scary one. It was a huge pay cut to get involved but I decided that I was young enough to take a risk. That was 19 years ago, and here we are today.”

STANDING OUT It is fair to say that a lot has happened since Warwick joined the Alu-Cab journey back in the early 2000s.

The company was founded off the back of Bergh’s own travel experiences. Space and weight posed constant challenges, challenges which inspired the creation of the first ever aluminium canopy specifically engineered for adventure travellers. The product, which provides a practical way of utilising space and accommodating weight in overlanding vehicles, has been

ALU-CAB AFRICA

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Fastenright’s expertise in stainless steel fasteners aligns seamlessly with Alu-Cab’s dynamic approach in the automotive and manufacturing sector.

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Manufacturing Outlook Issue 2 | 117

subject to constant refinement ever since. As this process continued, with accessories for the canopy being innovated alongside improvements to the core product, the more Bergh and Warwick realised its boundless potential.

Today, the company stands proud as a home-grown South African enterprise that operates its own fully developed manufacturing facility in Cape Town, where the journey started, and employs well over 600 people.

It produces a vast portfolio of vehicle accessories designed to make the overlanding experience as seamless and comfortable as possible, ranging from a fridge slide-through to a full-blown sliding camper with central heating, and many more nifty items in between. Alu-Cab sells globally, with significant customer bases in Europe, North America, and Australia, where overlanding is often cited as being born.

So, passion and heart aside, what has enabled the company to command a status as a market leader?

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“J E R E M Y O F F E R E D M E A N O P P O R T U N I T Y T O W O R K AT A L U - C A B … I T WA S , AT T H E T I M E , A V E R Y S C A R Y O N E . I T WA S A H U G E P AY C U T T O G E T I N V O LV E D B U T I D E C I D E D T H AT I WA S Y O U N G E N O U G H T O TA K E A R I S K . T H AT WA S 1 9 Y E A R S A G O , A N D H E R E W E A R E T O D AY ” – WA R W I C K L E S L I E , C E O , A L U - C A B

ALU-CAB AFRICA

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Manufacturing Outlook Issue 2 | 119

ALU-CAB AFRICA

“I think we’ve got two main differentiators that make us stand out from the competition,” Warwick explains. “The first and foremost is our innovation and R&D. We always try to come up with new and different solutions to problems that people experience in vehicular travel or otherwise.

“The other main differentiator is the scope of products that we offer. We don’t concentrate on only one sector of the industry. We have a very broad spectrum of products which allows us to be as close to a turnkey accessory supplier as possible.”

RESPONSIBLE GROWTH Warwick and Alu-Cab, in reaching this point, have also ensured that the journey to becoming and now

120 | Manufacturing Outlook Issue 2

sustaining a successful company is grounded in principle and responsibility.

“We’re all about being conscious and sustainable,” he states. “We truly care about our impact on the

environment and we’re dedicated to making a positive, lasting change for future generations. We run a large CSI program that focuses on African conservation, both locally and beyond.”

Indeed, the firm is involved in a variety of initiatives, working closely with a range of organisations to support anti-poaching and endangered wildlife conservation, as well as community upliftment.

These include collaborations with the Ford Foundation, the Endangered Wildlife Trust’s Vultures for Africa Program, and the Freshwater Research Centre on its Saving Sandfish Project.

Alu-Cab also keenly supports with the Thornybush K9 Unit, where it sponsors dogs to protect the environment against poaching.

ALU-CAB AFRICA

TURNING A PASSION INTO A BUSINESS MANUFACTURING OUTLOOK: HOW IS THE SPIRIT OF ADVENTURE CAPTURED ACROSS THE COMPANY AND ITS PRODUCT RANGE? WARWICK LESLIE, CEO: “Alu-Cab is owner-run, which I think is an important part of conveying our passion or excitement for travel. No-one wants to be working harder than they need to for their daily tasks. You’re out there to enjoy yourself and not be struggling with putting tents up or moving from camp to camp or whatever it might be.

“We are continually learning, making adjustments and improving our products based on our own experiences in our own travels, because we get a huge kick out of being able to simplify the experience for our customers and for ourselves.”

In terms of its own business operations, the company leads by example, playing its part in the circular economy with its in-house recycling initiative that runs across the entire footprint of factories.

Operating a response company also entails the empowerment of people and communities. Here, Alu-Cab is active on many fronts.

“We invest in the growth and development of our staff through an active training program,” Warwick explains. “Many of our team members come from diverse backgrounds and are without formal qualifications – at Alu-Cab, we believe in providing opportunities for everyone to succeed.

Manufacturing Outlook Issue 2 | 121

COMPANY NAME SECTOR

“We’re also committed to uplifting our community and putting in the time and effort required to ensure that our employees are equipped with the necessary skills to excel. Our HR department prioritises internal hiring for promotion and development, but when necessary, we also seek talent externally. We’re passionate about individual development and strive to uplift not only our staff but also 122 | Manufacturing Outlook Issue 2

the community around us.”

Supporting local enterprises through the supply chain is another important component that contributes to social value creation.

Alu-Cab’s procurement strategy revolves around utilising local suppliers wherever it is feasible, although a small portion of its stock does require sourcing from afar.

However, the firm relies heavily on the reliability and quality of its local

ecosystem of suppliers and service providers, and invests significant energy and resources into nurturing mutually beneficial partnerships.

“We pride ourselves on taking care of our suppliers and this ensures that we can deliver the best possible product at the most competitive price, all while supporting the growth and success of our local community,” Warwick adds.

ALU-CAB AFRICA

“ W E P R I D E O U R S E LV E S O N TA K I N G C A R E O F O U R S U P P L I E R S A N D T H I S E N S U R E S T H AT W E CAN DELIVER THE BEST POSSIBLE PRODUCT AT T H E M O S T C O M P E T I T I V E P R I C E , A L L W H I L E SUPPORTING THE GROWTH AND SUCCESS OF OUR LOCAL COMMUNITY” – WA R W I C K L E S L I E , C E O , A L U - C A B

TIME FOR CONSOLIDATION Looking ahead, Warwick remains grounded. Rather than continuing to pursue aggressive expansion which could be unsustainable in the longer term, the priority now is to consolidate and streamline the organisation.

“Due to our rapid growth over the last five years, we have ended up being quite fragmented in our manufacturing spaces because we’ve been forced to take whatever properties came up in

the area,” he explains.

In response, Alu-Cab is in the process of consolidating five of its 15 factories. In the second half of 2024, the company will consolidate the remaining factories into a single building, bringing the total manufacturing real estate footprint down to just two sites. This, Warwick states, is key to unlocking efficiencies and working more coherently.

