Often referred to as the gamification of training and education, leveraging VR, AR, and AI has become an accepted standard among industry leaders in fields like automotive, aviation, defense, offshore operations, and healthcare. These technologies have become key tools for organizations seeking to enhance training programs and operational efficiency.

The gamification concept involves using immersive video game-style design to deliver educational content, making learning more engaging and effective. This approach has gained momentum in the post-pandemic era, where virtual solutions have become the norm, allowing companies to bridge the gaps between remote workers and create immersive training experiences.

Manufactured efficiency
As the barriers to adopting virtual and augmented realities continue to decrease—and the capabilities offered by artificial intelligence continue to increase—more operations are integrating these technologies, amplifying their benefits. Automotive manufacturers, aviation leaders, and other industries have been using VR, AR, and AI for design, prototyping, lean manufacturing, and factory setup. These technologies are also valuable in training workers in a digital environment.

For example, digital twins—a technology that virtually replicates physical assets—are used by manufacturers to simulate components, products, systems, or processes, optimizing productivity and efficiency. These digital replicas gather vast amounts of data through sensors to streamline operations and facilitate safer, faster procedures. While this is a simplified explanation, it highlights the incredible potential of these technologies, especially in an era where a skills gap in manufacturing requires immediate attention.

The manufacturing sector is facing a shortage of workers with the necessary manual, operational, and technical skills. According to the Association for Manufacturing Excellence, the global labor market is short 10 million manufacturing jobs, with a disconnect between available positions and the talent pool. This labor gap drives up unemployment rates and negatively impacts the economy in both developed and developing nations. Fortunately, VR, AR, and AI technologies have the potential to help bridge this skills gap, providing solutions to upskill workers and address the industry’s immediate needs.

Unlocking the possibilities with technology
In a world where most people are attached to their screens, virtual and augmented realities powered by AI are emerging as powerful tools for training and engagement. These digital training environments simulate real-life scenarios, providing workers with an immersive experience to interact with various components of a digital interface. This allows trainees to gain skills, experience, and confidence, all while enabling educators to measure performance and enhance outcomes.

Virtual reality creates an immersive environment through hardware such as headsets, which separate users from the physical world, while hand trackers allow for physical interaction within the virtual realm. On the other hand, AR overlays digital information onto the real world via mobile devices or smart glasses. Companies like Apple have used AR to transform how users interact with their devices for work, education, and beyond. As Apple’s website states, “It’s the perfect way to visualize things that would be impossible or impractical to see otherwise.” This enhanced interaction creates a more dynamic and engaging learning experience.

AI enhances these immersive experiences by adding human-like qualities to avatars and non-player characters (NPCs), enabling real-time problem-solving and decision-making. For manufacturing training, the creation of accurate virtual environments is crucial—particularly for mission-critical tasks with high risks. Chris Cambouris, IT specialist, early adopter, and CEO of Titan Tek Biz, offers immense insights into the value these technologies can afford.

“I believe that VR, AR, and AI have a significant role to play in manufacturing training, especially as industries look for more innovative and effective methods to improve their workforce. At Titan Tek Biz, we’re seeing how AI-driven platforms and AR/VR can simulate real-world scenarios, making it easier for trainees to learn complex tasks in a risk-free, controlled environment. This technology can bridge the knowledge gap faster and help manufacturing firms improve precision in training,” he explains.

Optimizing outcomes and value-added innovation
The integration of VR, AR, and AI in manufacturing training offers numerous advantages, including real-time data collection, scenario development, and workflow optimization. These technologies allow for flexible training scenarios, enabling simulations that can adapt to changing priorities. The ability to create realistic environments ensures that training is both effective and relevant, especially when applied to mission-critical tasks.

These immersive training environments improve retention, recall, and safety outcomes, while also reducing onboarding time. However, when misused, issues such as cyber sickness, eye strain, and headaches can arise. Despite these challenges, VR, AR, and AI-driven training programs also enhance soft skills such as leadership, communication, and collaboration—critical components of company culture and performance. Furthermore, these technologies facilitate compliance training through data analytics, which can help organizations make informed decisions based on real-time feedback.

There are also significant cost savings associated with these technologies. Although the initial investment may be high, the return on investment grows over time. Digital training programs can be reused, saving time and reducing the need for costly facilitator-led sessions. Employees can also train at their own pace, minimizing downtime and improving overall productivity.

Cambouris underscores the advantages of VR and AR, saying, “Immersive training environments in VR or AR allow employees to experience real-time problem-solving without the risks or costs associated with real-life training setups. These technologies enable hands-on learning, which has proven to be more effective than traditional methods. AI, on the other hand, can provide personalized training programs that adapt to an employee’s learning curve. At Titan Tek Biz, we’ve seen how AI-enhanced tools can speed up the learning process by providing real-time feedback and adjusting to a user’s performance levels.”

Managing expectations
While VR, AR, and AI offer great potential, there are barriers to adoption. These include skepticism, learning curves, technical issues, health concerns, and challenges related to privacy and data management. However, these obstacles are not insurmountable, and the value these technologies add to training is becoming increasingly recognized. As Cambouris notes, “These technologies create new opportunities for employers to optimize training environments, ultimately making them more cost-effective and efficient.”

As the manufacturing sector struggles to fill millions of available jobs, the integration of VR, AR, and AI in training programs can help bridge the skills gap, improve employee performance, and boost profitability. These technologies are rapidly becoming a multi-billion-dollar industry, offering transformative potential for companies to stay competitive and innovative in the evolving workforce landscape.

The post Virtual Reality, Augmented Reality, and Artificial Intelligence<p class="company">Revolutionizing Manufacturing Training</p> appeared first on Manufacturing In Focus.

In the 1920s, North Carolina’s industries expanded to include production of furniture, textiles, chemicals, and other manufactured goods, and these sectors soon surpassed farming. By the late 1990s, other sectors emerged including tourism, government, commercial and financial services, and handicrafts and pottery, especially in the Blue Ridge and Piedmont regions of the state. For years, other key industries in the state have included farming (chickens and hogs in particular), and growing peanuts, corn, soybeans, and potatoes. These sectors, along with fishing, mining, forestry, and manufacturing, have helped support North Carolina’s economy for decades. North Carolina was nicknamed the Tar Heel State, an expression that refers to the pitch and tar used to coat the hulls of wooden ships, and today, the area’s manufacturing tradition remains as strong as ever.

South Carolina emerged as a prominent manufacturer of nondurable goods and became home to U.S. military facilities, including Shaw Air Force Base and the Marine Corps Recruit Depot (MCRD) at Parris Island. Like North Carolina, the state also has an active fisheries industry, along with forestry, tourism, transportation, mining, and manufacturing.

While many of North and South Carolina’s long-time industries remain, others have joined them over the years, including aerospace, biotechnology, transportation, information technology (IT), business and financial services, and many others.

According to the North Carolina Department of Commerce, “Many of the world’s best-known brands across a range of future-focused industries call North Carolina home.” While mindful of the state’s legacy industries such as tobacco, textiles, and furniture, North Carolina is fast becoming home to the next generation of industries, including biotechnology, pharmaceuticals, energy, plastics, and chemicals.

With an estimated population of about 11 million, a median age of 39, and an unemployment rate of 3.8 percent, North Carolina is increasingly attractive to a range of business sectors, both established and emerging. A few years ago, the Department of Commerce issued its Strategic Economic Development Plan for the State of North Carolina: Goals, Strategies, and Tactics for the New Economic Landscape. A comprehensive, 19-page document, the Plan outlined critical areas in the realms of workforce recruitment, supporting local businesses and industries, and building vibrant communities, including decreasing childcare costs for working families and ensuring that North Carolinians possess high-quality post-secondary credentials. Realizing the vital importance of education to the future workforce, North Carolina Governor Roy Cooper announced an $805 million investment in early childhood education and childcare programs through North Carolina Child Care Stabilization Grants, and proposed significant pay increases for teachers.

