While initially, PMF manufactured specialty stainless steel products using a unique flow-turning process, under the leadership of Birger H. Engzell, the company expanded into components for jet engines, the food industry, and pulp and paper manufacturing, prompting a relocation to Williamsport, Pennsylvania in 1955, a move that helped launch Williamsport’s Industrial Park and set the foundation for PMF Industries.

In 1961, Engzell founded Precision Metal Forming (PMF) in Williamsport, leasing a 5,000-square-foot facility and setting the company up to grow quickly. The facility was expanded a number of times in the 1960s and 1970s to accommodate increased production and new equipment, and the company soon becoming known for precision stainless steel hollow-cone, cylinder, and ogive shapes serving the aircraft, food, filtration, and pulp and paper industries.

Leadership transitioned to Donald E. Alsted in 1982, and in 2001, PMF was acquired by principals John Perrotto and Ken Healy, with the remaining stock allocated to a PMF Employee Stock Ownership Plan (ESOP). This alignment of employee success with company growth fosters a motivated workforce.

Since the buyout, PMF has grown to 85 employees and over 175,000 square feet of manufacturing space, confirming its position as a leader with a bright future in advanced metal manufacturing.

“We’re committed to reinvesting in the company to best serve our growing list of customers,” says John Perrotto, President and General Manager. “We continue to bring on supporting processes to our niche—which is flowforming—and to do a lot of research and development. We’re always looking at new technologies. It’s all to do with the best way to manufacture a customer’s component.”

PMF’s 65-year milestone reflects its longstanding dedication to precision manufacturing, innovation, and strong customer partnerships, Perrotto adds. Since 1961, the company has become a trusted leader in flowforming and specialized metal forming for the aerospace, defense, energy, and industrial markets, with success driven by a skilled in-house engineering team, fully integrated manufacturing processes, and a hands-on, problem-solving culture.

“By keeping design, tooling, forming, machining, heat treat, and inspection all under one roof, PMF maintains exceptional quality control, protects customer confidentiality, and accelerates response times,” says Ken Healy, Executive Vice President and Director of Engineering. Additionally, with decades of technical expertise and a commitment to continuous improvement, PMF remains a go-to partner for complex, mission-critical components, perpetuating a legacy of craftsmanship, engineering excellence, and customer trust.

That trust is certainly enhanced by PMF’s in-house engineering team, a key strategic advantage that enables seamless collaboration between design, process development, and manufacturing. Working alongside machinists and operators, the engineers can accelerate problem-solving, improve communication, and optimize forming solutions. For customers, this means faster development cycles, higher reliability, and greater confidence in prototypes and final products. Sensitive designs and proprietary processes remain secure on-site, while PMF’s integrated approach ensures precision, consistency, and innovation, making the company a responsive and trusted partner.

It’s also important that PMF continues to emphasize investment and the development of supporting processes. “I don’t know of any other flowformer who is able to complement the flowforming process with the supporting process as we do,” says Perrotto. “These are processes that really give us the ability to produce the unique shapes and other products that customers are looking for.”

For example, incorporating heavy flanges within the flowforming process—a unique capability of PMF—is a result of PMF’s highly developed available technology as well as its extensive knowledge of manufacturing processes. “We also collaborate with our partners to come up with the best scenario; we just really work very well with our customers,” Perrotto says.

PMF actually works with its customers toward clear-cut, improved ways to make a part, adds Healy. “What are the areas they’re having problems with? Were they looking at trying to move from another vendor to PMF? What are some of the trouble areas we could re-engineer to make a better quality part for them?”

Once those questions are addressed, PMF handles everything from the initial quote to final inspection, keeping the customer fully involved. “We want them to be satisfied with what they have as a product,” Perrotto says. “That’s why our customers have kept coming back for more than 40 years.”

PMF also distinguishes itself from other contract manufacturers through its depth of expertise in advanced metal forming technologies, utilizing integrated manufacturing processes and rigorous quality control standards that serve critical industries worldwide.