Developing the innovation pipeline

and maintaining strong market positions across its territories are also key priorities. Succeed here also, and fast-forward a year to 18 months, AluCab will be poised to take the next big step on its overlanding journey.

ALU-CAB www.alu-cab.com Manufacturing Outlook Issue 2 | 123

PREMCAR PTY LTD ASIA PACIFIC

E N G I N E E R E D, E N H A N C E D, ELECTRIFIED We speak to Bernie Quinn, Engineering Director and Partner at Premcar Pty Ltd, about how the company is helping global carmakers and their Australian importers create new cars that buyers really want Writer: Lauren Kania | Project Manager: Thomas Arnold

When the three big brands – Ford, GM-Holden, and Toyota – stopped assembling cars in Australia, there was a public belief the car industry in the country had died. This wasn’t true.”

The opening statement of Bernie Quinn, Engineering Director and Partner at Premcar Pty Ltd (Premcar), reflects the reality of how many of the companies underpinning the Australian automotive industry have continued to grow with new car engineering and manufacturing.

In the case of Premcar, an Australian engineering services provider and new-vehicle secondary manufacturer, the company has not only continued despite the disappearance of traditional big car brands but has experienced exponential growth unlike anything seen before.

“All of this is evidence that Australian car-making never died.

At Premcar, we transferred our deep experience and skills into the next

evolution of car manufacturing in Australia,” confirms Quinn.

Today, major carmakers of all sizes commission the company for almost everything. From developing entire new-vehicle platforms to enhancing a model series for a new buying

audience to tuning a new car model’s steering and handling, Premcar does it all.

Premcar’s tagline – “Engineered.

Enhanced. Electrified.” – aptly summarises what global automakers have come to rely on the company for.

Manufacturing Outlook Issue 2 | 125

PREMCAR PTY LTD ASIA PACIFIC

Based in Epping, Australia, Premcar has been in business for nearly three decades and has proven its reliability and deliverance of high-quality services and products through consistent evolution and an innovative mindset.

Having been an engineer for 28 years, 20 of them spent at Premcar, Quinn has always held an inexhaustible passion for cars.

“Everything I did in my earlier years enabled me towards working with cars, so it was natural for me to pursue 126 | Manufacturing Outlook Issue 2

an engineering degree to participate in an industry that I’ve been obsessed with my entire life,” he excites.

Invigoration and unstoppable enthusiasm are ingrained within the core structure of Premcar and are evident in everything the company provides to its vast clientele.

AN AUSTRALIAN MANUFACTURING RENAISSANCE “We’re seeing a renaissance of manufacturing in Australia, especially

in the car industry. In the case of Premcar, this change has been customer-driven,” explains Quinn.

Australian automotive consumers have been the centrepiece of Premcar’s mission since its inception.

With buyers walking into new car dealerships wanting vehicles that satisfy their particular needs and wants, it is critical for companies to meet these expectations and provide high-quality, exceptional cars.

As a prime example, highperformance AMG models have accounted for as much as 30 percent of total annual new car sales for Mercedes-Benz in Australia.

“Everyone at Premcar understands why; as the company behind Ford Performance Vehicles (FPV) for many years, Australian buyers want something special,” comments Quinn.

Premcar offers exactly that to its customers: something special.

One of the biggest differentiating factors when comparing Premcar to the competition is how the company puts its customers at the centre of every decision made, through its triad of business, product development, and manufacturing processes.

“We’ve built all three of these with the original equipment manufacturer (OEM) carmaker, and their customers in mind. This is why we use our own proprietary product development system, which we created to accurately fit our manufacturing process,” specifies Quinn.

Additionally, Premcar uses a systems and design-led approach when engineering and enhancing new cars. Doing this means that customers receive the new vehicle they want, which is of the utmost importance as ‘Made in Australia’ is a big drawcard for new car buyers in the country.

“Ultimately, our attention to detail and understanding of what our customers need makes us a company of choice. The new cars we create all have this understanding built into them, which explains why they’re so

MANUFACTURING OUTLOOK: HOW DO YOU TRY TO EMPOWER YOUR STAFF AND RECOGNISE THE CONTRIBUTIONS THAT THEY MAKE? Bernie Quinn, Engineering Director and Partner: “With a very low staff turnover, the feedback from our team is that we’re an employer of choice because we empower them and help to build their careers.

“In fact, we’re about to celebrate a number of staff who have dedicated 20 years to the company.

“We work to create the best environment for our team by recognising people and rewarding them appropriately. We’re also flexible due to the varying needs of everyone in our company. Balancing all of this is critical because it helps us attract and retain the best individuals and build their careers so they’re fulfilling and rewarding.”

popular with buyers – it’s what we’ve been doing for 27 years,” confirms Quinn.

FROM SKETCH TO SHOWROOM Working primarily with large global car manufacturers such as Nissan, Toyota, Ford, and Mazda, Premcar highlights the importance of partnersupplier relationships and how they contribute to the company’s success.

“We have great connections with our suppliers because we foster mutually respectful relationships; we don’t approach these commercial arrangements with a typical customer-supplier attitude,” notes Quinn.

“We take a relationship approach and always keep a long-term view.

We thoroughly believe that openness and fairness are the best ways for

everyone to benefit from these relationships,” he continues.

This effort to form strong, longterm connections with suppliers results in unparalleled quality and service that is tailored to the Australian market, allowing manufacturers and consumers alike to feel confident in their purchase.

Additionally, Premcar, along with its Australian supplier network, which includes SKF for specific bearing products and Tenneco for springs and dampers, collectively employs thousands of people in the local car industry, contributing to the overall longevity of this critical market.

“With some of our suppliers having been with us for more than two decades, we know that when a newmodel vehicle is about to be released to the market, we can rely on them to be on-site and agile to help ensure every final check is met according to quality, time, and cost,” comments Quinn.

Manufacturing Outlook Issue 2 | 127

Airbag Man: From humble beginnings to the leaders in Airbags and Air Suspension Solutions.

W

hen it comes to vehicle suspension systems, finding the right balance between comfort, performance, and practicality is essential.

Whether you’re driving a classic workhorse from the 1980s or a late model with more bells and whistles, having a reliable and versatile Air Suspension kit can greatly enhance your driving experience. Airbag Man has been established for over 25 years and takes pride in offering specific kits that cater to the needs of both old faithful models and the latest vehicles on the market. Airbag Man’s long relationships with esteemed brands such as Firestone Airide, DriveRite AMK Group & Dunlop Systems & Components ensure a commitment to innovation, quality and customer satisfaction.