Since 2018, North Carolina has seen over 73,000 new jobs created and has attracted more than $19 billion USD in private business investment. “North Carolina is now in a solid position to remain competitive for economic development opportunities in our key targeted industry sectors—aerospace, automotive, clean energy, information technology, and life sciences,” states the Plan.

This fall, North Carolina State University Professor Emeritus Mike Walden called North Carolina’s economy “a powerhouse of growth in recent decades.” Not to be outdone, South Carolina is also experiencing considerable growth. As of this year, South Carolina’s gross state product (GSP) achieved an impressive $271.8 billion, with 2.7 percent growth over the five years prior to 2024, with leading sectors including real estate and rental and leasing, manufacturing, and retail trade.

For decades, the Carolinas have built a reputation for their strong manufacturing base. In South Carolina, manufacturing chemical goods—such as agricultural fertilizers, synthetic fibers, pharmaceutical chemicals, and industrial chemicals—earned the state greater revenue than its historic textile sector. Still, the state’s textile industry remains strong, producing goods made from both cotton and synthetics.

In the late 1990s, other types of manufacturing moved or expanded to South Carolina, including paper and paperboard, electronics, plastic and rubber products, and motor vehicle parts and accessories. Today, the state is renowned for its ability to attract both small enterprises and Fortune 500 companies.

A key player in the automotive sector, South Carolina is becoming popular with electric vehicle (EV) companies for many reasons, including an available and skilled workforce and competitive tax rates. These factors and others have resulted in the state seeing increased manufacturing interest in communication and critical data centers, refrigeration companies, payment solution businesses, and lithium-ion cell makers. At present, the state is home to approximately 3,850 manufacturing companies employing almost 280,000 workers, and boasts the presence of companies such as Volvo, The Kraft Heinz Company, BMW, and Boeing Commercial Airplanes.

Similarly, North Carolina continues to draw a diverse range of manufacturers and service-oriented businesses, including Honeywell International, Lowe’s, the Bank of America, Duke Energy, and Coca-Cola Consolidated. According to the Economic Development Partnership of North Carolina, the state was ranked America’s Top State for Business for the second year in a row by CNBC, as of 2023. The CNBC study examined 86 metrics in 10 categories of competitiveness, and North Carolina emerged as number one in Workforce and “highly in the Economy, Technology and Innovation, and Access to Capital categories,” stated the study.

In fact, in less than a decade, North Carolina has seen well over 100,000 well-paying new jobs for companies including Apple, Boom Supersonic, and Toyota in both urban and rural areas of the state. Other investments in the state in recent years include Bosch allocating $130 million to expand its Lincolnton facility and ProKidney dedicating $458 million to a Greensboro biomanufacturing facility.

The Carolinas’ long-standing legacy in manufacturing continues to be a cornerstone of their economic success, driving growth and innovation across diverse industries. From textiles and furniture to advanced technologies like aerospace and biotechnology, the manufacturing sector in both states has adapted to meet evolving global demands. Recent investments, such as Google’s expansion in South Carolina, underscore the region’s ability to attract world-class companies, further solidifying its manufacturing prowess. To sustain this momentum, prioritizing workforce development and integrating advanced manufacturing technologies will be essential. By leveraging their rich industrial heritage and embracing innovation, the Carolinas are well-positioned to remain leaders in U.S. manufacturing for decades to come.

The post A Manufacturing Powerhouse<p class="company">Enduring Success in the Carolinas</p> appeared first on Manufacturing In Focus.

Over the years, the company has grown from a small distributor of industrial equipment to a provider of cutting-edge manufacturing solutions. From its early days of selling simple spray guns and sanders, Air Power now offers highly advanced automation systems and a range of services including equipment repair, project coordination, and custom solutions designed to increase efficiency for manufacturers across various sectors.

On the grow
Since its inception, Air Power has strategically expanded its presence, leveraging both organic growth and acquisitions to serve customers across a broader geographic area. From its central hub in High Point, North Carolina, the company began expanding into nearby states, adding branch locations in Virginia, South Carolina, and beyond. In the late 2010s, Air Power made its first major acquisitions, purchasing companies in Georgia and Florida, which further solidified its presence in key regions.

In recent years, Air Power has continued to grow, acquiring a company in Baltimore during the pandemic and relocating it to Pennsylvania to better serve its expanding customer base. Recently, the company strategically expanded into Texas, Louisiana, and Oklahoma, a move that strengthens Air Power’s commitment to driving manufacturing innovation in these key regions. “We are thrilled to expand our reach and bring our comprehensive range of solutions to these new markets,” said Dan Senff, President of Air Power, in a news release. “This expansion represents an exciting opportunity to provide our customers with unparalleled service, innovative products, and an enhanced experience. Our team is ready to hit the ground running, delivering the same high-quality service our partners know and trust.”

Today, the company operates across a number of states, from Pennsylvania to Florida and westward to Texas, with international operations in Monterrey, Mexico serving clients in the industrial hub of Saltillo.

The company’s reach goes beyond just geographic expansion. With its services not restricted to any one sector, Air Power serves a wide array of industries, including aerospace, military contracting, off-road and on-road vehicle manufacturing, and the truck and bus sector. Through this diversification, Air Power has built a robust foundation that allows it to provide versatile solutions for customers worldwide.

A commitment to service
The team’s commitment to providing comprehensive solutions is reflected in its range of key services, all designed with the customer in mind. The company’s approach to customer service starts with its account managers, who are paired with specialists that have deep expertise in specific areas such as paint lines, assembly cells, dispense applications, and robotic automation. This unique combination allows Air Power not only to sell equipment but also to actively help customers solve their operational bottlenecks and enhance their manufacturing processes.

Indeed, the company goes above and beyond the initial sale with its robust bench and field service offerings. These services ensure that equipment remains in optimal condition, minimizing downtime and maximizing uptime. Whether it’s routine maintenance or urgent repairs, Air Power’s commitment to service ensures that customers experience the least amount of disruption to their operations.

A key differentiator for Air Power is its in-house engineering team, which designs custom solutions that integrate seamlessly into existing manufacturing systems. This capability is particularly valuable for businesses looking to enhance their production lines with automation and specialized equipment tailored to their needs. The company’s engineering team works closely with clients to develop and implement solutions that drive efficiency and productivity.

Another crucial aspect of Air Power’s service offering is its project coordination team, which ensures that every customer project is executed flawlessly. From the moment an order is placed, the team manages everything, including equipment procurement, staging, assembly, testing, and installation. This high level of project oversight ensures that customers enjoy a smooth, seamless experience throughout the entire process.

To maintain industry standards and ensure that equipment operates within required specifications, Air Power also provides calibration services both in-house and on-site. This commitment to calibration and compliance is vital for manufacturers who need to meet stringent operational standards.

The company offers three specialized customer labs at its High Point, North Carolina facility, which provide a controlled environment where customers can test equipment before making a purchase. With dedicated spaces for dispensing, finishing, and fastening, the labs allow clients to ensure that the equipment they choose is the best fit for their specific needs, giving them confidence in their purchasing decisions. Together, these services showcase Air Power’s dedication to not only selling equipment but also providing comprehensive, customer-centered solutions that support long-term success and operational excellence.

Embracing automation
As the manufacturing industry continues to evolve, Air Power has embraced digital automation and data-driven solutions. In today’s competitive market, repeatability and profitability go hand in hand, and data plays a crucial role in achieving both. Air Power utilizes cloud-based systems and MES (Manufacturing Execution Systems) to track, monitor, and analyze data, allowing customers to make more informed decisions about their operations.

One key advantage of automation is its ability to improve efficiency and reduce waste. As Jai Armitage, Marketing Director at Air Power, says, “Repeatability is profitability.” Automation, combined with data analysis, enables manufacturers to consistently achieve the same high-quality results, improving productivity while minimizing the cost of operations.

Air Power’s ability to provide automation solutions, ranging from robotic spray applicators to complete finishing systems, has made it a trusted partner for companies looking to streamline their operations and increase their production capabilities.