“At the core of PMF’s capability is our proprietary flowforming process that achieves exceptional dimensional accuracy, uniform wall thickness, and superior mechanical properties, often eliminating the need for secondary machining or welding,” says Healy. Complementing these qualities are PMF’s deep drawing, hot spinning, press forming, and vacuum annealing capabilities, which can form complex geometries with a wide range of materials including stainless steels, nickel alloys, aluminum, and other specialty metals.

PMF’s fully integrated production facility provides complete in-house control over every stage of manufacturing, from raw material processing and forming to heat treatment, CNC machining, electropolishing, passivation, and finishing, an integration that ensures consistent quality, short lead times, and traceable production records that meet or exceed the most demanding customer and regulatory requirements.

Additionally, PMF’s engineering and tooling design teams collaborate closely with customers from concept through production, optimizing part design for manufacturability, cost efficiency, and long-term performance.

The company’s Nadcap-accredited quality systems and AS9100 certification reinforce its commitment to process control and continuous improvement. By combining decades of specialized metal forming experience, multi-process capability, and precision-driven manufacturing culture, PMF Industries sets the benchmark for technical excellence and reliability. The team’s continuous innovation and improvement in technological ability have paid off, and PMF Industries has grown significantly in recent years, driven by its advanced metal forming expertise and reputation for manufacturing precision-critical components.

“Leveraging our broad capabilities in flowforming, deep drawing, and precision machining, PMF is now being engaged by several of the industry’s top prime contractors to support next-generation defense and aerospace programs,” says Perrotto. “This includes the manufacture of rocket motor cases for military applications and high-pressure cylinders for commercial satellite and launch vehicle systems.”

This continued investment in technology, process development, and quality assurance has positioned PMF as a strategic supplier for complex, high-performance components and assemblies where reliability, strength, and dimensional accuracy are paramount.

Focused on expanding its market share through strategic investment in advanced manufacturing technologies and process innovation, PMF Industries’ technical roadmap includes increasing its in-house capabilities in heat treating, precision metal forming, and materials processing to enhance product performance and reduce lead times. In parallel, PMF is pursuing strategic partnerships with industry leaders to integrate complementary technologies—specifically carbon fiber overwrapping and additive manufacturing (3D printing)—with its core metal forming expertise.

These combined technologies will enable the production of next-generation hybrid structures that deliver superior strength-to-weight ratios, reduce lead time, and enhance design flexibility for aerospace, defense, and commercial space applications. With its collaborative engineering approach, PMF aims to deliver even greater value to customers and strengthen its position as a leading innovator in precision metal forming.

The company has also committed more than $7 million to expand its manufacturing capabilities in response to growing demand for commercial space components. This investment includes large-diameter spinning equipment designed to handle larger flow-formed cylinders, enabling the production of closed-end cylindrical vessels with precise material thickness.

Complementing this capability is one of the largest vertical heat treat spray-quenching furnaces for aluminum tempering in the industry, providing superior mechanical performance. Together, these state-of-the-art assets position PMF as a leading supplier of larger-diameter COPV (composite overwrapped pressure vessel) liners, supporting commercial space programs—strategic investments that underscore PMF’s commitment to advanced manufacturing, technological leadership, and the ability to meet the evolving demands of the aerospace and defense sectors.

Healy tells us that skilled labor shortages and delays in critical materials, necessitating careful planning and flexibility, remain a challenge in the industry; PMF, however, continues to deliver precision components 98 percent on time.

“The company has leveraged its in-house engineering and fully integrated manufacturing capabilities to overcome supply chain and staffing pressures, successfully supporting complex R&D programs and mission-critical production,” says Perrotto. “These achievements highlight PMF’s resilience, technical expertise, and commitment to customer success.”

In the coming years, PMF aims to expand its technical capabilities and manufacturing footprint with key milestones that will include advanced aluminum heat treating processes, large spinning operations, and hybrid manufacturing techniques.

“These will enhance the company’s ability to produce complex, high-performance components with efficiency, precision, and innovation, reinforcing PMF’s position as a trusted partner in the most challenging aerospace, defense, and industrial programs,” stresses Perrotto. “For the future, we’re always looking at coming up with the latest technical advances so we can enhance those processes.”