Let’s take the iconic leaf sprung Land Cruiser as an example. Airbag Man has specific Air Suspension kits from the 60 Series and right through the range of 70 series Land Cruisers over the years, covering models from the 1980s all the way up to the current LC70 range. However, Land Cruisers are not the only vehicles they cater to. Airbag Man’s range of kits also includes popular models such as the Ford Ranger, Toyota Hilux, Isuzu D-Max, Holden Colorado, Mitsubishi Triton, Mazda BT-50, and VW Amarok.

No matter which vehicle you drive, Airbag Man has a kit to help your suspension when needed.

One of the key advantages of Airbag Man is its Air Suspension kits are adaptable to existing factory suspension setups or aftermarket suspensions. This versatility allows you to upgrade your suspension system without major modifications and ensures you can enjoy the benefits of air suspension to assist your existing suspension setup. Whether you’re seeking to enhance your stock suspension or improve aftermarket components, air suspension seamlessly integrates and offers customisable solutions for your specific needs.

What sets Airbag Man apart is the simplicity of its Air Suspension kits. They have designed them as easy add-ons that provide the necessary support when needed, without detracting from the ride quality when your vehicle is empty. This means that whether you’re towing a heavy load or driving with only passengers and fuel, Airbag Man Suspension kits will adapt and provide optimal performance.

To further enhance the functionality and convenience of these kits, Airbag Man offers a range of modular on-board

air control options. The standard kits include tyre-style inflation valves, allowing you to adjust the air pressure as required. However, if you desire additional features, Airbag Man has various options available to suit your needs and budget. From pneumatic switches to wireless remote controls and auto-leveling capabilities, you can customise your air suspension system to perfectly meet your needs.

Investing in an air suspension helper kit, whether it’s to compliment your coil spring or leaf spring suspension, not only improves your driving experience but also offers practical benefits. By ensuring proper load levelling and weight distribution, you can enhance safety and stability while towing or carrying load. Additionally, the adjustable nature of air suspension allows you to fine-tune your vehicles optimum height, under all load conditions. This prevents unnecessary “bottoming out” of the suspension, resulting in improved comfort and maintaining the full suspension articulation over various terrains.

With a lifetime airbag manufacturer’s warranty, Airbag Man stands behind the quality and durability of its products with decades of proven results and customer satisfaction.

This warranty offers peace of mind, knowing that your air

suspension system is built to last and backed by the manufacturer.

Air suspension has a proven track record, having been utilised successfully for decades in various applications.

For reference, Airbag man has designed and manufactured solutions for Isuzu, and our helper kit for the Ford Ranger is a Ford Licensed Accessory. Its reliability and effectiveness have been demonstrated in commercial vehicles, off-road enthusiasts’ rigs, and everyday drivers’ cars.

The longevity and positive reputation of air suspension systems speak volumes about their performance and customer satisfaction.

Airbag Man’s range of products goes beyond the light commercial sector. They offer solutions for Heavy Truck and Bus, Agriculture, Industrial, Custom Applications, Caravans, Trailers, and more. Airbag Man designs and manufactures a significant range of Air Suspension systems for the caravan market, and is currently supplying to Premcar under their Terraglide suspension. Additionally, Airbag Man provides solutions for wheelchair accessible vehicles, ambulances and other emergency vehicles.

Whatever your vehicle or application, we have the perfect air suspension solution to meet your needs.

Visit airbagman.com.au for more information, email info@airbagman.com.au or call 1800 247 224

PREMCAR PTY LTD ASIA PACIFIC

One such example of a successful release is Premcar’s recent Nissan Patrol WARRIOR, a world-class, fullsize 4x4 SUV. Retaining all of Nissan’s famed luxury, versatility, and quality, the WARRIOR was developed in Australia with local engineers using locally developed components that make it perfectly suited to Australian roads and terrain.

A major part of the WARRIOR’s success is due to it being engineered like that of an OEM-level new vehicle. All of the locally developed components and systems were fully integrated to work together with the vehicle, meaning that it operates as if the carmaker themselves created it.

“The WARRIOR is a great story about the depth of Australian engineering know-how and the quality of our local manufacturing.

Believe me, you need both to create a vehicle like this,” prides Quinn.

Meeting and exceeding the necessary high standards for design,

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“ T H E B I G C A R B R A N D S M I G H T H AV E STO P P E D ASS E M B L I N G C A R S I N AU ST R A L I A , B U T A U S T R A L I A N B U Y E R S H AV E N ’ T L O S T T H E I R D E S I R E F O R ‘ M A D E I N A U S T R A L I A’ .

CAR-MAKING IS ALIVE AND WELL” – B E R N I E Q U I N N , E N G I N E E R I N G D I R E C TO R A N D PA R T N E R , P R E M C A R P T Y LT D

engineering, and manufacturing is what Premcar prides itself on, ensuring that innovation and customer-centricity are always at the forefront of the company’s priorities.

A CUSTOMER-DRIVEN CHANGE With a vast majority of new car buyers wanting vehicle choices that are tailored, special, and fit for a particular purpose, Premcar is not only meeting these expectations but surpassing them.

A commonly expressed desire that is continuing to increase in popularity

is that of electric vehicles (EVs).

“New car propulsion systems are changing. Battery-electric vehicles (BEVs), for example, are quickly becoming mainstream, and EV technologies are crossing different vehicle classes. We are keeping pace with these changes and the many others being brought to the carmaking world,” expands Quinn.

Premcar locally developed its first EV back in 2009 when it converted an Australian Ford Territory SUV to full battery-electric power. It has remained close to EV developments ever since.

HISTORY OF PREMCAR: 1996: Tickford Vehicle Engineering (TVE) was established in Australia with the launch of the Tickfordenhanced Ford Falcon GT. 2001: TVE becomes Prodrive Automotive Technology Australia.

2010: The supercharged Ford ‘Miami’ V8 petrol engine is revealed.

2012: Prodrive Automotive Technology Australia becomes Premcar after a change in ownership.

2017: Leading international automotive engineering firm RLE International joins Premcar.

2019: Leading global carmaker Nissan teams up with Premcar to develop and build a new rangeleading version of its awardwinning Navara pick-up model.

2023: New vehicle production milestone with Premcar’s engineering and production centre in Epping producing its 5,000th new car. The award-winning Nissan Patrol WARRIOR is released to critical acclaim.

The company has gone on to complete different EV projects for automakers, such as complete platforms for new EV model ranges and new car EV conversions.

“We are very well-versed in EVs. We’ve got the right skills and knowledge to create zero-emission vehicles to global OEM car-making standards,” confirms Quinn.

With the company’s engineering skills and experience, Premcar is actively contributing to the greater global need for cleaner transport.

Additionally, the company takes

its corporate social responsibility practices seriously by participating in the annual R U OK? Day, offering mental health awareness sessions with external providers, and even hosting on-site massages for its staff.