A strong team
At the heart of Air Power Manufacturing Solutions is a team of dedicated professionals, each contributing to the company’s ongoing success with their unique expertise and unwavering commitment to customer satisfaction. As President of Air Power Manufacturing Solutions, Dan Senff plays a key role in setting the overall direction for the company. With a focus on people, partnerships, and products, he emphasizes the importance of a culture built on trust, transparency, and customer-centricity. Under his leadership, Air Power has maintained long-standing relationships with customers since its founding in 1967, a testament to the company’s commitment to always doing right by its clients.

“We hire for character and train for skill,” says Senff, reflecting on the company’s hiring philosophy. This approach ensures that its teams are composed of individuals who align with the company’s values, fostering a strong sense of community and dedication. Senff also highlights the importance of staying true to the company’s mission statement: “We don’t grow just for the sake of growth. We grow because we can be a partner in the community, ensuring sustainability and long-term success.”

Kevin Averette, Operations Leader, oversees both the operations and competencies within Air Power, managing several critical teams that support the company’s broader goals. His responsibilities span warehouse operations, inventory management, and purchasing, ensuring that the day-to-day operations run smoothly while maintaining a focus on the customer experience. “Having application engineers on each team is like having subject matter experts at the core of our strategy,” Averette explains. “They are the ones who really make a difference when it comes to delivering solutions that align with the customer’s needs and manufacturing process.”

The application engineers play a pivotal role in providing deep product knowledge and expertise. With 20-plus engineers within these teams, they are instrumental in creating lasting value by consistently applying the right equipment and resources to customer projects.

Kyle Crawford, Sales and Marketing Manager, emphasizes the company’s culture, stating, “We all work for a living, but we also don’t live to work.” The company places a strong emphasis on work-life balance and the well-being of its team members, creating a positive and supportive work environment where employees are motivated to go above and beyond.

In addition, Air Power fosters a culture of continuous improvement and learning. The company invests heavily in training for its employees, ensuring that account managers, engineers, and customer service teams are always up to date on the latest technologies and manufacturing trends. This commitment to training is reflected in the company’s growth and its ability to remain at the forefront of innovation.

Standing apart
The key to Air Power’s success lies not only in its depth of expertise but also in its collaborative approach. Application engineers work closely with the sales teams to ensure that each solution is tailored to the customer’s process, and the close-knit nature of the company ensures that all employees, from engineers to account managers, are aligned in delivering superior value to the customer.

“We’re different from our competitors because we can provide a comprehensive solution, pulling together multiple competencies to address complex manufacturing needs,” says Averette. “Customers don’t have to deal with multiple vendors; they can rely on us for all their needs.”

The company’s strong culture, centered around family values, trust, and employee well-being, plays a critical role in this success. “We focus on people first,” says Senff, underscoring how internal relationships and the well-being of employees directly contribute to the company’s long-term partnerships with clients.

As the manufacturing industry becomes more interconnected, Air Power’s vision is to expand its reach both geographically and technologically. The company is exploring expansion into new regions, including the western U.S., while continuing to grow its presence in key markets such as Mexico. As the global economy becomes more integrated, Air Power is well-positioned to support manufacturers anywhere in the world.

Certainly, Air Power Manufacturing Solutions has come a long way from its humble beginnings, and its growth reflects the company’s dedication to customer service, innovation, and a strong, supportive culture. With a focus on providing complete, tailored solutions from equipment sales to engineering and field service, Air Power has become a trusted partner for manufacturers looking to enhance their operations and embrace automation. It stands out as a company that understands the importance of both expertise and culture in driving lasting success, and continues to thrive because of its strong, cohesive team and its focus on delivering exceptional service.

As the company continues to expand its capabilities and geographic footprint, it is clear that Air Power is poised for continued success in the evolving manufacturing landscape.

The post From Humble Beginnings to Industry Leadership<p class="company">Air Power Manufacturing Solutions</p> appeared first on Manufacturing In Focus.

Specializing in more than just plastic pellet processing, the Currier team excels at maximizing profitability for customers by focusing on the minute details of their processes.

Currier identifies and addresses areas for improvement by thoroughly examining customer processes, often working directly on site. “We focus on being a broader supplier-partner to companies,” says Ron Ringleben, Vice President of Business Development. “Everything we do is 100 percent customized to specifications. We don’t make the same part for two different customers.”

Operating from two facilities in Auburn, New York, Currier handles complex processes for clients, some of whom have been with the company for over a decade. As these projects are scaled up, Currier adds volume and value, reducing carbon footprints and improving sustainability. In one instance, the company saved a customer nearly 80,000 miles in packaging transportation mileage over the course of a year—a benchmark it aims to surpass in future years.

Troubleshooting clients’ fabrication, packaging, and shipping processes has been a key part of the company’s expertise since its early days. When its leadership realized that standing out in unique ways would guarantee the company’s longevity, they tasked engineers with developing innovative solutions that would improve both productivity and customers’ bottom lines.

The result is a fully integrated, full-service offering that sets Currier apart, providing everything clients need in relation to the plastic components it supplies. Beyond molding services, Currier also offers parts assembly, parts and systems engineering, parts fabrication, packaging development, logistics, warehousing, and more.

The company also diversified to offer both blow molding and injection molding services, particularly to the medical industry, specializing in consumables for in vitro diagnostics and life sciences.

As an ISO 13485-certified outfit, Currier is capable of meeting exacting tolerances through sophisticated automation. This specialization has made the company a niche supplier with highly sought-after capabilities for leaders in the medical field. Other key parts of this offering are the inspection and verification of parts, assembly, packaging, and shipping.

John Currier, now President, joined the company founded by his mechanical engineer father, Raymond Currier, in 1982 when he was nearly 60. John’s leadership has fostered a supportive company culture that has earned deep loyalty from its staff. “My father’s influence outlasted his time here,” John says of the period following Raymond’s retirement in 1987. “I was in college at the time and thought, ‘How do we know we can do this?’ My brother Jim, on the other hand, took the view of ‘How do you know we can’t?’” John recalls, reflecting on their differing perspectives on their father’s decision to start the company at such a late stage in life.

With a strong technical background, Raymond Currier brought unique insight to his sales role, which he described as that of a “sales engineer.” Today, the company has an engineering sales team that fulfills this same function. “We provide a solution to you. And it might not be what you’re thinking,” John says. All customers are welcomed with the same all-hands-on-deck approach and attention to detail, with a focus on solving pain points quickly and efficiently. The process is thorough, leaving no stone unturned in finding the best solution tailored to each customer’s unique needs.

To uphold its strong and supportive company culture, Currier hires for more than just technical skill. The company uses a meticulous hiring process to ensure that every new employee is an ideal fit for its culture and committed to the company’s long-term goals. For potential hires joining the team from much larger companies, for instance, Currier’s high level of involvement and technology-driven approach must be a comfortable fit for them to join the team.

At Currier, big achievements are celebrated with initiatives like ice cream trucks, cookouts, and other fun team-building activities that bring people together to unwind. This positive attitude, combined with a carefully considered hiring process, has helped Currier earn a spot on Plastics News’ list of Best Places to Work three times in recent years.

“We leverage the benefits of being a smaller company. Bigger companies tend to lose that culture, that small feel,” John says. Protecting and nurturing this culture has helped the company weather staff shortages.

Currier’s commitment to hiring passionate people has also helped the company build long-lasting relationships with customers who know they can rely on the team during challenging times.

John’s philosophy on investing in enthusiastic problem-solvers is simple. “Being energetic, passionate, and optimistic—it fuels the people around you,” he says. In return, employees are encouraged to embrace lateral thinking and explore new possibilities that could benefit customers.

Currier is committed to evolving alongside emerging technologies, ensuring that its clients get exceptional value beyond the company’s molding services. By integrating next-generation systems into everything from assembly to packaging, the company has become a preferred solutions provider for many customers.

“A lot of this focus is on our healthcare clients,” says Ron Ringleben, Vice President of Business Development. “We’re taking parts and assembling multiple pieces. We’re either buying customer-specified parts or making multiple parts and assembling them.”

