Renowned for his pioneering work in computer theory, Turing quipped a few years before his death in 1954, “No, I’m not interested in developing a powerful brain. All I’m after is just a mediocre brain, something like the President of the American Telephone and Telegraph Company.” Had he lived longer, it would be fascinating to hear Turning’s thoughts on just how advanced and prevalent AI has become.

By the 1970s, some manufacturers were already adopting computers and rudimentary AI in their processes. In the decades since, common tasks once performed only by humans, such as telephone directory assistance, online tech support, and banking services, became dominated by early AI. Today, systems are so realistic we may not even be aware the ‘person’ we are talking to online or on the phone is actually a machine. Developing at breakneck speed, AI is now part of our daily lives.

What is AI, exactly, and how is it—for better or worse—affecting our lives? One of the most succinct definitions comes from multinational technology giant and research organization IBM. “Artificial intelligence (AI) is technology that enables computers and machines to simulate human learning, comprehension, problem solving, decision making, creativity and autonomy.”

Virtually all disciplines, from education to medicine and mining to manufacturing, are undergoing dramatic transformations thanks to AI. In finance, AI analyzes market trends, manages investor portfolios, and even makes personalized wealth management strategies. AI in the medical field is helping doctors diagnose illnesses faster and more accurately. And in manufacturing, AI continues playing a crucial role in how companies make products faster and with greater profitability.

In manufacturing, AI pairs particularly well with robots and with humans working together. It can identify parts, orientation, potential flaws, or safety hazards. It can make decisions on the fly to correct a mistake, improve efficiency, or increase precision, and it can notify humans when intervention is required or stop a process before an accident occurs. And, unlike human beings, AI doesn’t tire or get distracted on the job.

In the recent book AI for Everyone: How to Use Artificial Intelligence to Your Advantage, Kai L. Thornton writes: “Artificial intelligence (AI) is no longer a concept confined to the realms of science fiction and academic discussions. It has become an integral part of our daily lives, shaping how we communicate, work, learn, and even entertain ourselves. For entrepreneurs, professionals, students, and everyday users, AI offers unprecedented opportunities to enhance productivity, automate tasks, and stay competitive in a rapidly evolving world.”

For human workers, the ever-increasing deployment of AI is not all sunshine and roses. Automation and robotics had already impacted the workforce before the implementation of modern AIs, and that trend is only accelerating. Lower-skilled, repetitive jobs like assembling manufactured parts and data entry have already been replaced in many cases, allowing one human worker to do the job of 10, and now AI is quickly expanding to replace even that one remaining human in the loop.

According to recent data from The Organisation for Economic Co-operation and Development (OECD), almost 27 percent of jobs worldwide are at high risk because of automation, creating the potential for mass worldwide unemployment. In his recent book Artificial Intelligence – Friend or Enemy? Robert D. Little writes: “As machines and algorithms replace human labor in these sectors, economic inequality could widen dramatically, as those without advanced skills may find it difficult to secure alternative employment in a rapidly evolving job market.”

Although some costs are coming down, AI, like all technological innovations, is still costly to implement. For massive, multi-billion-dollar corporations, affordability is not an issue; however, for small and medium-sized enterprises (SMEs), the price of implementation and maintenance remains a barrier. Faced with these financial constraints, some SMEs will find completion in the future challenging. This will be especially challenging for low-wage workers in developing countries.

Despite challenges, AI continues to advance modern manufacturing for many reasons. In just a few years, AI has surpassed expectations for many through machine learning (ML), a subset of AI. Instead of technology being used solely to program machines, algorithms analyze and learn from data which is then used to made decisions and predictions. For some fields, such as finance, ML is reducing errors and increasing efficiencies. In other sectors, such as cybersecurity, ML algorithms are being used to monitor and detect cyberattacks before they happen. And in manufacturing, ML helps optimize processes, automate tasks, and detect imperfections which could otherwise delay production, costing companies time and money. One of the greatest advantages of ML in manufacturing is its ability to monitor machines used in production themselves and proactively determine predictive maintenance needs before they become an issue.

Last year, the Washington D.C.-based advocacy group National Association of Manufacturers (NAM)— America’s largest manufacturing trade association—released Working Smarter: How Manufacturers Are Using Artificial Intelligence. Containing key findings and insights, the report discusses how AI can be a force for good.

“Manufacturers have been at the forefront of developing and implementing intelligent systems and AI technologies, including machine learning, deep learning, natural language processing, machine vision, digital twins and robotics,” writes Kathryn Wengel, Executive Vice President and Chief Technical Operations & Risk Officer, Johnson & Johnson, and Chair of the Board, National Association of Manufacturers. “This has positioned manufacturers uniquely as both developers and deployers of AI innovations, providing invaluable insights into the effective and responsible use of these technologies.”

Wengel cites how Johnson & Johnson is using AI as a “force multiplier” in key areas, including drug development, restocking hospitals, sorting masses of data, and “yielding insights for the improved health and wellness of people around the world. It aids us in creating targeted treatments and getting them to the right patients at the right time.” Among the many other benefits of AI are safety and effectiveness guardrails during clinical trials and greater control over supply chains. These factors, and others, see manufacturers working smarter, safer, and more effectively than ever thanks to AI.

In the near future, AI will continue playing an even more prominent role in all sectors, especially in manufacturing, from streamlining processes in the office to machine learning and greater use of robotics on the shop floor.

In 2023, NAM’s Manufacturing Leadership Council conducted surveys on reasons why America’s manufacturers are investing in transformative manufacturing 4.0 (M4.0) technologies and AI. Some of the many reasons include reduced costs, improved operational efficiency, greater operational visibility and responsiveness, improved quality, and greater speed to market. For manufacturers of all types, one of the biggest factors behind increased use of AI remains to “compensate for labor shortages.”

75 years after proposing a test to determine if a machine can exhibit intelligent behaviour, it would be fascinating to hear Alan Turing’s thoughts on today’s complex AI systems and how they learn and perform. Perhaps he would find them “terrific” in all senses of the word.

The post AI Reshaping Manufacturing<p class="company">Promise, Progress, and Potential Pitfalls</p> appeared first on Manufacturing In Focus.

When done well, packaging hits several notes to create that “I’m so excited to open this!” feeling. Much more than just a wrapper of an item, packaging can bring together design, psychology, and impressive functionality.

There have been many milestones in the advancement of packaging spurred on by new techniques, technologies, and materials, but one of the biggest impacts on packaging was COVID-19 and its fallout, which dramatically changed how much more seriously people thought about the packaging of all the goods they were receiving (given we were receiving so many things through delivery channels).

“COVID-19 accelerated a lot of trends that were already in progress at the time,” says Jennifer Christ, manager of consumer and commercial goods at The Freedonia Group, in a Packaging Dive article about the long-term impacts of the pandemic.

This is the point where e-commerce really took off and when businesses had to find solutions to meet their customers’ needs, fast. That meant that considerably more packaging was needed for fulfillment. Up to that point, boxes were made largely for retail, but in the new age of e-commerce it was shipping that mattered more. The other element that changed was the size of the orders, which dropped from more items to fewer, but sent out more frequently.

At the same time, people also began to order a lot more takeout meals. This is where all those food delivery apps gained their substantial followings, and from a packaging standpoint, it opened the door to more innovations like tamper-evident containers that helped protect the quality of food.

But, with all this demand for packaging, an important question has come up: what happens after we open the package?

“The increasing use of single-use delivery packaging made the amount of waste more obvious to consumers and thus the call for more sustainable container options,” says Christ. The materials that are going into packaging have become more sustainable, another factor driving different approaches and innovations.

One example of this comes from Starbucks, reports Packaging World. The coffee giant has partnered with a Finnish company to make cups for cold drinks in their cafés in the U.K. from compostable materials. The upside of these cups is that they can do away with the plastic-lined paper cups that cannot easily be recycled. What remains to be confirmed is how well these cups can hold the liquids, avoiding leakage or condensation.