“It’s all about making people aware of the importance of not only their own personal well-being, but the well-being of others around them, and even people outside of the company,” explains Quinn.

Continuing to manage the significant growth the company has been creating in a healthy and sustainable manner is a key priority for Premcar in the upcoming years.

As demand increases for new cars developed and manufactured in Australia, employee numbers at Premcar will continue to grow.

By the end of 2023, the company will have expanded its revenue by approximately 50 percent.

“We’ve experienced a lot of business expansion in the last 10 years, and we pride ourselves on being a large Australian car industry employer and player,” concludes Quinn.

The future is tremendously exciting for Premcar. Being in such a dynamic and constantly evolving industry, the potential is endless.

PREMCAR PTY LTD Tel: +61 3 8317 8200 info@premcar.com www.premcar.com Manufacturing Outlook Issue 2 | 131

Reimagining Rotation for a Better Tomorrow The power of rotation is found everywhere throughout modern society, whether it is the cars, buses, or trains that take people around, wind turbines that provide power to millions, or even aeroplane engines that transport travellers and cargo around the world.

In fact, wherever there’s movement, SKF’s solutions can be used. For over 115 years, SKF has been developing products and solutions that help in friction reduction and contribute to improved energy efficiency and greater value for our customers’ operations. Today, our products are used all over the world and in a large variety of rotating applications, ranging from renewable energy, such as wind and ocean power, to heavy industries like mining, metal, and pulp and paper.

SKF is a prime example of combining hands-on industry experience with a vast product portfolio and knowledge around bearings, seals, lubrication management, condition monitoring, and maintenance services to meet customer needs across a wide range of industries and numerous geographies.

Today, SKF is setting new standards and creating partnerships, as it has with Premcar, to develop products and solutions that offer competitive advantages to customers, and at the same time, contribute to a sustainable society.

including bearings, seals, and lubrication systems, as well as rotating shaft services and engineering solutions.

With such a broad offering, we cater to Australia’s leading industrial sectors such as railways, mining, and metals as well as automotive sector including vehicle aftermarket for passenger vehicles and commercial vehicles segment.

We are headquartered in Melbourne, where we offer sales, engineering, and customer support and have strong presence in Perth, Queensland, and Sydney. With the help of our distributors and partners, we remain committed to providing value-added solutions to our customers across industries.

AO: Can you delve into the partnership that you have with Premcar?

APAC Outlook (AO): Can you introduce us to SKF with an overview of your main products and services?

SKF: We have been operating in Australia for over 100 years. The company’s presence dates to 1908 when SKF was the first to import bearings into the country. Since then, SKF has steadily expanded its operations and product offerings. Today, SKF offers a broad product range

SKF: As a purpose-led company, we are always looking for ways to collaborate for the continuous advancement of our products and solutions. The opportunity to collaborate with Premcar started in May 2022 at one of the largest automotive shows in Australia. This led to further collaborations on bearing selections, and eventually the hub bearing unit was selected. Additionally, we worked closely with our automotive and engineering team in India to make sure that we are offering the right solution to the customer.

The automotive market in the country is usually focused on the aftermarket since Australia is not a design and manufacturing hub. For us, it’s a market we have never been much involved in. However, this partnership with Premcar offered a new foundation for expansion in the growing vehicle aftermarket.

As a trusted manufacturer of wheel end, engine,

SKF Bearings

drivetrain, and suspension components, plus the bearing, tooling, and lubrication products that underpin them, we are well-positioned to become a preferred supplier for the commercial vehicle segment that requires a steady supply of high-quality repair components for the aftermarket.

AO: What about the specific support and services that you provide to Premcar?

SKF: For us, everything begins with understanding the needs of our customer. With Premcar, we started with discussing the product concept, then diving into preliminary selection and basic dimensioning, followed by choosing which one of our products would be the best fit. Secondly, we used our advanced simulation tools to collect the inputs that go on a wheel bearing, for example, the diameter of the tire and the type of speed the vehicle is going to be travelling at. Along with our team in India, we worked on the simulation to ensure that we are as realistic as possible. This is because if you design something that doesn’t work during trials and you need to go back and redesign it, that costs time and money.

Thirdly, we had several rounds of dialogue for gathering inputs, reviewing the design parameters, and re-running the simulation to develop the final solution in the shortest time possible. It’s interesting that at the end of this process, the next generation is already under discussion.

This is a good example of how our response to an idea has led to more business opportunities.

into the development of solutions for these industries, growing hand in hand with our customers.

AO: Why SKF? SKF: This partnership with Premar is a very good example of SKF’s unmatched customer-centric approach, our true capability, and what we can do to solve customers’ challenges. It exemplifies how we can collaborate both externally and internally to develop products and businesses faster and more easily. We believe in working closely across the full value chain - customers, sales, logistics, manufacturing, supply chain, and R&D to generate ideas and then move them towards implementation in the shortest time possible.

As a global leader within the industry, we want to keep pushing the boundaries. This means continuously developing new ways to do business, to innovate, and to work together with our customers and partners to help transition to a cleaner world.

AO: What sets SKF apart from the competition and makes it a partner of choice?

SKF: SKF has something that very few industrial companies have - a deep understanding of almost all industrial and automotive applications. With 41,000 employees in over 129 countries, SKF develops technologies that offers our customers a competitive edge. Our products, solutions, and services help machines run smoother and with less emissions, as well as enabling the growth of clean technologies, such as renewable energy and electric vehicles. SKF’s ability to master the complexity of meeting customer needs across a wide range of industries and numerous geographies, is our greatest strength and key to our success. As we position ourselves for future, will continue to invest more

Hub mounted on the Axle

www.skf.com

S PA R K I N G SUCCESS As electrical infrastructure in Australia continues to evolve, Chris Ware, General Manager of Mayfield Industries, shares how his company contributes to the growth, development, and success of the industry Writer: Lily Sawyer | Project Manager: Nicholas Kernan

MAYFIELD INDUSTRIES ASIA PACIFIC

T

he electrical industry in Australia is undergoing a transformative phase driven by the transition to a low-carbon economy.

This evolution is characterised by the widespread adoption of renewable energy, the continuous development of cutting-edge technologies, and a growing consumer demand for increased choice and control.

Within this dynamic landscape, the sector faces a range of challenges and opportunities. These include maintaining the reliability and security of energy supplies, integrating energy storage, fortifying grid resilience and flexibility, and reducing overall greenhouse gas (GHG) emissions.

Operating in this evolving space proves to be both challenging and rewarding for Mayfield Industries (Mayfield), an Australian company that specialises in electrical infrastructure, such as low-voltage (LV) and medium-voltage (MV) switchboards, switchrooms, motor control centres, transformers, protection systems and kiosk substations.