In the past, labor issues largely drove automation in the medical industry; today, however, the main driver is precision—something that’s simply unachievable without automation. “A lot of automation now has a dozen cameras to inspect parts. Not only do these cameras inspect parts, but they also log inspections,” John explains, emphasizing the importance of traceability in the field. As a result, while the company’s early investments were focused on primary machinery, recent years have seen more capital invested into customized automation than any other equipment. Today, Currier’s engineering team specializes in seamlessly integrating automation into its molding processes.

Thanks to its speed and efficiency, Currier is expanding its market share in the healthcare industry, accelerating its already strong growth trajectory. This trend is expected to continue for the foreseeable future. And, alongside this focus on healthcare, Currier continues to serve a variety of other markets, including packaging. With its sights set on continued growth and expansion, Currier is optimistic about establishing a presence in Europe.

“With the right customer base, we can do it,” says John.

The post Custom Molding with Precision and Passion<p class="company">Currier</p> appeared first on Manufacturing In Focus.

“Before this investment, the ripping, cross-cutting, and the planer were three separate operations. Now, we have put that all together in a big, automated line,” says President and Owner Sébastien Grenier proudly. “With that line, we were able to double our capacity.”

Even as the company embraces technology, Algonquin maintains an ecologically friendly ethos. “We are 100 percent green. Our product is made from renewable sources,” explains Grenier. The company buys lumber in different widths directly from sawmills “and then transforms everything in the plant,” he continues.

Key products range from kitchen cabinets and skirting boards to decorative mouldings, picture rails, and staircase components. More specialized goods include mouldings for caskets and playing tables. About 60 to 70 percent of the company’s work is done with maple, although it is also fond of alder, walnut, poplar, pine, cherry, and oak. As a business-to-business enterprise, Algonquin counts architectural millwork firms, finishing companies, and kitchen cabinet designers among its clients.

“We are exporters. We are based in Mirabel, Quebec, but only one or two percent of our sales are from Quebec. We have a lot going to the U.S. and western Canada; all the rest goes to Europe,” says Grenier. To this end, the company has Customs-Trade Partnership Against Terrorism (C-TPAT) certification. C-TPAT is a voluntary program, spearheaded by U.S. Customs and Border Protection, to streamline and secure the cross-border supply chain.

Algonquin Mouldings’ services are self-performed. “We don’t subcontract anything,” says Grenier, who points to the company’s multi-million-dollar investment in technology as evidence of its can-do spirit.

The automated rip and cross-cut line was purchased from System TM, a Danish equipment manufacturer that belongs to the Homag Group, the “world’s leading provider of integrated solutions for production in the woodworking industry and woodworking shops,” according to the Group. Algonquin’s scanners, which are used for ripping (making cuts that are parallel to the grain in the wood) and cross-cutting work, were made by Italian firm MiCROTEC.

Core elements of the System TM line include an Opti-Feed 6000—an automated infeed system that can automatically feed long workpieces. Opti-Feed 6000 offers high-capacity de-stacking capability, and frees a human operator from having to perform repetitive tasks.

Batches go through a planer that trims boards to ensure they all share a consistent thickness along their entire lengths, then are moved to a MiCROTEC Woodeye Rip scanner which scans wide lumber and transmits data to the rip saw. A conveyor then transports parts to a MiCROTEC Woodeye Crosscut scanner. Using lasers, sensors, and cameras, the scanner scrutinizes the wood surface for cracks, knots, discoloration, or any other type of defects. An inspection that might take a human operator minutes to accomplish takes only a split second with the cross-cut scanner, says Grenier. Once scanned, parts are cut by an TM Opti-Kap 5103 cross saw from System TM.

Both MiCROTEC scanners have AI capability. “Instead of having my technical people analyzing all the data, the AI does it for us,” Grenier explains. He compares the new rip and cross-cut line to a performance car and notes the uniqueness of using AI-powered scanners for woodcutting. “I got a letter from MiCROTEC, the Italian supplier, that said we were the first to buy his new model with AI in the entire lumber industry in the world. We were pretty proud of that.”

The system was so futuristic in fact, that it required special training for staff. “We have two engineers in charge of that new line. To make sure we were ready for it, I took my two engineers to the Massachusetts Institute of Technology to make sure we understood the AI,” Grenier tells us.

These purchases reflect the company’s mission “to become a 4.0 factory.” Also called the Fourth Industrial Revolution, Industry 4.0 refers to ‘smart’ manufacturing plants that make optimum use of computers, sensors, scanners, software, online networks, and other solutions.

Environmental responsibility is another key company value, and something Algonquin Mouldings takes very seriously. Algonquin is a zero-waste business and recovers virtually all of the wood fiber from the production process. The company has been certified by the Forest Stewardship Council (FSC), an organization that accredits companies in the lumber business that engage in sustainable sourcing. This practise ensures there is no long-term net loss of forests.

“Normally, when you think about the business of cutting trees, you don’t think of that as a green industry,” says Grenier. In fact, it is in the best interest of all operators in the wood sector to take a measured approach to sourcing and to encourage replanting. Otherwise, forests would be denuded, and business would dry up.

And there is another reason why Algonquin Mouldings emphasizes technological and green practices, and that is to attract younger workers. “The lumber industry is a pretty old industry and not the kind of [sector] that attracts the new skilled generation. Every new generation wants to go to Apple or Google, not into the lumber industry.” Young people in general are partial to both new technology and environmentalism, so embracing both “is the way we attract them and be ready for the future.”

Algonquin Mouldings was founded in the early 1990s by René Warnet and was family-owned until a few years ago, when it was purchased by Grenier. Like all companies, it has endured its share of challenges. A recent one has come in the form of steep interest rates, which have driven up the price of supplies. Due in part to these high interest rates, the company had to slim down from its usual complement of 65 to 70 workers (including office staff) to roughly 40 today. But at present, Grenier is looking to add new staff members. “Now with interest rates decreasing a bit, we see that business is [improving], so we are already starting to hire a little bit,” he shares.

Given the nature of what the company does, safety is paramount. Algonquin Mouldings has a safety committee that meets regularly and inspects the plant to take note of potential hazards. “I’ve been here 12 years, and I don’t remember the last accident,” Grenier says.

In terms of promotion, the company participates in trade shows and other industry events. Representatives recently visited China “because they are a huge buyer of Canadian maple. We went there to find new clients, make sure people know us,” explains Grenier.

Given that Algonquin Mouldings does not sell directly to the public, it is important that “the right businesses need to know us. We have a group of salespeople around the world… They are in charge of going to the right place and right business [to tell them] we can supply [wood products] at very competitive prices, especially with the new automation we have in the plant,” he continues.

For the time being, the company would rather focus on enhancing its existing core strengths than adding any new services or products. Grenier is, however, thinking about acquiring other companies to boost market reach.

Heading into the future, “The plan is to grow,” he states. “The goal is to just take a bigger part of the market in two ways: investments into productivity and also buying other plants.”

The post Where High-Tech Solutions Meet an Ecological Mindset<p class="company">Algonquin Mouldings</p> appeared first on Manufacturing In Focus.

But that was then, and this is now. Since 2008, ThermalWood Canada, a thermally modified wood manufacturer based in Bathurst, New Brunswick, on Canada’s east coast, has been offering construction customers around the globe finished hardwood products—and more recently, wood products for the music industry—all manufactured through a carefully timed process of heat and steam, with temperatures ranging between 185 and 215°C.

This process changes the physical properties of the wood and, without using chemicals harmful to the environment, creates a stable, durable, mold- and insect-resistant, environmentally friendly, and aesthetically attractive product. It is, quite literally, the wood of the future.

Back to the beginning
Robert Lennon, President and Co-owner of ThermalWood Canada, takes us back to 2005 and the day his brother-in-law, Pierre Friolet, who operated a company that did tree cutting and preparation for sawmills, “showed up on my doorstep with an armful of thermally modified wood and said, ‘Here’s the way of the future. This is the way we have to go.’”