Another interesting company to highlight is London, U.K. startup Notpla, which has partnered with Just Eat to introduce plastic-free, seaweed-coated takeaway food boxes. Now it is scaling operations to the wider foodservice industry with its fully biodegradable and compostable solution, writes James Darley for Sustainability Magazine.

Changes to one of the most popular condiments could also be coming, reports Darley. Kraft Heinz’s ketchup bottles use a cap that is not easy to recycle because of the multiple materials it uses. But Heinz is working on a fix whereby the caps will be made using a single type of recyclable plastic.

Technology in the industry is also providing new solutions and possibilities for how we receive the goods that we want. Like just about everything else today, we can’t talk about the innovations in packaging unless we include AI in the discussion. AI is helping to improve almost every step of packaging, from the supply chain to quality control and ultimately to the options available for the actual packaging itself.

We all love it when something is made especially for us (or at least looks like it was made especially for us). And that is what AI can offer to manufacturers. Let’s say you live in New England and you are a Boston Red Sox fan; AI could allow for a quick and targeted design change to packaging in your area to include “Let’s go Red Sox” if the team is in the World Series, then quickly revert back after the season ends, or better yet change to “Champs” if the baseball team wins the series.

Packaging done well not only makes the most of the latest innovations; it also uses elements that intersect with our psyches. For instance, the color of a package can impact how we react to what’s inside. Warm colors like red, orange, and yellow can bring out feelings of excitement, happiness, and warmth. Likewise blue, green, and purple conjure feelings of calmness, nature, and royalty.

Then there is what the package feels like when touched. And this makes a lot of sense when you think that after seeing the package, the most important impression for people is what a package feels like when it is handled and opened. Creating a positive tactile experience can hinge on how smooth a package is or, for that matter, how rough it may feel. These psychological forces can strengthen the initial experience of a company’s product and help establish brand loyalty.

“The more you get to know your customers, the more you get to know their preferences,” says Ben Voyer, Cartier Chair Professor of Behavioural Sciences in an article for London Packaging Week. “The key is to build an offering of what directly reflects those preferences.”

Bringing together these elements into packaging can create something that transcends the form and makes a lasting mark in pop culture. Say the name ‘Cracker Jack’ and you almost instantly picture the red, white, and blue box with the sailor on the cover and a dog at his feet. That image dates to 1919 when it was first introduced (the candy itself came about circa 1896). The packaging seems simple, but it works. To further the treat’s childlike appeal, the package makes the most of bright colors and a fun curly font.

It also tugs on the nostalgia strings, not just because we think back to getting the prize out of the box as a kid but because that same basic image has endured through several generations; we have something that we can share with our grandparents.

There are also other ways to appeal to an audience through packaging, like exclusivity. Tiffany and Co. has been known since 1845 for its blue packaging, as Mladen Milosevic describes for DesignRush. In this case, the packaging really starts with that distinctive blue hue. The color, a robin’s-egg blue, was trademarked in 1998 for the company’s exclusive use. Psychologically, the blue hue evokes a sense of security and safety but also a sense of mystery, which brings us back to that exciting feeling of wanting to know what’s inside—because if it’s from Tiffany’s, it’s probably going to be nice.

Taking this one step further in the early 20^th century, the company developed its iconic little blue box. The materials of the box are the medium that exudes exclusivity and status by including touches like a blue suede back and a box that is made from custom paper that carries a distinct weight and texture to set it apart in the competitive luxury jewelry market. Then there is the understated name printed on top in a further refined touch.

If we move from luxurious exclusivity to more mass appeal, there is of course the funky little box with its funky little figure inside. Funko Pop! vinyl figure boxes work by leaving nothing to the imagination. For this company, it starts with the figures, such as sports stars or movie characters, which are petite yet larger than life. But the real accomplishment is that the box itself makes people, ironically, not want to open it. It’s the total package that completes the consumer experience. To reinforce the collectable experience, the number of each figure is displayed prominently on the top right of the box, and some will contain a sticker indicating a limited release. And then there’s the big window that displays the figure to nearly 360 degrees. The packaging brings that extra punch through a combination of colour and the standard cube shape, making it fun to handle, stack, and of course, display for collectors.

Companies are always aiming to leave a lasting mark on their customers and there is no better way to represent a brand than the choices that go into the packaging of their product. Far from just something that is needed for protection during shipping, well-designed packaging can create a direct link between the values of the company and its consumers every time they see the product—even before they open it.

The post The Total Package<p class="company">The Art and Science of Packaging Design</p> appeared first on Manufacturing In Focus.

The company has been growing successfully ever since, making a name for itself by delivering innovative solutions for unmet needs. After profiling the rising star in 2023, Manufacturing in Focus is checking back in this month to hear the company’s latest news.

Wieland Healthcare’s focus continues to be on providing the most durable and reliable solution—and making sure that solution best fits the patient’s needs. The team’s relatively new Soul collection, which includes the Soul mate and Soul sofa, has proven to be a hit. “It’s our most recent, most innovative product offering that we’ve introduced to the market,” says Market Manager Emily Wentz.

The Soul sofa is a multifunctional unit with an open base and legs that are tall enough for the Soul mate to slide underneath for storage. This companion piece functions as an ottoman and nightstand, or can be unfolded to transform into a rolling chair, allowing families to sit closer to their loved ones.

The Accord collection is another popular Wieland Healthcare offering. In a signature, patient-first move, the team has added more options to its Accord recliner, which has been on the market for about a decade and is ideal for patients receiving infusions. “We’ve added things like heat and massage and a fold-down table that gives the nurse, the caretaker, or even the patient an extra surface to work from or to set their tablets or personal belongings on,” Wentz explains. “And then we’ve also implemented power options—places for you to plug in your tablet or your phone while you’re sitting there getting treatment.”

To get these additions just right, the team listened carefully to patient feedback and responded. “In all that we do, everything is based on Voice of Customer research, making sure that we’re doing the right thing, that we’re solving problems and not creating more problems,” says Wentz. Wieland took the entire picture into consideration and recognized that patients will be in the Accord recliner for the entire duration of an infusion; this means paying attention to details such as “the placement of where the power plug is and the kind of massage that’s implemented into the chair—making sure that the heat doesn’t get too hot for the oftentimes fragile patients that are sitting in the seat. We’ve also made the seat and the back more comfortable, considering that people are going to be sitting in these chairs longer than they might if they were just in a typical [healthcare] environment, where you see most recliners. We’ve made sure that the seat and the back are much more comfortable to sit for longer periods of time.”

The company’s specially designed sleep sofa, which gives families the opportunity to spend days as well as nights at their loved one’s bedside, remains popular. The sleepToo sofa includes an adjustable table so that family members don’t have to leave the patient’s room to eat. And the table-couch combo transforms into a bed with a simple push of a button.

Wieland Healthcare has consistently been ranked as one of the top ten manufacturers serving the acute healthcare market. “We’re incredibly proud to be among them,” Wentz says. “I think that we’ve earned our place in the industry based on [our] warranty and product reliability. That’s always been a key factor in our success. We stand behind our products… If it’s broken, we’ll fix it. It’s just that simple. And I think it says a lot about our commitment to being reliable and it fosters trust with our customers. They keep coming back.”

This strong focus on customer service ensures that customers are taken care of throughout a product’s lifecycle. “When you become a customer of Sauder Manufacturing, the Wieland brand specifically, you’re part of the family from the moment that you purchase a product all the way through its life,” says Wentz. “We’re going to be there with you every step of the way. If you have an issue, you know you can always count on us. Call customer care, and they’re going to connect you to the right person. You’re going to be taken care of when you have a Wieland product in your facility.”