“As a company, we actively engage with industry shifts, applying our collective skills and knowledge to navigate challenges and capitalise on emerging opportunities,” opens Mayfield’s General Manager, Chris Ware.

“We collaborate closely with diverse stakeholders to create value for our clients, ensuring that our products and solutions align with the changing demands of the market,” he continues.

In recent years, the oil and gas industry has experienced a period of deceleration, however signs of recovery are evident as clients within this sector increasingly invest in projects geared towards reducing their carbon footprint.

Mayfield is strategically positioned to seize the opportunities arising Manufacturing Outlook Issue 2 | 135

MAYFIELD INDUSTRIES ASIA PACIFIC

from the shift towards a decentralised power generation market; its suite of products is well-suited to meet the diverse requirements of power generation and distribution.

SWITCHED ON SOLUTIONS Since its inception in 1936, Mayfield has expanded its capabilities and national footprint, becoming a leader in engineering, design, manufacturing, and servicing.

It provides critical electrical infrastructure for various industries, such as mining, power generation, renewable energy, oil and gas, water, and wastewater.

The company strongly focuses on project management, value engineering, agile modification, dependable delivery, detailed

SWR225 HVAC

136 | Manufacturing Outlook Issue 2

documentation, and 24/7 maintenance services.

A comprehensive product range enables Mayfield to accommodate a diverse range of specifications and operational requirements, reflecting its commitment to delivering tailored and innovative solutions.

“Over the years, we’ve not only cultivated our own intellectual property but also secured various manufacturing license agreements.

As a result, our product line is characterised by its ability to offer custom solutions, such as Modular Demountable (Moducell) and Modular Fully Withdrawable (Okken) configurations,” informs Ware.

“To stay abreast of market demands, we continually subject our products to type testing, ensuring

they remain at the forefront of industry requirements,” he continues.

Crucially, Mayfield’s consistent employee base of 160 across facilities in Adelaide, Perth, Sydney, and Brisbane underscores its dedication to fostering a skilled and stable workforce.

This approach to staffing enables the company to maintain high levels of locally available expertise and service quality, ensuring the continued satisfaction of its clients nationwide.

MAKING A DIFFERENCE In 2019, Mayfield made the strategic decision to centralise its production of Moducell, relocating it from Malaysia to Australia.

The switch to local manufacturing was pivotal in mitigating challenges

MAYFIELD INDUSTRIES ASIA PACIFIC

MANUFACTURING OUTLOOK: COULD YOU OUTLINE THE COMPANY’S DEDICATION TO THE LOCAL AUSTRALIAN MARKET? CHRIS WARE, GENERAL MANAGER: “At the heart of our commitment to local manufacturing is a strategic approach to sourcing components from the Australian market, reflecting our dedication to supporting and bolstering local industries. We buy 99 percent of our components from Australia.

“To facilitate this process, Mayfield boasts a centralised procurement team tasked with managing purchasing activities and overseeing the company’s procurement needs from a company-wide perspective.

“The centralisation of our procurement operations enables us to harness synergies and economies of scale, offering our suppliers consolidated purchasing opportunities across the broader operations of Mayfield.

“By consolidating our purchasing efforts with a collaborative approach, we not only enhance efficiency but also contribute to the overall growth and sustainability of the local supply chain.”

caused by the COVID-19 pandemic, such as offshore production limitations and disruption to delivery lead times.

The company’s manufacturing facility in Edinburgh, Adelaide, where the majority of local production takes place, boasts a comprehensive production plant and remains dedicated to ongoing product improvement.

“A notable example of our commitment to innovation is our ability to provide a typetested arc fault containment for our Moducell switchboards on the line side of the incomer. This distinctive feature sets us apart, positioning us as a leader in delivering advanced and reliable solutions,” Ware divulges.

Additionally, safety is at the forefront of Mayfield’s design philosophy, which is embedded throughout the entire lifecycle of its products.

“From conception to production and beyond, we prioritise the

well-being of users and ensure that our products not only meet but exceed safety standards,” shares Ware.

This holistic approach underscores the company’s commitment to providing cutting-edge solutions that prioritise the safety and satisfaction of its clients.

A ROCK-SOLID INVESTMENT Mayfield is an active and important contributor to Australia’s mining sector, which is currently experiencing a surge in demand and investment.

Within the industry, it provides a range of solutions for mining operations across Australia.

The company’s projects within the sector encompass power distribution systems, motor control centres, transportable switchrooms, data centres, and substation kiosks.

“Mining remains a cornerstone of our business and is our most robust sector. At Mayfield, we’ve cultivated robust relationships with Tier 1 miners, positioning ourselves as a trusted supplier in this industry.”

Due to its commitment to

excellence and technical expertise, Mayfield finds itself as a preferred partner for many clients.

“Our dedication to delivering highquality solutions has allowed us to consistently meet the unique demands of Tier 1 clients,” elaborates Ware.

Broadly speaking, Mayfield’s product variety and versatility means it can be considered a key supplier to a vast range of sectors.

Its key sector contributions include mining, renewables, utilities, infrastructure, and power generation and distribution.

A RENEWABLE FUTURE Mayfield has made strides in the renewable energy sector, particularly in solar, wind, and battery energy storage systems (BESS).

“The convergence of solar, wind, and BESS technologies represents a promising avenue for clean and reliable power generation,” explains Ware.

Mayfield has successfully supplied products to numerous significant BESS projects nationwide, making impactful contributions to ventures Manufacturing Outlook Issue 2 | 137

Offering Industry-Leading Solutions Since 2011, DIS Fire Systems has offered complete fire consultancy solutions to a broad range of clients in all sectors of the fire industry.

design solutions, remote site works, preliminary design layouts, and detailed system design and engineering.

Our comprehensive database has an impressive list of customers: Sydney Metro Line Wide, Melbourne Metro Line Wide, Brisbane Airport Traffic Control, Wambo Wind Farm, Geoscience, Arafura Rare Earths, and Pilbara Minerals are just a few projects completed by us within the last 12 months.

DIS Fire Systems have focused their energy through their internal engineers to investigate solutions for Lithium Ion battery fires, we now have access to solutions that not only suppress the fire but detect the possibility of fire before thermal runaway and a fire starting. These solutions are specifically tailored to each application and are at the forefront of technology.

As design engineers, distributors, and contractors, DIS Fire Systems is fast becoming the largest independent solutions provider for all fixed fire systems in the country. With offices throughout Australia, each warehouse houses enough stock to provide important local support.