Friolet had been on a mission to find new harvesting equipment for his own business, and it was purely serendipitous that he discovered this technology that had been developed in Finland for use with softwood. This, he believed, presented an exciting manufacturing and entrepreneurial opportunity in the North American wood industry, where it was virtually unknown.

At the same time, Lennon, who had enjoyed a 30-year career as an engineer at Brunswick Mines, which had just announced its closure, was facing the decision of whether to accept a position with the company on another continent, something his family did not want him to do. “As I was helping Pierre put a business plan together, doing research, and getting more involved, I was thinking this would be a good time to exit the mining world and enter the entrepreneurial world,” he says.

“The mine was scheduled to close in 2008, but it kept going for five more years and so I did both jobs; I continued in a leadership role at the mine and worked at developing our business. I didn’t take a salary as I was already being paid, and that allowed us to grow and become viable,” Lennon shares.

“This was a new technology in an old, mature market, and only a few people knew about it, so it required a lot of education. On top of that, there couldn’t have been a worse time to start a business than during the recession of 2008.”

The recession, however, forced Lennon and Friolet to change their business model, because in the beginning they were only going to offer their services for thermal modification. Wood manufacturing businesses would send ThermalWood their lumber, which would be treated and sent back for them to develop and manufacture their own product.

But when the recession started, no one in North America was ready to start developing their own products, so ThermalWood had to either close its doors or reinvent itself.

“Reinventing was more to my liking because I can’t quit once I start, so what we did was look for where the money was and where people understood the product, and that was Europe,” Lennon tells us. “That changed our target area, and because we couldn’t offer them service, we had to offer them product. So, we started to develop our own products and now we ship to countries around the world.”

The process and the product
The thermal wood treatment process as noted was first developed for softwood lumber, but because Lennon and Friolet wanted to use maple, ash, birch, and oak imported from mills in Quebec and Ontario, as well as New York, Indiana, and Pennsylvania, the equipment they purchased had to be converted, with over 200 recipes developed and tested for treating each type of hardwood. The wood, carefully stacked with a two-inch space between each layer to allow heat and steam to circulate clockwise, is loaded into the propane-heated kiln at the optimum temperature and length of time, which varies for different species.

In the process, the wood is physically changed at a molecular level, transforming the sugars such that it becomes hydrophobic and unattractive to insects and other pests. This means it does not soak up moisture from the air and is resistant to water damage, so will not warp, swell, shrink, or rot. An added benefit is an attractive, rich, and even coloration, which becomes darker the longer it is left in the kiln.

“Treating hardwood to create a stable, insect- and mold-resistant product has allowed these species to play in markets they couldn’t have played in before,” says Lennon. “They would normally be designated for furniture or interior use, but because of our process, we can take them outside.” This has resulted in a line of exterior siding and decking products, and components for outdoor furniture in addition to interior products such as flooring, wall and door panelling, furniture, and butcher block counter tops.

The company has also experimented with local underutilized species, such as tamarack and hemlock, which most sawmills do not want to cut because they are resinous and gummy. But after thermal treating, these species become as hard as steel, and when left outside in the sun for three months, weather to look like old barn wood. Customers are using it for accent walls or sliding doors for closets, but because of softwood lumber tariffs, it is only sold locally.

The company’s finished hardwood products are shipped across Canada—with distributors in Alberta and British Columbia—as well as to the United States, several European countries, and the Caribbean. European consumers appreciate the benefits of thermally treated softwood and are excited by the range of hardwood options, while the products’ termite-resistant qualities are particularly valued in the Caribbean. “Architects in Barbados took a piece of our wood and shoved it into a termite mound and the termites didn’t touch it for six months,” Lennon says.

Obsidian Ebony—creating a buzz in the music industry
In 2020, Lennon heard about difficulties musical instrument manufacturers, especially luthiers, were experiencing in sourcing good quality ebony wood for guitar fingerboards. Ebony is valued for its stability, ensuring a guitar will not go out of tune mid-performance due to humidity, but sadly the exotic African wood is becoming an endangered species. It wasn’t long before Lennon launched an R&D project to see if he could find a wood alternative for ebony, and after several years of trial and error—and building a small testing kiln—finally found a sustainable alternative, which is as hard and durable as ebony, and as dark and shiny in appearance.

Obsidian Ebony is made from torrefied maple that has been infused with resin under pressure and then cured under heat, for a much longer time than the other treated products, as the longer the time, the darker and more durable it is. “That makes a very stiff piece of wood that has the same density and colour as ebony. Moreover, we feel good about it, because it’s a sustainable product, and we could be helping to save a species that is becoming extinct.”

Obsidian Ebony has been industry-tested by luthiers including Fender and Gibson, who found it to be very workable, and guitarists who enjoyed playing instruments made with it. It’s also been favorably reviewed in such magazines as Tone Journey (April 2024) and Guitar World (September 2024), which noted the process “replaces 35 years of air drying and gives it a vintage sound.”

“We’ve soft-launched it,” Lennon explains, “and now that we have proof of concept and respect in the market, we’re preparing to take it to a commercial level.”

As that’s happening, he’s also thinking ahead to other applications for Obsidian Ebony and perhaps other exotic woods such as rosewood, and their potential for other stringed instruments—bass, violin, viola, cello—as well as bridge blanks and headstock veneer. He is also working with luthiers who are sitting on a substantial supply of lower grade ebony and treating it for them to improve its performance qualities; when that stock has been used up, he anticipates a customer for Obsidian Ebony. “It’s how you develop good customer relationships,” he says.

Bigger can be greener
ThermalWood Canada is about to roll out a three-year, multi-phase expansion plan, which will involve a 5,000-square-foot extension to its current 46,000-square-foot building, as a place to store wood. “We are also buying a smaller kiln so we can address the needs of the luthiers.” That will be followed by the acquisition of another kiln, the same size as that currently in operation. The new kilns on order are the “new generation of kilns” which will re-circulate the heat so it can be reused and brought back into the system, with no fumes escaping the building. When the new ones come in, the old one can be connected to the new system, and “we will stop losing energy to the outdoors.”

Preventing waste from entering the landfill is another issue that concerns Lennon, who is addressing it in several ways. One is by grinding up wood chips and narrow, leftover strips of solid wood and selling it in bulk as mulch. Typically, mulch blows away and has to be replaced, but this is an environmentally friendly product with no dyes or chemicals, it looks great, and since it doesn’t retain water, it releases it back into the ground in a timely fashion.

In addition, wood chips have been approved by the Canadian Food Inspection Agency and are being sold for barbecuing. Lennon is currently exploring a market for wood dust, which has high concentrations of lime and, when mixed with peat moss and topsoil, can help plants grow.

All of this is only possible because the company’s wood has not been treated with chemical preservatives. As Lennon says, “We like to be environmentally friendly, and it’s all about seeing what we can do. Our planet is going downhill; Mother Nature is changing her course because of things we have done, so if there is anything we can do now to change that course, we’re going to try. We’re just putting a little dent in it, but if everyone’s doing a little bit, then together we can make things happen.”

The post Thermally Modified Wood That’s Built to Last<p class="company">ThermalWood Canada</p> appeared first on Manufacturing In Focus.

Combining decades of technical expertise with industry know-how, the PDC takes customer projects “from concept to full implementation,” according to the company. “The team provides customers with test cut samples, quality verification, and project launch assistance,” says Salay Quaranta, Vice President of Sales.

“We’ve created a space to do customized test cuts and development work with customers on machines exactly like the machines they are purchasing, helping them shorten their launch time,” explains George Media, Vice President of Operations. “When they walk into the room, they’ll have a ‘Wow!’ moment because they will see our vision and the need for the Process Development Center,” he says.

“Our team of advanced application engineers covers a wide range of technology, from Swiss multifunction and laser to performing test cuts, critical dimension and feature verification, and supporting product development. It’s a space where our clients, partners, and technical experts can tackle even the most challenging small-part manufacturing projects,” continues Media.