Of course, a continuously evolving market has been one of the challenges the company has faced on its road to success. “Since COVID, this market, this industry, has been ever-changing,” Wentz tells us, and paying attention to customer research has been key to overcoming this challenge. In fact, this “has always been the backbone of everything that we do: actively listening to what’s going on in the market—with our customers, with nurses, and with our designers and even the dealers, our distribution channels. It’s about making sure that we’re actively listening to feedback directly from each of those individuals and then taking what we’re hearing and applying it directly to the products that we’re trying to get to market.”

The company even has a program dedicated to gathering and listening to customer feedback. “We’ve just hired someone new to help us maintain that and keep it sustainable. It’s not just sending out surveys and emails, but it’s going to the customer on-site—visiting their facilities, going to trade shows throughout the country, nurse shows, design shows, healthcare facility shows—to get at every angle and extract as much information as possible.”

Continuous improvement is currently a key focus for the company. “A lot of times, you’ll hear continuous improvement or CI, and sometimes it can be just a buzzword, but here we literally live and breathe continuous improvement,” Wentz says. “We have people dedicated to that in those programs, from holding Kaizen events, to lean practices, to filling out A3s for [problems]. We’re continuously trying to improve things and not just on the production floor, but even in the office, in our marketing processes, and in our customer care processes. Because we realize that ultimately, that’s what’s going to satisfy the customer. If we can improve ourselves here, it’s going to trickle down to our customer too.”

Not content to rest on their laurels, the team has more solutions in the works for the near future. “We are looking at launching a couple of new products, one of which is another recliner option,” Wentz shares. She can’t release too much information about this exciting development just yet, but the product is sure to hit home with patients and providers alike. “As always, the goal is to solve problems with the patients and the caretakers. That is, of course, our main goal.”

After three decades of delivering innovative, patient-centered solutions, the Wieland Healthcare team is more than ready to keep meeting this goal.

The post Healthcare Furniture That Puts Patients First<p class="company">Wieland Healthcare</p> appeared first on Manufacturing In Focus.

“Janco was founded by two gentlemen in the composites industry who saw an opportunity,” says Peter Giczewski, President of Janco. “And obviously there was one, because we’re still here 52 years later, which is pretty amazing.”

While the company has experimented with various industries, including the fracking sector, its primary focus has remained on the electrical industry. The team specializes in fiberglass and resin-based products, leveraging these materials to create high-quality, durable components. “Fiberglass and resin materials have just exploded over the last 20, 25 years,” says Giczewski. “We see an incredible opportunity to expand beyond our current markets.”

The company operates as a full-service provider, offering deep expertise in fiberglass and resin systems. Unlike some manufacturers that simply produce parts, Janco works closely with customers to ensure that each product meets specific application requirements. “We don’t physically design the parts. Our customers come to us with their needs, and we recommend the best glass and resin system to provide the best value at the best cost,” Giczewski explains.

The company utilizes two primary manufacturing processes: filament winding and pultrusion. Filament winding produces high-strength components, commonly used in the electrical sector, while pultrusion allows for rapid production of cost-effective parts. “If you wanted to rank them by difficulty, pultrusion is easier,” Giczewski shares. “A pultruded part is done in 10 to 15 seconds, whereas filament winding requires multiple steps like oven curing, grinding, and cutting.”

One of Janco’s biggest competitive advantages is its ability to perform nearly all manufacturing processes in-house. This ensures strict quality control, reduces lead times, and allows for highly customized solutions tailored to each customer’s needs. “We have the expertise to handle fiberglass and resin systems from start to finish, all within our facility. Because of this, we can easily accommodate custom work. Whether it’s a unique resin formulation, a specialized component size, or a complex shape, we have the skills and equipment to deliver exactly what the customer requires.”

Janco’s experience with fiberglass and resin systems allows the company to tackle even the most demanding applications. “Many of our customers need components that must withstand extreme environmental conditions, including high voltage, chemical exposure, and outdoor weathering. Our deep understanding of resin chemistry and fiberglass reinforcement allows us to formulate solutions that meet these stringent requirements,” says Giczewski.

The ability to manage the entire production process internally allows Janco to remain agile and responsive to customer demands. “By keeping everything in-house, we don’t rely on external suppliers for crucial steps in the process. This helps us maintain high standards, control costs, and ensure consistency in every product,” he adds.

Beyond manufacturing, Janco operates a full paint shop, which plays a crucial role in extending the lifespan of its fiberglass components. Fiberglass, while durable, is susceptible to UV degradation, making protective coatings essential for outdoor applications. “Probably 40 or 50 percent of the parts we make get painted, because without it, UV rays would degrade the resin in about 18 months.”

By having an in-house paint shop, Janco ensures that every product receives high-quality, durable coatings that enhance longevity and performance. “Having our own paint shop means we don’t have to rely on third parties for finishing work,” says Giczewski. “This keeps production streamlined, maintains our quality standards, and guarantees that every product leaving our facility meets our exact specifications.”

Of course, Janco’s paint shop also allows for greater customization in color and finish. “Some customers have specific color requirements for branding or safety purposes; others need specialized coatings that provide additional chemical or abrasion resistance. We can accommodate all of these needs under one roof.”

The Janco team is committed to delivering products that meet the highest quality standards, and every step of the production process is carefully monitored to maintain consistency and reliability. “Our job is to make customers happy, day-in and day-out, hour-in and hour-out. We deliver a quality product at a fair price. Of course, one quality issue is one too many for me, but we strive to provide a full-service solution where our customers don’t have to send parts elsewhere for machining or painting. We do it all.”

This turnkey approach allows Janco to offer customers a seamless experience, eliminating the need for additional processing steps. “When customers work with us, they know they are getting a product that has been designed, manufactured, finished, and quality-checked all under one roof,” Giczewski emphasizes. “That’s a huge advantage.”

Such an advantage means that Janco has steadily expanded over the years, currently employing around 85 team members. Indeed, a key factor in the company’s success is its experienced workforce. “We have a great core of workers with long tenures,” says Giczewski. “One of our employees, who retired two years ago, was the eighth person hired by the company 52 years ago.”

Now, to support its growing operations, Janco is investing in new pultrusion equipment. “We’re adding two new state-of-the-art pultrusion lines from Kent Pultrusion in Ohio to increase our capacity,” Giczewski says. “It’s not about replacing old equipment; it’s about meeting growing customer demand. This is a significant investment for us and an exciting time.” At its headquarters in Mishawaka, Indiana, Janco has room for further expansion. “We could easily double or even triple our business within our existing footprint,” he says, “and if necessary, we have the property to expand our facility further.”

Like many manufacturers, Janco has faced challenges in attracting and retaining skilled labor. “The labor shortage was a significant issue for about 30 months after COVID, but over the last 18 months, we’ve seen a lot more labor availability,” he notes.

To attract and retain employees, Janco particularly emphasizes job stability. “Indiana is very manufacturing-oriented and business-friendly; we don’t have big swings in production. A lot of our business is in electrical distribution and fuse tube manufacturing, which aren’t very cyclical industries,” Giczewski explains.

“In my 16 years, we’ve never had to lay anyone off,” he says. “That’s a key selling point for us when attracting new team members,” as is the strong family culture Janco fosters with its employees, which enhances engagement and retention. “All employees, from the plant supervisor to the newly hired trainee, are treated the same in the Janco family.”

And Janco’s reach extends far beyond Indiana. “We ship worldwide—China, Australia, Europe, Mexico, Canada, the Dominican Republic, Puerto Rico.” Despite its global reach, the company remains firmly rooted in its commitment to customer satisfaction and quality. Janco is ISO 9001:2015 certified, ensuring that quality management systems are upheld to international standards.

“Electrical distribution customers don’t like to change suppliers unless necessary,” says Giczewski. “That’s why we focus on consistency. The majority of our business remains in the electrical sector, and we continue to refine our processes to ensure we meet our customers’ needs.”

With new investments in pultrusion capabilities and room for further expansion, Janco is positioned for a bright future. “We deliver a good quality product at a fair price, and we do it with consistency and reliability,” says Giczewski. “That’s what sets us apart.”