Headquarters which is located in Seaford, Victoria, DIS Fire Systems are able to maintain its expertise by providing internal and external training, participating in high-level technical advisory and special interest groups for the Fire Protection Association of Australia (FPAA) and the National Fire Industry of Australia (NFIA).

The many elements that comprise the company’s core skills provide additional support, including research, development and training, writing design guidance, and advising on fire safety policies. Our fire systems specialists are local engineers, maintenance, and admin support, and they ensure they maintain close relationships with fire contractors, consultants and end users.

Engineering services include site commissioning, full function testing, integration, system specifications, systems budgets, objective system alternatives, objective

EFFICIENTLY PROVIDING SERVICES The fundamental principles that DIS Fire Systems adhere to include working with clients to clearly outline requirements, outcomes, and objectives. This is alongside scoping, and

1300 476 588 sales@disfire.com.au disfire.com.au

managing and executing work in a cost-effective and timely manner, whilst providing a practical and quality solution.

rated sealants and mastics, fire insulation for a large range of different applications.

It is essential that DIS Fire Systems maintains a flexible, compliant, and professional approach with its customers.

Putting clients at the forefront, we will also minimise costs by applying efficient and practical working methods, while using the experience of focused, competent, and dedicated personnel.

Our wide range of fire dampers consists of pressure relief vents with an aesthetically pleasing design of various shapes and sizes. The solid welded construction has a multi-flow vent and is four-hour fire-rated, with a 90 percent free vent area. Options for fire dampers include combined pressure relief/extraction fans and boxed pressure relief/extraction fan units with the choice of an acoustic louvre to minimise noise levels.

We ensure that our personnel have extensive industry experience and proficiency; individually, they possess specific expertise combined with a practical and flexible approach. This allows DIS Fire Systems to successfully undertake a broad spectrum of activities within the fire industry.

Gas suppression products offered are Inert (IG-541, IG-55, IG-100), Novec 1230 (FK-5-1-12), FM200 (FE227-EA, HFC227), Carbon Dioxide - CO2, Aerosol Systems and In-Cabinet Trace Systems.

Our approach is to be the benchmark of quality and delivery within the industry.

A MULTI-MARKET APPROACH Positioning itself in multiple vertical markets, DIS Fire Systems provides fire engineering services across all sectors of the industry, such as mining, marine, offshore, manufacturing, defence, energy, telecommunications, and oil and gas. With different levels of engineers, procurement, and technical support, each state retains a similar set up.

We are a distributor of Komtes Siex Systems and a total solutions provider of Hygood, TYCO / Johnson Controls, Marioff and Kidde products originating from the US and Europe.

DIS Fire Services provides specialist consulting with its dedicated engineering services to support fire equipment operations and maintenance, engineering change execution, minor and major project scope of works and delivery, troubleshooting and operation analysis, risk integrity reviews, and business improvement consulting.

PRODUCT RANGES DIS Fire Systems has an extensive product range of gaseous suppression systems, foam concentrate, foam equipment, foam proportioning systems, high-pressure water mist, low-pressure water mist, and high-speed deluge.

Other products and systems the company offers are high pressure pipe and fittings, wet chemical products, dry chemical products, marine systems, vehicle suppression systems, and SIEX trace (UL/FM).

We offer design, supply and support of detection systems including VESDA, pre-engineered vehicle systems, fire hydrants and fire hose reels, room integrity testing, hypoxic system air handling fire prevention systems, systems design and verification of sprinklers, deluge and pre-action sprinkler systems.

Additionally, DIS Fire Systems can provide fire stopping solutions such as, fire pillows, fire collars, fire wraps, fire

AREAS OF EXPERTISE Delivering projects ranging from feasibility studies to delivery of equipment, DIS Fire Systems provides the following services: • • • • • • • • • • • • •

Site survey/audit Technical writing and specifications Concept engineering studies Detailed design execution Project management Procurement execution and management Quality control management Fabrication and construction Government Construction management Healthcare Commissioning support Water management

DIS Fire Systems is the complete package of engineering design, hydraulic calculations, technical drawings, on-site testing and commissioning, full-function fire testing, room integrity testing and certification.

MAYFIELD INDUSTRIES ASIA PACIFIC

MAYFIELD CORE VALUES – AT A GLANCE SAFETY – Safety first in everything Mayfield does.

PARTNERSHIPS – Mayfield’s

“ B A S E D O N A B E L I E F T H AT O U R P R O D U C T S A N D S E R V I C E S C A N B E C ATA LY S T S F O R P O S I T I V E C H A N G E , W E A S P I R E T O L E AV E A P O S I T I V E M A R K O N T H E E N V I R O N M E N T, S O C I E T Y, A N D E C O N O M Y ” – C H R I S WA R E , G E N E R A L M A N A G E R , M AY F I E L D I N D U S T R I E S

clients and suppliers are partners in its mutual success.

PEOPLE – People are core to Mayfield’s future.

INNOVATION – The company creates value through continuous improvement and innovation.

INTEGRITY – Mayfield is engaged, decisive, and acts with integrity.

QUALITY – A reputation for high standards.

COMMUNITY – The company supports its community.

ENVIRONMENT – Protecting the environment is important to clients, communities, and businesses.

140 | Manufacturing Outlook Issue 2

such as the Victorian Big Battery, Sydney West, Torrens Island, and more recently, Western Downs and Collie.

These endeavours underscore the company’s dedication to playing a pivotal role in advancing the clean energy landscape in Australia.

Mayfield’s ongoing collaboration with Tier 1 EPCs exemplifies its commitment to advancing clean energy solutions. The collaboration leverages expertise and industry experience to bring innovative and sustainable products to the forefront.

Mayfield prioritises industry collaboration as a cornerstone of its strategy in order to remain at the head of a rapidly evolving energy market.

“Looking ahead, we are actively engaged in developing a range of new products designed to catalyse further growth within the renewable energy sector,” Ware states.

“We anticipate that these locally manufactured and supported products will not only reinforce our presence in the renewable sector but also stimulate job creation, foster economic growth, and fortify our competitive edge in the market.

“This strategic move aligns with our vision to benefit not only our shareholders but also our stakeholders and society at large,” he adds.

NEW HORIZONS As Mayfield anticipates the upcoming

HiSpec Heavy Haulage HiSpec Heavy Haulage (HHH) is based in Edinburgh SA and we specialise in oversized and heavy load transport across Australia. With years of practical experience and knowledge, we have an in-depth understanding of wide load transportation requirements and standards. As one of Australia’s most reliable and trusted heavy and abnormal load transport companies, let us transport your load with safety, precision and expertise.