Now located in Tsugami America’s headquarters in Windsor, Connecticut, Innovative Machine Group (IMG), is home to the Make Ready department. An ISO 9001:2015 registered company, Make Ready was created “with the sole purpose of providing fully customized Tsugami machines to the end-user customers of Tsugami America and its distribution,” the company notes.

In this 30,000-square-foot facility, Tsugami machines undergo extensive quality checks before they reach customers. Customization is tailored to each order, and the Make Ready team ensures that all non-standard machine options are fitted and tested. The entire process is photographed and documented prior to packaging and shipment.

Tsugami America’s customers and distribution partners view the Make Ready program as an extension of their engineering capabilities. “So, when they receive their Tsugami machine, they are ready to go,” adds Media.

Previously split between two buildings, the Tsugami America and IMG facilities are now under one roof, streamlining operations and ensuring complete customer service.

The Make Ready program truly sets Tsugami America apart from the competition. Each precision machine is prepared to meet specific customer requirements. Specially configured options—both custom and standard—are installed, tested, and programmed. “As soon as it’s shipped and set up on the customer’s floor, it is powered up, training can begin, and parts can be made. This saves three to four weeks of machine preparation on the customer’s floor,” comments Media.

Depending on customer specifications, precision machines can be ordered and delivered in just a few days, while highly customized solutions may require a longer lead time. To complement the entire package, Tsugami America’s own service technicians travel to customer sites to ensure everything works smoothly and cover everything from preventative maintenance to spindle and attachment repairs.

“We support all aspects of Tsugami machine tools and operations,” says Quaranta. “Our service technicians are located across the United States and beyond, with the support of our distribution network partners in Canada and Mexico. We can help with the installation of the machine, training classes, and any other development support customers may need.”

Together with its sister company IMG, Tsugami America employs approximately 110 people, including many veteran engineers. “Everybody touches machines, contracts, and works directly with customers,” explains Media. “Service and engineering make up the bulk of our company. We want to help customers and our distribution team, which requires qualified, hands-on people, not someone in an office somewhere telling them what to do.” The company prides itself on assisting clients at every stage, from project inception to decommissioning.

The three core philosophies of Precision Tsugami machine tools are accuracy, speed, and rigidity. “This is reflected in every machine platform, enabling the company to deliver the highest quality in manufacturing components produced on a Tsugami solution,” says Quaranta. “Tsugami America—along with our distribution partners across North America—provides extensive support, from advanced manufacturing and process development to service and aftercare with preventative maintenance programs.” She continues, “We pride ourselves on being close to our customers and their manufacturing needs.”

Since becoming North America’s exclusive source for Precision Tsugami machine tools in 1978, Tsugami America has provided innovative products and engineering solutions to clients across the U.S., Canada, and Mexico, serving well-known companies in the medical manufacturing, aerospace, defense, energy, and automotive sectors.

“We are present everywhere, from OEMs to Tier 1 and Tier 2 suppliers and contract service providers, including job shops,” says Quaranta. “You’ll find Tsugami solutions in many different industries.”

The small parts produced on Tsugami America’s precision machines are used across multiple sectors, including life-saving medical devices, critical aerospace components, satellite parts, and cutting-edge energy and defense technologies.

Tsugami America has a robust library of videos showcasing its equipment in action. “We like to get people hands-on, and part of that is telling our customers’ stories. Their real-life experiences speak louder than anything we can say,” says Tsugami America’s Brand Marketing Manager, Amy Schildwaster. “We believe our equipment is top-of-the-line, but it is our customers who prove it.”

To be sure, Tsugami America’s Process Development Center represents a significant advancement in the company’s commitment to supporting customers at every stage of the manufacturing process. By providing tailored support through customized test cuts, project assistance, and comprehensive aftercare services, Tsugami ensures that clients are equipped to meet the challenges of small-part manufacturing. With a customer-centric approach, extensive technical expertise, and a focus on precision, Tsugami continues to strengthen its position as a leader in machining solutions, empowering industries like medical, aerospace, and defense to achieve excellence in production.

The post Revolutionizing the Customer Experience<p class="company">Tsugami America</p> appeared first on Manufacturing In Focus.

Norcan’s focus on quality, innovation, and customer satisfaction has made it a trusted name in an industry where precision and reliability are paramount.

At the core of Norcan’s success lies its ability to adapt and meet the specific needs of its diverse clientele. Whether it’s servicing small hydraulic components like log splitters, overhauling large equipment such as excavators and wheel loaders, or troubleshooting industrial hydraulic power units, Norcan ensures that every project receives its full attention.

“Our mission is to deliver unmatched service and innovative solutions,” says Chris Fearon, Norcan’s E-commerce Manager. “Every job, no matter how big or small, gets our full attention because we know how critical hydraulic systems are to our customers’ operations.” This commitment to excellence underscores Norcan’s philosophy: the understanding that its success is inherently tied to the success of its clients.

Norcan Fluid Power has earned its reputation by excelling across a variety of industries. From the pulp and paper sector to mining and construction, the company provides essential services that keep operations running smoothly. Industries like pulp and paper rely heavily on uninterrupted workflows, where even minor downtime can lead to significant financial losses. To address this, Norcan offers on-site services, deploying skilled technicians to customer locations to resolve hydraulic issues quickly and efficiently. This proactive approach minimizes disruptions and reflects Norcan’s dedication to delivering customer-focused solutions.

Norcan’s engineering capabilities further set it apart. The company specializes in designing and manufacturing custom hydraulic power units for industrial and OEM applications. These systems are tailored to meet specific operational needs, ensuring optimal performance even in the most demanding environments.

“Innovation is part of our DNA,” says Fearon. “We’re not just fixing problems; we’re designing systems that help our clients push boundaries and achieve more.”

A key component of Norcan’s enduring success is its talented and diverse workforce. Employing approximately 150 professionals across multiple branches, Norcan boasts one of the most comprehensive talent pools in the Canadian hydraulics industry. The team includes a Professional Engineer, Certified Engineering Technologists, Engineers in Training, and skilled tradespeople such as Millwrights, Machinists, and Red Seal-Certified Technicians. This diverse expertise ensures that Norcan can tackle projects of any scale or complexity, providing customers with the confidence that their hydraulic systems are in capable hands.

The customer service team is another standout feature of Norcan’s operations. Many of its members hold Red Seal certifications as parts technicians, equipping them with a rare depth of technical knowledge. This expertise allows them to provide valuable guidance and accurate solutions to customers. Additionally, the supply chain team, led by a professional with a supply chain management designation, ensures that inventory levels are optimized to meet client demands. Norcan’s sales team further enhances its capabilities, with professionals possessing mechanical engineering backgrounds who can offer expert insights and customized recommendations.

“Having the right people in the right roles is crucial to our success,” Fearon emphasizes. “It’s not just about technical skills; it’s about building a team that’s passionate about what they do and committed to helping our customers succeed.” This focus on teamwork and mutual respect is deeply rooted in Norcan’s history as a family-run business, a tradition that has continued even after its acquisition by Certified Power Incorporated (CPI) in 2023.

The acquisition of Norcan Fluid Power by CPI marked a new chapter for the company, but it did not alter its core values or operational independence. Now part of Summus Inc., Norcan benefits from enhanced resources while retaining its identity and dedication to service. Under the leadership of Chad Trinkner, CEO of Summus Inc., and Pepe Diligenti, the President of Norcan Fluid Power, the transition has been smooth, allowing Norcan to continue operating as an independent entity within a larger corporate framework.

“Being part of Summus has opened up new opportunities for growth while allowing us to stay true to what has always made Norcan successful,” Fearon shares. “We’re able to leverage additional resources while maintaining our commitment to customer satisfaction.” As the largest Canadian company in the Summus Inc. portfolio, Norcan’s contributions are instrumental in shaping the group’s collective success.