Janco Engineered Products exemplifies the balance of innovation and stability in the manufacturing sector. Its legacy of quality, a dedicated workforce, and a forward-thinking approach to expansion means the company is poised to continue meeting with success.

The post Over 50 Years of Quality, Innovation, Growth, and Family<p class="company">Janco Engineered Products</p> appeared first on Manufacturing In Focus.

From vital medications and immunizations to fresh seafood, confectionery, veterinary, and more, the company utilizes recyclable packaging in the form of corrugated boxes, reusable gel packs, molded foam transport containers, and polypropylene and polyethylene food containers. These products support sustainability by being 100 percent recyclable as well as safe—and unbeatable at protecting perishable items.

How the industry got its edge
Identifying a need in the seafood packing industry, owner Jim Freeman founded the company in 1998 in a 2,000-square-foot location in South Portland, Maine, shipping perishables—whether direct-to-consumer or for distribution or food service—and exporting to Asia and Europe. The company quickly outgrew its original facility and in 2001, expanded into a 5,000-square-foot location, eventually filling an impressive 18,000-square-foot distribution facility in Portland.

In 2009, Pack Edge also leased space from Americold in Portland and set up a gel production operation, producing its first gel pack that same year. “That quickly expanded, and in 2010, we added a second gel machine,” says Andrew Frank, Director of Operations. “We were making gels there and freezing with Americold, so we started making plans to build our own freezer and production facility.”

In 2015, Pack Edge added a 5,000-square-foot shipping addition to the larger Portland facility and constructed a new building in Cumberland, a production site with its own blast freezer and storage freezer, along with adding a third gel machine.

“Now we’re up to three gel machines and we’re in two different buildings in Portland and Cumberland,” says Frank. “In 2018, we had just a small walk-in freezer in Portland that we used to hold and distribute out of. We realized we needed more freezing capability and frozen storage space, so we added a 200-pallet freezer in Portland in 2018.”

Pack Edge also transitioned into an ESOP in 2019, allowing for a retirement and exit strategy for owner Jim Freeman, who is still president of the company.

All for one, one for all
An ESOP (Employee Stock Ownership Plan) offers the sponsoring company and its participants numerous tax benefits while also giving workers ownership interest in the company in the form of shares of stock. “This was a way to ensure that the company wouldn’t get dissolved or bought by competition or any of those unpredictable situations,” Frank explains. “It protected us, and it protected the employees.”

Employees are heavily involved in the company’s operations; for instance, a committee called the Ownership Committee, comprising a group of employees from a variety of different departments, works to embody and build that ownership culture.

“All of us are pulling in the same direction,” Frank says. “Every efficiency or safety aspect we incorporate—any aspect where we can make gains really benefits us all, our stock value and everything we’re working toward as a company.”

Back to a better future
As the company continued to grow and thrive, plans were made—once again!—for a larger space, and toward the end of 2024, Pack Edge moved into its new 55,000-square-foot home in Saco, with all operations under one roof for the first time in the company’s history.

“We have capacity, especially in freezing, that we’ve never had before, so we’re geared to grow,” says Frank. “It will let us go for a lot of growth this year and be efficient about it. We’ll be able to do more with less in this facility.”

One of the underestimated benefits of being under one roof, aside from all the new space, storage, and freezer capacity, is the ease and efficiency of communication it brings, he says. “Having all the managers and employees together has really reduced the mistakes that can happen over the telephone or email, and it’s made working together as a group far more effective.”

Another value that’s important to Pack Edge is its commitment to recycling and environmental solutions, especially with the company moving further into the science and pharmaceutical sectors.

“That’s where we realize how important sustainability is for those companies,” says Al Tilbe, Director of Sales. He notes that Pack Edge works with a vendor that provides ClimaCell (a certified, fully curbside recyclable box liner) and corn starch-based solutions. Pack Edge is also looking into sustainable and recyclable gel packs.

Pack Edge’s ClimaCell product has been accepted by the paper recycling sector, which means that customers in any municipality can dispose of the product in their blue bin with no additional steps other than breaking down the box, which is the product’s biggest selling factor for Pack Edge.

“That was huge for us,” says Tilbe. “We’ve seen a lot of companies pushing for a certain product because they feel that it’s sustainable, when it really isn’t. Most of our customers are actually buying online and having products shipped to them at home. Not everybody has facilities available to do industrial composting.”

Customers are highly appreciative, particularly in the life sciences sector, and even though some seafood distributors haven’t made the jump yet, the company is seeing a growing interest among them in treating the environment more kindly.

Staying alive …
Although the past few years have brought huge upheavals around the world to business processes and supply chains, Pack Edge aims not to pass price increases from vendors on to its customers. “It’s always been a challenge in this industry,” says Tilbe, who notes that things grew worse during COVID concerning sourcing issues, market volatility, and the reliability of vendors. Pack Edge, however, managed to weather the storms.

“We’re a company that can pivot fast,” says Frank. “We can build relationships. We have multiple ins with multiple manufacturers. When we get an increase or have trouble getting something, we have multiple sources and avenues to go down to keep our customers happy. We do all the legwork for them, and they get to continue with their day-to-days.”

While sourcing has improved somewhat since the bad days of the pandemic, importing has changed—and permanently, he adds. Nevertheless, Pack Edge pivots successfully and continues to navigate its way through the issues.

And the company is definitely doing a lot right, having celebrated its 25^th anniversary in 2023, an impressive milestone. “We’re chasing our best year yet,” says Frank. “We have some pretty lofty sales goals.”

Not a company to rest on its successes, Pack Edge continually works to keep clients satisfied with the value-added services it offers, including providing various kitting options for its customers. “We tailor what they need,” Tilbe says. Life sciences customers, for instance, “have their printed box to put the gels in with their sustainable products, the ClimaCell, and then we’ll ship to them that way. That’s something they really appreciate.”

Along with providing customized sizes and prints, the company is also one of only two in the entire northeast that offers frozen gel packs. “You don’t see a lot of gel producers actually offering them frozen,” says Frank. “It’s a huge added value and it pays off in the long run.”

… and staying ahead
Of course, customer service has always been a priority and will remain so in the company’s drive to remain accountable. “If you ask any of the companies or individuals that we work with, they’ll say we’re a customer-centric company,” Frank says. “They’d agree that we go above and beyond to meet our customers’ needs and fulfill everything that’s requested.”

It’s that attention to interpersonal relationships that helps the company stay ahead, stay dependable, and stay successful.

“That we’re employee-owned is also very different,” Tilbe says. “All our employees, from manufacturing to sales, from top to bottom—everybody wants to be here, and they have a different attitude than in typical companies.”

Providing the best customer service possible and keeping employees engaged in all areas of the business has placed Pack Edge at the leading edge in an industry that is continually changing and growing, particularly on the sustainability side.

“A big mission of ours in building up this environmental, recyclable, drain-safe image is that we want to be not just a perishable-packaging company, but a sustainable packaging company that’s not only shipping better products for their customers but is reducing the carbon footprint of other industries out there,” Frank says. “We try to make a real difference in this industry.”

The post Smart Solutions in Sustainable Packaging<p class="company">Pack Edge</p> appeared first on Manufacturing In Focus.

As part of the Curry Family of Companies, owned by cousins Patrick Curry and Mathew Curry and including carbide tooling manufacturers Carbro and Endurance Carbide, Fullerton Tool Company fabricates a wide range of solid carbide cutting tools like end mills, burrs and saws, specialized milling cutters, and other tools used to create specialized metal components for a variety of industries. The company is especially well known for its high-performance form tools capable of complex tooling, which eliminate the need for multiple tools and machines.

In serving customers with parts and components fabrication for sectors including automotive, medical, aerospace, and more, the company sees its role as more than just tooling fabrication; instead, Fullerton supports the manufacture of the components that America runs on. In some cases, like artificial hip insertions, helping Americans run becomes quite literal.