While standard loads can easily be moved on roads with minimal fuss and preparation, some additional planning and expertise is required for larger and oversized loads. At HHH our professionals draw upon over 30 years of experience to effectively plan and execute moves of oversized loads interstate and across lengthy distances.

Offering strategic solutions, we can discern ideal vehicles and floats, identify the most efficient and safe routes, secure additional escorts, complete surveys, and arrange permits and approvals from government departments and authorities.

We feel that our overall knowledge with respect to competitive pricing, adaptability, expertise and experience enables us to successfully undertake any project your company may have and welcome all your transport requirements.

Our company fleet is comprised of Volvo Prime Movers with a comprehensive range of low loaders and specialised platform trailers. Our reliable and professional drivers can provide Australia wide service, seven days a week.

To ensure reliability and availability, our equipment is maintained onsite in our workshop facilities by our qualified mechanics or by the manufacturer’s workshops.

All regulatory authorities and escorts are arranged prior to commencement

Paul Maione – pmaione@hsic.com.au | hsic.com.au |

Moducell Demountable Switchboards

142 | Manufacturing Outlook Issue 2

MAYFIELD INDUSTRIES ASIA PACIFIC

In a demanding industry, we are focused on quality when sourcing and supplying copper, brass, bronze, aluminium, stainless steel, nickel alloy and high-performance alloys.

Quality-assured Nationwide Extensive company warehouses range Detailed Expert catalogue online metallurgical and hard copies knowledge

Service focused

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Apart from thousands of standard items in stock, we can provide stocking arrangements where customers require non-standard products, special sizes and to your unique specifications. Austral Wright Metals is a leading importer and distributor of nonferrous and stainless steel products. Call us and put us to the test.

Proud major supplier to Mayfield Industries

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“ B Y C O N T I N U O U S LY I N T R O D U C I N G C U T T I N G E D G E S O L U T I O N S , W E A I M N O T O N LY T O M E E T B U T E X C E E D T H E E V O LV I N G N E E D S O F OUR CLIENTS AND THE MARKET” – C H R I S WA R E , G E N E R A L M A N A G E R , M AY F I E L D I N D U S T R I E S

year, its central focus revolves around a set of key priorities aimed at enhancing operational excellence and fostering continuous improvement.

“A paramount goal of ours is to elevate and institutionalise awareness and process efficiencies, a mission we intend to accomplish through the implementation of 5S (sort, set in order, shine, standardise, sustain) and LEAN methodologies,” outlines Ware.

The integration of 5S principles instils a culture of organisation, cleanliness, and standardised work processes within the company.

Simultaneously, Mayfield’s LEAN principles emphasises waste elimination, streamlined workflows, and the continuous pursuit of perfection.

“This methodology aligns with our overarching goal of achieving operational excellence and delivering maximum value to our clients,” emphasises Ware.

Employee engagement and training initiatives are integral components of Mayfield’s strategy to empower its workforce with the skills and knowledge necessary to drive positive change.

6/11/2023 2:36 pm

The company’s key priorities for the coming year are rooted in the fundamental belief that ongoing improvement is essential for sustainable success.

“Through the adoption of 5S and LEAN methodologies, coupled with a dedication to employee development, we aspire not only to meet our targets but exceed them, thereby ensuring the long-term resilience and success of Mayfield,” Ware concludes.

MAYFIELD INDUSTRIES Tel: +618 8169 1000 enquiries@mayfieldindustries.com.au www.mayfieldindustries.com.au Manufacturing Outlook Issue 2 | 143

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C R E AT I N G A CHEMICAL LEIDOSCOPE

POLICOLOR-ORGACHIM GROUP EUROPE & MIDDLE EAST

With a constantly expanding product range of paints and resins for various industries, as well as domestic use, PolicolorOrgachim Group’s CEO, Irina Mandoiu, talks about its reinvention and innovation Writer: Rachel Carr Project Manager: Nicholas Kernan

Irina Mandoiu, CEO

S

panning two countries, Policolor-Orgachim Group began as two separate entities, both with a long-standing reputation in the paint industry.

In Romania in 1965, Policolor was founded, while Orgachim had already been established in the Bulgarian market since 1901; the two companies are therefore part of the manufacturing heritage in their respective countries. It was 1998 when the merger occurred, with Policolor acquiring 51 percent of Orgachim’s shares.

Manufacturing Outlook Issue 2 | 145

“Orgachim is a brand with high awareness, reinventing over 95 percent of itself decade by decade, keeping up with consumer needs, developing successful brands, and being a trendsetter in the industry,” opens Irina Mandoiu, CEO of Policolor-Orgachim Group.

The group produces resins, speciality chemicals, and coatings, operating in the architectural, automotive, construction, and industrial sectors.

Mandoiu finds production a fascinating field, especially as it involves fast adaptation and learning to keep up with consumer challenges, as well as inspiring and creating new trends.

“This is where most professionals are shaped, allowing them to continue within the same sphere or migrate to other areas with a solid knowledge base and a deeper level of dynamism.

However, those of us currently leading production units are responsible for changing the perception or even the 146 | Manufacturing Outlook Issue 2

label of this profession,” she observes.

With over 20 years of experience coordinating sales, distribution, operations, and marketing strategies, the challenge of being a CEO is a natural continuation of the experience that Mandoiu has accumulated as she leads Policolor-Orgachim Group into the future and onto global recognition.

GENERATION-LEADING INNOVATION “Younger people no longer want to work in factories; the average age of our production employees is 50+ years. Therefore, we need a new plan.

To attract a new generation, we need to be technologically advanced, which is the direction we are currently pursuing in both locations,” Mandoiu emphasises.

The next generation is more accustomed to tablets and phones than pens and paper, and PolicolorOrgachim Group is constantly

evolving.

“We choose innovation that matters and improves quality of life.”

The most recent example is Policolor’s success in Romania this year, where all substances, products, organisation and referential (SPOR) interior paints have been classified as A+ and A under French volatile organic compounds (VOC) regulations.

French VOC testing in EUROFINSaccredited laboratories in Denmark provides information on indoor air

POLICOLOR-ORGACHIM GROUP IN NUMBERS • • • • •

Four plants Four legal entities 200 employees in Romania 500 employees in Bulgaria €38 million revenue by the end of Q2 in 2023

POLICOLOR-ORGACHIM GROUP EUROPE & MIDDLE EAST

“ W E A R E C O N T I N U O U S LY L O O K I N G F O R T R E N D S I N M A N U FA C T U R I N G , N E W E Q U I P M E N T S U C H A S PA L L E T I S I N G R O B OT S , S U S TA I N A B L E WAY S O F M A N U FA C T U R I N G P A I N T S , A N D FA S T E R P R O D U C T I O N U S I N G FEWER RESOURCES” – I R I N A M A N D O I U, C E O, P O L I CO LO R - O R G AC H I M G R O U P

quality with potential inhalation toxicity on a scale of classes ranging from A+ (very low emissions) to C (high emissions).