Norcan Fluid Power’s physical footprint spans eight branches across Western Canada, strategically located to serve a wide range of customers. Its branches in Langley, Kamloops, and Prince George in British Columbia; Leduc, Calgary, and Red Deer in Alberta; Saskatoon in Saskatchewan; and Winnipeg in Manitoba ensure accessibility for clients throughout the region.

Beyond its physical presence, Norcan’s e-commerce platform has emerged as a critical component of its operations. This digital initiative, led by Fearon, extends the company’s reach to customers not only across Canada but also in international markets, including the U.S., South America, Europe, Asia, and Australia. “The goal of our e-commerce platform is to make our expertise accessible anywhere,” says Fearon. “Hydraulics is a global industry, and we’re proud to contribute to it on a worldwide scale.”

The platform has been carefully designed to prioritize user experience, streamlining the process for customers to access the products and services they need. This digital presence has allowed Norcan to maintain strong connections with its clients, even amid challenges like the COVID-19 pandemic, which disrupted traditional supply chains and workflows.

Certainly, the pandemic posed significant obstacles, particularly in terms of supply chain disruptions. However, Norcan’s proactive approach enabled the company to navigate these challenges effectively. By forecasting customer needs and ordering inventory well in advance, the company maintained robust stock levels and minimized delays. “Our ability to adapt quickly was key,” says Fearon. “We worked closely with suppliers and customers to navigate the challenges together.”

In addition to supply chain challenges, Norcan has faced the ongoing difficulty of talent acquisition in a highly specialized field. The company has responded by focusing on hiring individuals with strong character and work ethic, then providing the training needed to develop their technical skills. This strategy has allowed Norcan to maintain a steady pipeline of skilled professionals who uphold its standards of excellence.

Strategic partnerships have also played a crucial role in Norcan’s evolution. A pivotal moment came in 2015, when the company transitioned from Sauer Danfoss to Bosch Rexroth as its primary supplier. This move diversified Norcan’s product offerings and strengthened its position in the industrial sector. The partnership with Bosch Rexroth has enabled the development of specialized build and conversion programs, particularly for the Bosch A10 series pumps, further enhancing Norcan’s capabilities.

Another key partnership is with Hengst Filtration, a leader in industrial filtration solutions. As one of Canada’s largest inventory holders of Hengst filters, Norcan ensures that its customers have access to high-quality filtration products essential for maintaining hydraulic systems.

“Innovation is a continuous process,” Fearon notes. “Whether it’s through new partnerships or refining our existing systems, we’re always looking for ways to offer better solutions to our clients.”

As Norcan Fluid Power continues to grow, its focus remains on optimizing operations, adopting new technologies, and exploring opportunities for expansion. The company is committed to staying ahead of industry trends and maintaining its position as a leader in hydraulic solutions.

“We’re always looking to the future,” Fearon says. “Our goal is to stay ahead of the curve—not just meet industry standards but set them.” This forward-thinking approach ensures that Norcan remains a trusted partner for businesses that rely on its expertise and dedication.

Norcan Fluid Power is more than a hydraulic solutions provider; it is a trusted partner, an innovator, and a model of operational excellence. With a talented team, a global reach, and an unwavering focus on customer needs, Norcan exemplifies what can be achieved through expertise, collaboration, and vision. As the company continues to build on its legacy, it remains a driving force in shaping the hydraulics industry and supporting the businesses that depend on its indispensable services.

The post Redefining Industry Standards<p class="company">Norcan Fluid Power</p> appeared first on Manufacturing In Focus.

From decontaminating military properties affected by chemical, biological, radiological, or nuclear (CBRN) attacks to cleaning industrial facilities, stadiums, and high-rise buildings, to measuring the thickness of paint and steel tanks on oil and gas plants to clearing roadsides from New York to the United Arab Emirates of pollutant gases, Apellix is expanding and refining the amazing potential of drones.

Apellix is leading North America and the world to a new era of technology-driven property maintenance and cleaning. With the leading cause of labor-related fatalities in the United States being “falls from a height,” this visionary company has utterly changed how the exteriors of buildings are cleaned: safely, for a start.

“At Apellix, we create elegant, transformative solutions to keep workers safe,” says Robert Dahlstrom, CEO, who reiterates the need for these products. “This is 2024. Why are people still hanging off buildings doing work?”

In a world where worker safety is an ever-growing concern, the company’s approach to employing drones makes sense. “Using drones as a platform to maintain facilities and clean structures is a safer, faster, and more economical way of maintaining structures,” Dahlstrom continues.

Besides cleaning, proper maintenance is also of the utmost importance to raising safety standards. The company’s applications focus mainly on standard procedures in the oil and gas industry where measuring the thickness of steel and other functions is imperative to human safety. And these capabilities are proving invaluable.

As steel corrodes, setting finite performance limits for components, Apellix’s drones measure the changing state of tanks, pipes, and other steel infrastructure as a safety mainstay for large oil and gas plants—especially where dangerous gases, high-pressure zones, and other threats can endanger human life.

“To our knowledge, we have the only drone in the world that can autonomously go into class I, division II hazardous locations and make physical contact with structures to take measurements,” Dahlstrom says.

Taking these capabilities a step further, about three years ago the company started developing a model to powerwash buildings, which it introduced to the global market just over a year ago. The product has proven wildly popular, with more than 19 companies from more than 13 countries visiting the Apellix facility to see this powerful new tool perform its magic. As a result, Apellix has seen impressive growth during this time as its new powerwash drone has shot to fame.

Rather than physically contacting structures, the new drone hovers a short, set distance from its target, washing it with a controlled stream of high-pressure cleaning agents. Tethered to terra firma, these drones manage hoses handling pressures of around 3500 psi, pumping eight gallons per minute. There is also a soft-wash, 300 psi option for less intense cleaning demands. “Our drone does both pressure- and soft-washing,” Dahlstrom explains.

The high adoption rate for these straightforward cleaning devices is due at least in part to the fact that they are so easy to implement and operate compared to more complex models performing more sophisticated tasks and needing a lot more technological savvy.

Apellix, Dahlstrom’s second company, followed in the footsteps of his first, a highly successful firm that specialized in software security applications. Within this context, Dahlstrom sees drones as flying computers, redefining the realms of software development and airborne devices simultaneously.

These innovative ideas have been a long time in the making. Painting houses while getting his education—even then a visionary entrepreneur— Dahlstrom happened upon the idea of employing drones to do the grunt work while wielding a paint roller one fateful day. “I had the idea for a spray-painting drone—keeping everything on the ground, tethered. I built a prototype and it worked better than I expected,” he says with a smile. The rest, as they say, is history.

Establishing Apellix on the back of this innovation and its patent, Dahlstrom never looked back. “This unlocks such a huge amount of economic value. It is, quite often, so much cheaper and so much faster.”

Apellix has sold over a million dollars’ worth of wash drones in the first six months of the product’s introduction. Since its inception in 2014, the company has spent a decade developing, designing, and fabricating top-quality drones. In parallel, the team has streamlined its research and development process to encourage sleek and easy pivoting to new applications of its ever-evolving drone technology.

As an intensely committed CEO, some of Dahlstrom’s greatest rewards come in the form of customer feedback. And for him, “every hour a drone is flying is an hour that somebody is not at risk of falling.” After all, optimally functioning drones bearing the Apellix brand indicate happy, safe, and successful customers.

Although the company’s drones are widely copied by opportunists abroad, right down to the company colors, Apellix customers know that by investing in its original equipment they are guaranteed premium customer support, top quality, and outstanding longevity on every drone. In this way, the company genuinely becomes its clients’ safety partner. One of its proudest moments was when Dahlstrom woke up to an almost miraculous social media feed one morning, following the cleaning of the Dallas Cowboys World Headquarters by a customer using Apellix equipment.

Similarly, another customer recently cleaned Disney’s headquarters in Anaheim, California, landing a handsome contract with the global giant on the back of the company’s recommendation.