Headquartered in Saginaw, Michigan, with another facility in the same town and one in Huntington Beach, California, Fullerton has a team of just over 200 permanent staff and around 55 regional sales associates and industrial representatives. This team is synonymous with improving on existing concepts through fresh approaches, often refining coatings, designs, and other adaptable aspects of tooling to create upgrades of traditional concepts. The company achieves such improvements consistently and with a dedication to quality.

Education plays a significant role in the company’s cultivation and maintenance of talent and skill. Improvement is so important to this company that it has established Fullerton Tool University, an in-house learning facility created to deepen the team’s understanding of the fields in which it specializes and the tooling and equipment that make its work possible. It is also home to FAST Academy, which provides three comprehensive courses for clients and the sales team to teach them how to optimally apply their tools to achieve cost savings, longevity, much-improved speeds, and precision material removal.

In the courses, participants learn how to achieve the same outcomes using the same tooling in around half the time, bringing a 20-minute cycle down to less than 10, for instance. “We have a striving and a passion for getting better. The only way you do that is to continue to educate yourself and your teams. We’re really big on that,” President Patrick Curry tells us.

Appearing as keynote speakers at the MMA Operations Conference hosted by the Michigan Manufacturers Association in Lansing on April 17 this year, Fullerton Tool Company representatives will introduce these value-added services to interested audiences looking to learn more about these models. “For us, our big point is about education: trying to educate people on what we’re all about, what we can do to help them be more successful,” Curry says.

Fullerton’s strong focus on education dovetails perfectly with the company’s commitment to innovation. As such, the company has an impressive selection of cutting-edge tooling components that have changed how tooling is done in many markets. One of its latest products, the V-MAC with improved chip breaking and removal capabilities on high-temperature alloys, is a high-performance end mill that cuts through difficult-to-mill metals with ease. Named after Morgan Arthur Curry, Patrick and Mathew’s grandfather and the company’s founder, the product is deemed the best of its kind that the company has ever released.

Fullerton is especially proud to be the main importer of InovaTools, a respected German brand of outstanding quality and innovation supplying sought-after mold and die tooling, into the United States. It carries a large inventory of these tools to provide customers with maximum support. The company also imports Hobe Micro Tools, popular in medical fabrication like the manufacture of dental molds and related small parts from cobalt chrome, titanium, and steel—especially those used for implants and surgery. Focused more on custom components, Hobe supplies complete machining packages to fabricate unique designs. Customers “look for innovative solutions that help them be successful in what they’re trying to produce,” Curry explains.

As Fullerton sees the medical surgery side of its business still recovering following the COVID-19 pandemic, Curry also notes a move away from electric vehicles. “There’s been major disruption in [the] automotive industry with the changes from electric vehicles back to maybe more of the [combustion] and hybrid engines,” he says. “That shift and change has disrupted that market.” He notes that many vehicle launches that were postponed because of COVID are now being brought back to life and made a reality. Of course, during that time, Fullerton’s business from the aerospace industry also dipped significantly, and it has taken a while to get it back into full operation again—but things appear to be back on track this year.

“It’s usually a slower process, but we’re seeing that industry starting to take off,” Curry shares. “Defense is also picking up. Moreover, the United States Navy is revamping and replacing aging vessels and equipment, bringing more business to Fullerton Tool Company.

With a legacy rooted in craftsmanship, innovation, and an unwavering commitment to education, Fullerton Tool Company continues to lead the way in American manufacturing. As industries shift and evolve, Fullerton adapts with agility—advancing technology, refining performance, and investing in knowledge. From supporting critical sectors like defense, aerospace, and medical to helping customers optimize their production through smarter tooling solutions, the company stands as a testament to the strength of values passed down through generations.

The post Innovation Through Education<p class="company">Fullerton Tool Company</p> appeared first on Manufacturing In Focus.

The expo is completely free to attend, a key advantage that sets this show apart and sets a welcoming, community-oriented tone. You can register for free at https://www.foam-expo.com/register?utm_source=focus&utm_medium=partner&utm_campaign=article.

The largest show of its kind in North America, this annual event is “focused on the foam industry… We welcome quite a diverse group of industry professionals, OEMs, buyers, and CEOs. Heavily focused on advanced engineering and high-performance materials, we welcome chief engineers, design engineers, chemical engineers, and product engineers under one roof—everybody involved in design and manufacturing products,” says event organizer Tom Rhodes, Portfolio Director of foam and adhesives at Informa Markets.

As the expo takes place in Michigan, Rhodes expects a large turnout from the automotive industry. He makes clear, however, that the show does not center on any one market. “We’re not just about the automotive sector; we welcome a large number of attendees and exhibitors who supply products to the aerospace, medical, packaging, construction, and leisure industries,” he explains.

As Rhodes notes, industrial foam is widely used across numerous industries including automotive, medical, and aerospace, where lightweight foam provides cushioning and insulation. Foam improves soundproofing and thermal efficiency in building projects and protects and insulates packaging. Medical equipment frequently incorporates foam for cushioning. Comfort foam, another branch of the foam market, is used to augment support and the soothing feel of furniture, mattresses, and the like.

This year’s Foam Expo will be co-located with Adhesives & Bonding Expo, a trade event that covers many related topics, concerns, and concepts. Informa Markets organizes both shows.

“One of the major benefits of co-locating is we’re offering wider access to more products, solutions, and expertise across both foam and adhesives. [The two shows] attract buyers and decision-makers who have an interest and need for both foam applications and adhesives applications,” states James Mackintosh, Event Director of foam and adhesives at Informa Markets.

Adhesives & Bonding Expo takes place in the same hall, and visitors are welcome to drop by both events. “If you’re attending, you have access to everything,” says Rhodes. “All the content on the show floor is free; attendance for both shows is free. We have a number of networking sessions as well that we run throughout the day.”

Each exposition will focus on the full supply chain of its respective sector, ranging “from raw materials all the way through the manufacturing process… to tier-one suppliers and end-users—following the product all the way through its entire lifecycle.”

There will be presentations galore at these events, with speakers and panels at the Industry Stage and the Solutions Stage. Combined, these stages will host over 60 speakers and feature more than 20 sessions and 16-plus hours of content. The industry stage will offer presentations about “industry drivers, industry inhibitors, macro challenges, the industry of tomorrow, trend development—all that good stuff that will be of interest for those who want to understand how the industry will develop over the next five to ten years,” says Mackintosh.

Past years’ presentations ranged from the technical— ‘Closing the Loop with Sustainable Raw Materials for Foaming and the Advantages of Recyclable Polypropylene Foam Production by Twin-Screw Extrusion Technology’ was the title of one lecture in 2024—to broader topics such as a keynote speech, ‘Shaping a Sustainable Future: An Automotive OEM Perspective Guiding the Next Twenty Years.’ Presentations at the solutions stage at the Adhesives & Bonding Expo will be more product, solution, and technology-based, says Mackintosh.

It is a safe bet that certain topics will dominate discussion at Foam Expo 2025, with supply chain issues being a leading concern. Numerous global factors can all negatively impact supply chains, and material costs have been unpredictable as of late, complicating business forecasts, so proposed solutions to such matters will certainly be discussed. Navigating Tariffs: Managing Supply Chain & Cost Challenges in the Industry is one such session; Trade Policy Under New Administration: Risks, Strategies & Global Implications another. “There’s a lot of volatility in play, a lot of unknown. These tariffs affect everyone,” Mackintosh notes.

Both vendor diversification and its counterpart—solidifying long-term relationships with suppliers and customers—for example, can help ease supply chain woes. Simplifying supply chains to decrease complexity and enhance transparency while identifying and addressing potential bottlenecks are other ways foam firms are dealing with this issue, says Mackintosh.