“This accreditation reflects the success of our R&D team, but more importantly, how a manufacturing company can change things for the better,” she states.

Policolor-Orgachim Group has integrated production capabilities for raw materials and finished products, with a capacity of 65,000 tonnes per annum, divided by product type

between Romania and Bulgaria.

In 2019, the Policolor arm of the group completed construction of its new factory in Bucharest after an investment of €7 million, which also included the value of the land.

“This relocation was necessary as the old factory had become situated in the middle of the city. The new site is an industrial area within a 2.5 hectare (ha) complex alongside a modern warehouse,” shares Mandoiu.

The state-of-the-art factory produces paints, decorative plasters,

enamels, and varnishes, as well as related products like primers and undercoats. Production lines include waterborne decorative paints, lacquers, and adjacent products.

“The site has internalised logistics, with the objective of both enhancing the quality and quantity of Policolor products and optimising the efficiency of delivery to customers,” she adds.

INVESTMENT STRATEGIES At the top of Policolor-Orgachim Group’s priorities are innovation and technological adaptation, with two recent investments underpinning the organisation’s strategy.

“Alongside the Bucharest factory, this year the company invested €2 million in expanding the initial construction and automating production. By 2025, we have planned investments of an additional €3 million for equipping the facilities with state-of-the-art machinery.

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POLICOLOR-ORGACHIM GROUP EUROPE & MIDDLE EAST

“The results have already emerged.

This year, we completed the new production hall, doubling the space to 3,000 square metres (sqm) and increasing the capacity to over 30,000 tonnes per year,” Mandoiu informs us.

Simultaneously, Policolor-Orgachim Group maintains investments in the support and relevance of commercial brands at the top of consumer preferences through communication campaigns, trade marketing, repositioning, and rebranding.

“We annually analyse and expand our target by optimising product performance and product line extensions, but we aim to protect profitability by harmonising the brands and product categories at group level.

“Our commercial policy is based on

increasing our presence in modern DIY retail, strengthening our presence in traditional trade, and developing new communication channels and business segments in the B2B sector with our partners,” details Mandoiu.

ONGOING CHALLENGES Along with Policolor-Orgachim Group’s success, there have been many challenges, some of which are ongoing. The most recent ones are faced by the anhydrides division, where operations have been constrained due to difficulties in accessing orthoxylene, the primary raw material in anhydride production, following the EU ban on imports from Russia in 2022.

The entire industry has been significantly affected by supply chain disruptions and price increases for

MANUFACTURING OUTLOOK: HOW DO YOU MOTIVATE YOUR WORKFORCE AND WHAT TYPE OF INITIATIVES ARE OFFERED TO EMPLOYEES? IRINA MANDOIU, CEO: “Beginning this year, all our people-related initiatives are grouped under the People of Policolor (POP) or People of Orgachim (PO) umbrellas. From the first level of Maslow’s pyramid, which is based on the idea that certain basic needs must be met before individuals can progress up the hierarchy to more complex needs, we offer a competitive benefits package adapted to each country, including hybrid work. We are very much focused on the well-being of the office and factory area.

“In the following year, we will introduce the concept of a benefits basket, and, in this way, the flexibility and the number of choices will grow exponentially. We are running health education and screening campaigns, connecting with all the organisations via the newsroom – a dedicated time to meet with employees. There is a monthly newsletter running throughout the organisation where we go beyond presenting what is new and focus on spotlighting our people. We also host a classical lunch with the CEO, and recently, an idea-generating process rewarding best improvement suggestions has gained popularity among our colleagues.

“Another important pillar is face-to-face discussions with employees, through a project called Open Talk. Based on this, external communication campaigns on LinkedIn have started, where we present each person and talk about their experiences in our company. To engage and connect across the organisation, we are also successfully running the Steps in Colour project, a massive market visit with people from different departments going into the field.”

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raw materials. However, the aspect that differentiates Policolor-Orgachim Group is the fact that it has its own factory that supplies a generous portion of the raw materials used in production, assuring constant quality.

“In times of crisis, a key criterion that remains steadfast is trust – trust in the mission and vision of our projects, in the team, and in the opportunity to build and further nurture business champions, both in Romania and Bulgaria,” Mandoiu highlights.

As one of the traditional paint producers in the area, PolicolorOrgachim Group has long-standing relations with international suppliers stretching back almost 30 years.

“One of our strengths is that we have shared projects with a common goal: the quality of the services.

Logistics is susceptible to outside influences, such as adverse weather conditions. One of the challenges of working with a logistics partner is therefore to ensure that it will perform best in times of crisis.”

The organisation aims to use local suppliers as part of its strategy to reduce CO2 emissions from transportation.

“Our last two projects headed in this direction, as we bought bulk raw materials as frequently as possible, reduced the number of orders for small quantities, and found alternative suppliers closer to our plants,” she says.

There are two different models of logistic operations for PolicolorOrgachim Group. In Romania, the external logistics are handled by a third-party supplier; in Bulgaria, the company has its own logistic infrastructure.

“We have our own warehouses and employees, but we externalised the transportation two years ago,” affirms Mandoiu.

A COLOURFUL FUTURE Policolor-Orgachim Group constantly looks to the future with exciting plans and key priorities.

“We are continuously looking for trends in manufacturing, new equipment such as palletising robots, sustainable ways of manufacturing paints, and faster production using fewer resources,” reveals Mandoiu.

In Bulgaria, Policolor-Orgachim Group has invested in new labelling and warehousing equipment that will help to reduce waste and contribute to a cleaner environment.

Furthermore, in Romania, the first step of automation has been finalised, with a state-of-the-art in-can tinting line produced by Dromont, one of the most reliable and innovative leaders in the field of automated lines and

solutions for paint coatings.

“Our strategy for the next five years is to increase productivity with automation and to use our most valuable resource – people – in processes where they can bring value to our business.”

Focusing on scaling its operations, Policolor-Orgachim Group is undergoing a technological and organisational transformation. This is alongside delivering an exceptional customer experience through innovation and sustainable products.

“As a responsible manufacturer, we constantly invest in environmental protection by producing cleaner

products for a safer environment, reducing waste, and safeguarding air and water quality. We also prioritise the well-being of our employees.

“On the social front, we are committed to supporting education, the arts, and a healthy lifestyle to become an example of excellence in sustainable practices,” closes Mandoiu.

POLICOLOR-ORGACHIM GROUP https://www.policolor.ro/ Manufacturing Outlook Issue 2 | 149

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