This brings us to the incredible range Apellix is developing for the United States military. “The army saw our washing drone and they saw the development of our spray-painting drone,” says Dahlstrom. When the Chemical, Biological, Radiological, and Nuclear (CBRN) Defense Division of the Department of Defense (DoD) came across the company’s work, it wasted no time getting the team to start working on technology that could protect, recover, and return state assets and surrounding air to a safe state following exposure to an episode of CBRN warfare.

The DoD project is seeing the birth of a new type of drone operation, capable of scanning, washing, and spraying affected areas of army assets with an existing light-activated decontaminant, similar to a latex-based paint, to decontaminate the air surrounding it as part of operation Apellix Breathe™. With a launch version of the product on its way soon, this dual-application technology will be employed in both industry and military operations while more sophisticated iterations continue to be developed.

To Dahlstrom, these drones could potentially prevent acts of aggression when enemies realize that nitrogen oxide attacks would be futile in the presence of technology that can thwart the efficacy of such attacks, reducing a 10-hour asset recovery process to 10 minutes. “Unlike a lot of drones that are weapons of war, we have just removed the incentive to drop a chemical weapon in the first place,” he says.

According to Dahlstrom, this is only the beginning. Predicting the momentum of the current wave of rapid technological evolution and its adoption in the market, the proof is evident in the company’s 300 percent growth rate for the year to date.

In the process, the company ensures that it benefits the greater good through charitable acts, as well. As a proud supporter of organizations like Pledge 1% and Founders Pledge, Apellix is dedicated to making corporate philanthropy commonplace around the world.

In his own capacity, Dahlstrom also supports the SYDA Foundation, which endeavors to maintain and cultivate the Siddha Yoga tradition. Another organization that benefits from his backing, PRASAD.org, works hard to provide various levels of healthcare and economic support to vulnerable individuals in the United States, Mexico, and India.

Dahlstrom speaks with equal generosity about the people who are the heartbeat of the firm. “I’m so blessed. We have so many amazing people that work for us at Apellix,” he says. “It’s one of these technologies that people see, they love, and then they want to come and work for us.”

Employing scientists from some of the most highly acclaimed global institutions, with more résumés arriving than the firm has vacant positions, the team is genuinely grateful for its good fortune.

As the company’s products are essentially flying computers, Dahlstrom sees the company’s mission as even bigger than that of developing self-driving cars. “We’re in a sexy area. What we’re trying to do with our future development is actually more complicated than self-driving cars,” he says. “Because a self-driving car, you tell it to stop, it just stops. If you tell a drone to stop, it falls out of the sky.”

The challenge is real. With drones making as many as 200 adjustments in a single second to simply enable hovering, the volume of artificial intelligence, machine learning, and computer vision that goes into creating these machines is significant. Add to that continuous research and development to improve existing technology, and it quickly becomes clear just how big the task is.

“It’s light years ahead of whatever you would do with a ground-based system like a self-driving car,” says Dahlstrom. The fact that Apellix vastly increases the safety factor on projects where its aircraft are employed makes the tremendous success of service companies using the machines even sweeter. Because seeing more people thrive—safely—remains one of Apellix’s greatest ambitions.

The post Smarter, Safer Cleaning<p class="company">Apellix</p> appeared first on Manufacturing In Focus.

Achieving cleanliness in food manufacturing facilities, institutional spaces, and industrial areas means using quality equipment to achieve quality results. Providing premium cleaning equipment, the FOAMit team is known for durable machines, reliability, and outstanding customer service. Helping to reduce customers’ long-term overhead expenses in this way, the company, as a business-to-business partner, frees its clients to focus on better serving their respective markets’ needs.

FOAMit has a responsibility to bring reliable cleaning equipment to a range of industries, as its machines handle a variety of cleaning and disinfection suspensions like mists, sprays, gels, foams, and more. Sectors served include agriculture, food processing, breweries and wineries, property restoration, healthcare, aviation and travel, hospitality, and others. One of the most interesting outcomes of serving so many industries is that applications in one often lead to innovation in another, and so the company’s customers obtain value from the team’s entire reach.

As an innovator, FOAMit is prolific; in the past year, the company has introduced a generous selection of new equipment. These include its utility-free, airless, footwear sanitizing unit that comes in three models, of which one offers a boot scrubber option. The unit is easy to set up and works entirely mechanically, allowing users to implement it anywhere around food plants, poultry barns, and other areas. This unit sanitizes footwear of potential pathogens, preventing cross-contamination between food production zones.

The company’s new Equip Series battery portable units vastly improve on older iterations of a similar product, the unit’s new lithium-ion portable batteries allow greatly enhanced application and wider use. Operational ease and portability are just two of the benefits that these units provide. As part of FOAMit’s commitment to keeping customers’ production facilities operational by creating products that are simple and fast to maintain, these units are also easy to replace and repair.

Similarly, a new drum rinse system is designed to triple-rinse 55-gallon drums for reuse and recycling. “We are very excited about our [drum rinse system]. It’s easy to use and saves our customers labor and water for an otherwise labor- and resource-heavy—yet necessary—task,” says Marketing Manager Sam Carbaugh of the button-activated system that is transforming operations for many customers. The product also significantly contributes to the environmental sustainability of companies’ operations.

FOAMit products are also user-friendly. They are simple to use, and the company shares information and guidance that makes ownership a pleasure. Its website is full of useful resources covering every aspect of product operation and other information.

While datasheets and user manuals provide written guidelines, FOAMit’s instructional videos provide detailed, step-by-step, visual guidance on operating and handling the equipment. This includes instructions on replacing valves, air regulators, and other mechanical elements. And customers know that, should they need further support, the FOAMit team is just a phone call away, always ready to handle customer questions.

Focused on strategic growth, the company has taken the time to ensure that its systems and capabilities are developed in a way that supports expansion. To achieve this, its teams are continually innovating and adapting to market demand. “Our design team is always keeping an eye out for what the next needs are for our customers and how we can make those in ways that are durable and long-lasting, but also cost-effective,” says Carbaugh.

It comes as no surprise that the company is on a winning streak with its focus on innovation and excellent customer care. “We have a high level of customer service. Our response rates are, I think, leading in the industry,” says Laura Klaasen, Director of Sales. This enables its customers and end users to remain consistent, securing uptime and productivity, which of course reflects in everybody’s bottom lines.

Whether it means providing audit support or shipping replacement parts to customers on short notice, FOAMit is always there to provide whatever is necessary to keep customers achieving their goals. Moreover, the company emphasizes effective and meaningful communication, leaning in to understand customer needs. “We try to speak our customers’ languages. We really learn what’s important to them,” Klaasen adds.

Navigating customers ranging from small businesses to large corporate enterprises makes FOAMit the ideal partner. Understanding customers’ operational systems as well as cultures gives the team a fundamental understanding of how to serve them in a way that enhances overall operations. Naturally, this approach extends to supporting clients through difficult situations and to expanding its capabilities when customers need their machines to do more. By embracing these conversations, FOAMit is allowing its customers’ applications and work environments to guide its evolution.

This is a multi-generational company under second-generation leadership, and the third generation has already taken up its position. Founded in a garage, the company grew from small beginnings into a flourishing business, outgrowing four buildings in its time. Today, the company’s founder still maintains a garage at its current facility to continue innovating and creating.

FOAMit’s mission of ‘making it better’ reaches beyond supplying top-notch chemical equipment and service. The team contributes to charitable causes like organizations providing children with meals, helping those working with children in foster care, and many others. It also contributes to Habitat for Humanity and local community clean-up drives. FOAMit is also an active participant in the Free Wheelchair Mission, an organization driven to give physically and economically vulnerable people around the world desperately needed access to wheelchairs that may not otherwise have been available to them.

Ensuring that it remains relevant, the company implemented an enterprise resource planning (ERP) system four years ago that has led to expanding lean manufacturing protocols and improving efficiency and output. Against this backdrop, designing and developing products with the ideal value, ease, and cost of ownership in mind means gaining more customers while making life and business easier for end users. “We are focused on growth,” says Klaasen about the firm’s plans to continue expanding its market share.

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