Technology is another key topic, with sessions to include Innovations in Thermal Management: Cooling Technologies for EV Batteries; Lightweight Revolution: Unlocking Sustainability and Efficiency; and Integration of AI and Six Sigma for Optimized Adhesive Selection in the Automotive Industry. AI “is being used more in the foam and adhesives industry to enhance materials selection, streamline formulations processes, and ultimately optimize manufacturing and output,” explains Mackintosh.

Sustainability, too, remains of great importance, and will be highlighted in the Sustainable Innovation: Bio-Based Additives for a Greener Future and Leading the Way in Sustainability: Innovators at the Forefront of the Foam Industry sessions. Environmental awareness is key to both expos, with many exhibitors opting to highlight eco-friendly solutions and products. “Sustainability is becoming more of an agenda-topping theme for everyone,” Mackintosh notes.

In addition to presentations, there will be demonstrations on the show floor centering on everything from new machinery and processes to technological developments and new products for end-users. “There’s a huge amount of innovation that we’re showcasing,” notes Rhodes with pride.

Organizers cite Foam Expo sponsor FSI and Schmitz Foam as leaders in sustainability. Based in Missouri, FSI is a self-described “world leader in polyurethane systems and technology.” The company offers a line of eco-friendly, biodegradable, and non-toxic products including spray foam, pour-in-place foam, and integral skin foam systems featuring FSI’s unique Ecomate technology. Schmitz Foam, a Dutch company with a branch in the United States, specializes in recycling foam residues and transforming them into new products.

Brand new elements at Foam Expo 2025 include Edge Expo, a space reserved for networking and meetings. “We wanted to create a strong, standout focal point… in the heart of Foam Expo,” says Mackintosh. Foam Expo “is prime time” for attendees who want “to get face to face with industry contacts, new and current,” he adds.

The Comfort Lounge is set to become another unique attraction at the expo. The lounge “shines a light on comfort products, materials, and technologies,” intended to serve as a hub for attendees who are either involved with the comfort foam industry or who simply want a cozy spot for some downtime.

Organizers expect over 400 exhibitors to participate in both expos, with the larger Foam Expo accounting for more than half of this total. There will be exhibitors from around the world at Foam Expo and big names represented, including 3M, Mitsubishi, and HP (Hewlett-Packard). An estimated 5,300 visitors are expected to check out the co-located shows over their three-day span.

Foam Expo organizers are also working with an industry association called the Engineering Society of Detroit to encourage engineering students to attend the show. The plan is to interest students in careers in the industrial foam sector by getting them to speak with exhibitors and listen to round-table discussions, says Rhodes. It is a clever strategy, given that Foam Expo has become a well-established success, as evidenced by a survey of people who attended last year’s show. 85 percent of respondents rated the expo as having ‘good’ or ‘excellent’ value while 82 percent rated networking at the event as ‘good’ or “excellent’. A further 80 percent said the show helped them find new companies, while 74 percent agreed or strongly agreed that the three-day show offered better connections than a year’s worth of LinkedIn.

Complementing this survey are flattering remarks from high-ranking attendees of previous Foam Expos. “Prior to Foam Expo in 2017, there was nothing specifically for the foam industry, so this show puts everybody in the right spot at one time,” John Vinci, Business Development Manager at Worldwide Foam, an Indiana company specializing in cross-linked polyethylene (XLPE) foam, told Foam Expo.

“My experience has been extremely positive, and the event is well organized. We’ve been here since Foam Expo started, so we are happy to come back every year to experience the great environment,” echoed Christoph Magnet, CEO of foam cutting equipment firm Bäumer of America.

“I learn something new every time here—even though I have been working in the foam industry for 27 years,” added Karl Hewson, Director of Technology and Development at Zotefoams, an international market leader in supercritical foams. “Three words to describe it would be: friendly, family, innovative.”

If all goes well, more rave reviews will follow this year’s Foam Expo in Novi, Michigan. Don’t miss your chance to be a part of this growing community; register today at https://www.foam-expo.com/register?utm_source=focus&utm_medium=partner&utm_campaign=article.

The post Industry Insights and Opportunities Abound at this Annual Industrial Foam Show<p class="company">Foam Expo 2025 </p> appeared first on Manufacturing In Focus.

SUHNER is a family-owned business now in its fifth generation, a rarity in today’s fast-paced corporate world. With manufacturing facilities in Switzerland, Germany, Italy, China, and the United States, the company maintains a strong global presence while staying true to its core values.

“SUHNER prides itself on being a custom solution provider,” says Ben Davis, SUHNER’s Marketing Manager. “We don’t offer cookie-cutter products. Instead, we work closely with our customers to develop tailored solutions that ensure their success, which in turn ensures ours.”

This customer-first approach has driven SUHNER’s success, allowing the company to build long-term partnerships across industries including automotive, aerospace, industrial manufacturing, and medical technology. The team’s ability to adapt to industry-specific challenges and innovate accordingly has kept it at the forefront of technological advancements.

“Our commitment to innovation is about more than just keeping up with industry trends; it’s about setting them,” Davis adds. “We strive to be the company that others look to when they need cutting-edge solutions.”

SUHNER provides a broad range of advanced metalworking solutions, including grinding and surface treatment, machining technologies, automated manufacturing, and high-quality components such as flex shaft technology, spiral bevel gears, 3D printing, and OEM motor solutions.

Mechanical Engineer Juan Martinez highlights SUHNER’s Electric Force Compliance modular, or EFCm-02 system, as a recent breakthrough. “With the EFCm-02 system, we’ve created a package for grinding, sanding, and polishing that is completely modular,” he explains. “It reduces costs and simplifies programming, making it easier for manufacturers to integrate into their existing workflows.”

This modularity means customers can adapt the system to meet their specific production needs, reducing downtime and increasing efficiency. It also allows SUHNER to provide a more sustainable approach by minimizing material waste and optimizing resource use.

Another key innovation is the company’s drive technology solutions, which are integral to various industrial applications. These high-precision components ensure superior performance, durability, and adaptability across different manufacturing environments. “Our drive technology is one of the most reliable in the industry,” Martinez notes. “It plays a crucial role in automation and smart manufacturing.”

Additionally, the company has been investing in digital tools to enhance its solutions. “We are integrating Smart Technology with 4G capabilities,” Martinez continues. “These technologies allow for smarter preventative maintenance and more efficient production cycles, giving our customers an edge in their industries.”

Beyond manufacturing, SUHNER distinguishes itself with exceptional after-sales service. “We don’t just sell a product and walk away,” says Martinez. “We offer U.S.-based repair services and ongoing technical support. If a customer needs help integrating our equipment or optimizing their production line, we connect them with our vast network of global integrators.”

This dedication extends to training programs and digital tools that ensure customers get the most from their investment. “We have an application center where customers can experience our technology firsthand,” Davis explains. “We offer practical demonstrations, personal training, and digital resources that make information accessible in today’s fast-paced digital environment.”

Additionally, SUHNER leverages data analytics to provide preventative maintenance, helping customers avoid costly downtime. “We use data to anticipate potential issues before they become major problems,” says Davis. “This proactive approach helps our clients maintain efficiency and productivity.”

Indeed, the company aims to go beyond being just a supplier by building lasting partnerships with its customers. Through continuous support, training programs, and digital tools, the company ensures that clients can fully leverage its solutions for maximum efficiency and success.

Even with over a century of experience, SUHNER faces the challenges of modern manufacturing, and one of the key obstacles has been overcoming siloed operations. With a diverse range of products and divisions, there was a tendency for teams to work independently rather than collaboratively. To address this, SUHNER has focused on fostering a more cooperative approach across its operations.

“We’ve realigned our marketing and sales teams, so they support one another,” says Davis. “By breaking down these silos, we’ve created a stronger, more cohesive company that better serves our customers.”

Another significant challenge has been keeping up with the rapid evolution of automation and digital transformation. “Industry 4.0 is changing the game,” says Martinez. “Smart factories, AI-driven production lines, and IoT-enabled machinery are reshaping the landscape. SUHNER is aware and strategically implementing and supporting our customers in these technologies to stay ahead of the curve.”

A commitment to sustainability is also a key focus. “Sustainability isn’t just a buzzword for us,” Davis emphasizes. “We’re looking at ways to reduce our carbon footprint, improve energy efficiency, and develop eco-friendly solutions. Our customers expect it, and it’s the right thing to do.”

In an industry with strong competition, SUHNER’s holistic approach sets it apart. Unlike companies that focus on a single product line, SUHNER offers a diverse range of solutions across multiple industries. “We have experience in so many different markets, and that breadth of knowledge gives us an edge,” Davis says. “Our competitors might have great products, but they often specialize in one area; we provide depth, variety, and the ability to customize solutions to meet customer needs.”

The company’s ability to integrate automation into its solutions further strengthens its competitive position. By offering turnkey automation systems alongside its core products, the company helps manufacturers streamline their processes and increase efficiency. “Automation is the future,” says Martinez. “By combining our expertise in machining, drive technology, material removal, and automation, we create solutions that offer long-term value.”

The team’s emphasis on collaboration and strategic partnerships only further enhances its competitive edge. “We don’t just work for our customers, we work with them,” Davis stresses. “This collaborative approach leads to more innovative and effective solutions.”

Looking ahead, SUHNER continues to prioritize automation, innovation, and expansion. With available land at its Rome, Georgia facility, this company is prepared to scale operations as customer needs evolve. “We are ready to grow alongside our customers,” Davis affirms. “Our success is tied to theirs, and that’s what drives us every day.”

As technology advances and industries evolve, SUHNER remains committed to delivering high-quality, custom-engineered solutions that keep manufacturers competitive. “We’re investing in research and development, forming strategic partnerships, and staying ahead of the curve,” says Martinez.

One of the most exciting prospects for SUHNER is the rise of smart manufacturing and AI-driven production. “The integration of AI and machine learning into manufacturing is a game-changer,” Davis says. “We’re actively exploring ways to incorporate these technologies into our solutions to help customers achieve higher levels of efficiency.”

Yet, as the company moves forward, its core values remain unchanged. SUHNER’s commitment to quality, innovation, and customer success continues to be the foundation of its growth. “For us, it’s about more than just business,” Davis concludes. “It’s about creating lasting partnerships, solving real-world problems, and pushing the boundaries of what’s possible in manufacturing.”

With a legacy built on customer trust, innovation, and adaptability, SUHNER is poised for continued success in the years to come. By blending tradition with cutting-edge technology, the company is securing its place as a global leader in metal processing solutions for generations to come.

The post Blending Tradition, Precision, and Customer-Centric Solutions<p class="company">SUHNER</p> appeared first on Manufacturing In Focus.

Abacus Automation was founded in 1982 by Richard “Dixie” Zens and Donald Alvarado, who turned a setback into an opportunity. After being downsized from their previous employment, they started Abacus Engineering Company, working out of their basements and building a solid reputation for high-performance automation and cost-effective design of manufacturing processes. They quickly moved into an incubator site for new businesses and then purchased a small building in the town of Bennington, Vermont. By 1999, they outgrew that building and built the existing location.

Now, with Scott Elithorpe, President, and partner Mike Perra at the helm, the company is poised for continued growth. “My partner and I have a long history here at Abacus,” says Elithorpe. “We plan to keep the company rolling for many years.” Their leadership ensures that the company continues to thrive by adapting to industry advancements while maintaining the core principles of innovation and customer-focused service.

What sets Abacus Automation apart is its commitment to custom-built solutions, designed entirely in-house from start to finish. Unlike companies that offer off-the-shelf products, Abacus works closely with customers to create machines tailored to their specific needs. “We build amazing machines from scratch,” says Elithorpe. “That transforms our customers’ ability to meet the needs of their markets, right from research and development through product testing, assembly, and packaging.”

Abacus Automation specializes in part handling and assembly, ensuring high throughput, eliminating ergonomic issues, and removing human error through automated handling and assembly systems. The company also focuses on highly adaptable flexible automation, offering tailored solutions to unique manufacturing challenges. With years of experience in building turnkey solutions, Abacus has the expertise to create efficient, streamlined systems that integrate seamlessly into existing operations.

Production quality control is another key area of expertise. Abacus incorporates multiple features to ensure a quality product, with every motion sensed, every critical process measured, and every operation sequence optimized. By integrating fast product changeover capabilities, Abacus allows customers to switch between different product styles with minimal downtime. This flexibility enables multiple products to run on a single production line, increasing efficiency and adaptability.

Efficient conveying and palletizing keep production running smoothly to meet customer demand. Abacus provides automated transfer systems and downstream packaging solutions that streamline manufacturing processes, helping businesses improve productivity and reduce costs. And every machine Abacus creates is built to last, a fact reinforced by the company’s high rate of repeat customers and word-of-mouth referrals.

“Our equipment is very high quality and well-supported, which is evidenced by the bulk of our business coming from repeat customers,” shares Elithorpe. “We design everything from scratch, making each project a unique build, but we also channel experience from past projects to ensure successful outcomes.”

Abacus Automation thrives not just because of its technology, but because of its people. With a team of over 40 employees, ranging from industry veterans to eager new talent, the company has cultivated a family-like atmosphere that fosters creativity and collaboration. Employees take pride in their work, knowing they contribute to meaningful and innovative automation solutions used worldwide.

“Everyone here is an essential part of the team and ensures we’re successful with our machine builds,” says Elithorpe. “A lot of us have been together for many years, which turns into a real family culture. We all have kids and grandkids of the same age, so we spend a fair amount of time together outside of work as well.”

This camaraderie translates directly into the company’s innovative approach. “A lot of creativity goes into our designs. We often have brainstorming sessions, and you never know where a great idea will come from; it’s not always from the person designing the machine. Sometimes, it’s someone who saw a process in a factory somewhere and can bring that insight to the team.”

Abacus Automation has built custom solutions for a diverse range of industries, including medical, aerospace, military, consumer, cosmetic, food, manufacturing, automotive, and many more. The company’s machines are in operation worldwide, from the United States to Europe, China, and the Dominican Republic.

“Some of our latest machines include one for a local business that produces critical parts for the aerospace industry and another for a manufacturer of medical devices used in hospitals and ambulances,” Elithorpe shares. “It makes you feel good when you’re making a machine that goes into something important like that.”

The company also focuses on developing automation that improves worker safety by reducing exposure to hazardous tasks. “A major challenge in manufacturing is dealing with processes that are hazardous for workers,” says Elithorpe. “We’ve developed an attitude that we’re not trying to replace humans with machines but rather move people away from tasks that could cause them harm. Let the machinery do the difficult work and free up the people for better work.”

Abacus Automation has consistently evolved to meet the demands of emerging industries. In recent years, the company has expanded into renewable energy, food production, and advanced material processing. These sectors require specialized automation solutions, and Abacus has leveraged its expertise to develop systems that increase efficiency and reduce waste.

“Our flexibility allows us to venture into new industries,” Elithorpe explains. “For instance, in the renewable energy sector, we’ve been involved in building automation for solar panel manufacturing. These machines help streamline production, making solar energy more accessible.” By broadening its reach, Abacus continues to adapt to the changing industrial landscape, ensuring its relevance for decades to come.

As automation technology evolves, Abacus Automation remains committed to staying ahead of the curve. One major trend is the shift from cam-driven equipment to electronically controlled and programmable systems. “Couple this with more vision systems and robotics, and it makes the equipment easier to adjust to customer needs. A lot of our customers want machines that can work for various product sizes and configurations instead of just one select product. The electronic route is more adaptable than a hard cam-driven machine.”

Another growing trend is the integration of automation with digital networks. “We see more customers who want to tie our machines into their networks so they can monitor them remotely,” Elithorpe says. “I suspect that data collection requirements will start increasing as well.”

The company is also exploring the use of artificial intelligence (AI) in automation. “AI-driven vision systems and predictive maintenance are game changers,” he adds. “By incorporating AI, we can create smarter machines that detect potential issues before they cause downtime. This helps our customers maintain efficiency and reduce costs.”

As Abacus Automation enters its fifth decade, the company remains committed to innovation while maintaining its personal approach to customer service. “What I believe sets us apart is our service,” Elithorpe states. “If a customer has an issue with a machine, they can call up and talk to the people who built it. We’re small enough to handle the small jobs but big enough to take on the large ones. Either way, every customer gets personal attention.”

With its commitment to quality, innovation, and customer satisfaction, Abacus Automation is set up for continued success. Whether developing groundbreaking solutions for new industries or refining existing processes, the company’s dedication ensures its impact on automation will endure for many years to come.

The post Ingenuity, Leadership, and Future-Forward Automation Solutions<p class="company">Abacus Automation</p> appeared first on Manufacturing In Focus.

Since 1990, Advanced Food Equipment (AFE), a manufacturer of premium quality cooling and freezing equipment, based in Ridgeway, Pennsylvania with facilities in The Netherlands, has emerged as an industry leader, empowering large commercial food processors to provide their customers with precisely the quality and standards they want.

Evolution of an industry
The cooling and freezing industry traces its origins back to 1820, when British scientist Michael Faraday produced a cooling effect by compressing and liquefying ammonia, and 1876, when German scientist Carl Von Linde finally developed an ammonia-driven system for making ice. But it wasn’t until after World War II that commercial walk-in freezers were introduced, making possible large-scale storage and freezing of perishable foods, gradually replacing traditional ways to preserve such as pickling, salting, and canning. At first, the results were far from perfect, with freezer-burned meat and fruit and vegetables that turned mushy when thawed.

AFE’s founder, Mike Webber, has had a long career in a still-evolving food industry, “with a focus on freezing, working for several different companies before deciding he wanted to start his own,” says Ryan David, AFE’s Director of Sales.

“His experience in the industry, before starting AFE, made him want to do something better because he saw a lot that could be improved in the cooling and freezing sector,” David explains, “From the beginning, the company has emphasized solving the needs of customers, with a focus on hygiene and quality, because Webber wanted to offer equipment that stood above the rest.”

Webber has remained active and involved in AFE, which began as a small family-owned operation and has since grown into a global player. Today, it is led by President Ben Brechtell, who came to the company in the 1990s as part-owner.

And the company’s scope has certainly grown. “We sell, install, and service the food processing equipment we manufacture throughout the U.S. and Canada; in Central and South America; in Europe; and we have some in Saudi Arabia, where an installation is happening now. There’s no geographical limit to where our equipment can be installed,” David says.

Cutting-edge equipment
AFE’s industrial freezers and refrigeration equipment adhere to CSA, USDA, and OSHA standards and exceed industry standards for health and cleanliness. They are carefully crafted from stainless steel, eliminating any joints or crevices that could trap food particles and thus inhibiting bacterial growth. The equipment also has HTST (high temperature short time) pasteurization capabilities.

“We work with several entities, including the American Meat Institute, who have come to our facility and evaluated our equipment from a hygienic and sanitary point of view, and they rated ours as the most hygienic they have ever inspected,” says David. “We want to make sure that food-related disasters don’t happen, and we’re proud that our ratings are so high. It’s something we hang our hats on, and we constantly look for ways to improve.”

Food processors in all sectors (beef, poultry, and pork; seafood; fruit and vegetable; pizza and pasta; dairy products; baked goods; potatoes, fries, and chips; and more) can choose from a wide range of applications to suit their specific needs.

Spiral freezers, designed for faster freezing and lower energy consumption, are available in three formats: the Packaged Spiral Freezer, which is available in single to multiple pieces that can be installed in days instead of weeks; the External Spiral Freezer, which is completely built offsite, and attached to the exterior of the facility with no special foundation or roofing requirements; and Site-built Spirals.

This latter solution is offered for installations where modular sections cannot be utilized and incorporates the same design methods. Also within the spiral family are Spiral Steamers, with varying cooking capabilities, and Spiral Coolers, providing ambient or conditioned cooling environments ideal for sensitive food products.

AFE’s IQF (individual quick freeze) Tunnel Freezers, including Belt Tunnel Freezers and Hybrid Tunnel Freezers, can handle a wide range of processes, and are ideal for processing small meat products as well as many varieties of fruits and vegetables.

The company’s Contact Belt Freezers, meanwhile, provide fast freezing times with minimal hydration, making them ideal for products like raw meat, seafood, candies, baby food, dairy products, fruit processing, and ready-to-eat meals.

Also available are energy-saving Multilevel Box Freezers, Plate Freezers—a thermally effective solution for food in packages or trays—and Blast Freezers. The AFE-30, the high-capacity, centrifugal evaporator fan on these freezers, draws air through the load to ensure even temperatures and is ideal for high-volume food preservation.

In addition to the cooling and freezing equipment, AFE manufactures Shakers, which are used for sorting products by dimension and length, aiming or orienting products, de-watering, de-fatting or degreasing of products, spreading or singling, sieving, grading, or dosing.

Efficiency and the environment
AFE’s engineers have implemented design features that are beneficial for customers, end users, and the environment.

The sequential defrost feature, for example, can save up to 30 percent in energy costs. As David explains, a freezer could have 10 coils or evaporators, manufactured from aluminum and magnesium to make them corrosion resistant, a concern because they change temperature often and can only run for so long.

To protect their life span, AFE’s design allows for one coil at a time to be isolated from the enclosure and shut down while it is defrosted, resulting in no lost production because the other coils are designed to handle the full capacity while one is out. This allows the freezer to operate for much longer periods.

With regards to cleaning, AFE has designed a CIP (clean in place) system, engineered to clean a very large area in a short time. It uses less water and detergent, ensures hygiene, reduces downtime and overall operating costs, and extends the life of the equipment.

The good news for any commercial food processing company is that they needn’t be an AFE customer to take advantage of this top-flight cleaning system, because AFE technicians can install an engineered retrofit CIP package into an existing Spiral Freezer or IQF Tunnel system from another manufacturer.

Reliable and timely service
AFE works with teams of service technicians located strategically throughout North and South America, managed centrally from its Ridgeway, Pennsylvania office, who carry out preventative maintenance as well as quarterly, biannual, or annual inspections and on-site freezing and chilling testing to ensure equipment is running optimally.

“But, much as we try to prevent issues arising, things come up that we need to respond to quickly,” David shares. “We recognize that time is money, especially in the food industry, so if a freezer is not working, it’s not making money for our client. We pride ourselves on quick response times, finding solutions, and being in constant communication with our customers to make sure we know what their needs are,” he says.

“There’s a misconception in the industry that AFE is typically more expensive than our competition, but if potential customers compare our equipment with our competition and review the value-added options we offer—the hygiene and the longer run times—then there’s no comparison,” he continues. In actuality, “AFE is less expensive because we offer more value in the long term. Return on investment is a big point of reference, and I like to point that out. As we move into the future, companies are paying more attention to hygiene and efficiency and longer run times. We see those trends happening now and we’re taking steps, using the newest technologies to run our freezers even more efficiently with longer run times so our clients can be even more profitable.”

On a personal note, he calls AFE “a great company to work for. With all the talk about food security, I take pride in being part of the process that can provide clean, safe, good-tasting food to the world,” he says. “One of the things that can get lost in the shuffle while we talk about the huge pieces of steel equipment we sell and install is that this equipment has a real impact on individual lives. I am happy to be working for a company that believes food security on a global scale is paramount.”

The post At AFE, Freezing Technology is Heating Up<p class="company">Advanced Food Equipment</p> appeared first on Manufacturing In Focus.