And, of course, he says, PMF will continue to place customer service at the forefront. “That’s one of the things that sets us apart: our ability to partner with our customers, helping them develop the best manufacturability of the products they’re looking to manufacture, and helping them research and develop that.”

The post Making Magic with Metal<p class="company">PMF Industries, Inc.</p> appeared first on Manufacturing In Focus.

Today, with approximately 50 employees across multiple California locations, Zemarc is using its anniversary not as a retrospective moment, but as a forward-looking platform. The company is expanding geographically, reshaping how engineering knowledge is developed and transferred, and responding to market volatility with faster, more flexible system design.

Zemarc’s 50^th anniversary will officially arrive in October 2026, with celebrations planned throughout the year. Internally, the milestone is being marked not by a single event, but by recognition of employee tenure, honoring team members with five, 10, 20, and even 30-plus years at the company. That focus reflects a core principle that has remained consistent since the company’s founding: Zemarc is, by design, an employee-first organization.

That philosophy has shaped not only how the company retains talent, but how it adapts during periods of economic instability. Manufacturing has faced extended lead times, shifting tariffs, supply chain disruptions, and unpredictable customer demand over the last several years, and Zemarc’s response has been to strengthen internal collaboration and decision-making rather than centralize authority at the top.

Employee-driven leadership structures now play a formal role in shaping the company’s direction. Two internal employee resource groups, the Customer Success Team and the Internal Resource Committee, serve as cross-departmental bodies that help leadership prioritize operational improvements and customer experience challenges. Rather than relying on a single executive viewpoint, Zemarc uses these committees to uncover issues early and align teams across locations. This bottom-up approach has become increasingly important as the company grows and diversifies its customer base, particularly in technically demanding sectors such as aerospace and space launch.

One of the most defining shifts in Zemarc’s evolution has been the deliberate build-out of a specialized engineering team focused on advanced applications. While the company supports a wide range of industries, aerospace has become a major driver of its technical development strategy.

Elizabeth Meyer, Principal Systems Engineer, describes aerospace engineering as fundamentally different from many traditional fluid power projects. Unlike repeatable industrial systems, aerospace and space launch applications often involve unfamiliar fluids, extreme temperatures, unique materials, and unconventional operating conditions. Engineers must adapt quickly and work directly with customers who may not be fluent in fluid power terminology.

“When you’re working with these newer space launch companies, it’s really important to be willing to try new things and push the boundaries of your knowledge,” Meyer says. “You can’t just fall into the same routine.”

Fluid power itself is a broad umbrella, encompassing hydraulics, pneumatics, and process gases. While these systems share common valving and control principles, each application introduces distinct engineering considerations. Zemarc’s engineering group spends significant time translating between customer language and system requirements, often educating client engineering teams along the way.

That educational role has become a competitive advantage, particularly as fluid power remains underrepresented in formal engineering curricula. Meyer notes that many engineers entering the workforce have little exposure to fluid power concepts unless they come from specialized programs or agricultural engineering backgrounds.

Zemarc’s engineering team is notable not only for its technical focus, but for its composition. The current engineering group is entirely women, a rarity in the fluid power and manufacturing sectors. Over the past year, the company added two new engineers, strengthening both its systems engineering and sales engineering capabilities.

The visibility of women in hands-on engineering roles has also influenced the company’s approach to internships and early-career development. Zemarc actively supports engineering internships, many of which have transitioned into full-time roles, and Meyer views these programs as essential to addressing the industry’s looming knowledge gap. “For engineering, some of these internships have led to jobs in the company,” she says. “Internships are incredibly important for getting this next wave of engineers.”

As veteran engineers across the industry retire, the loss of undocumented tribal knowledge has become a growing concern, and Zemarc has responded by investing in internal education and documentation efforts designed to capture experiential knowledge before it disappears.

One of Zemarc’s most influential initiatives is its Hydraulics 101 program, developed as both an internal training platform and an external educational offering for customers. Rather than focusing on individual products, the program emphasizes system-level thinking, how components interact, how applications drive design decisions, and how modern fluid power solutions differ from legacy systems.

Internally, the program supports continuous education across departments, helping sales and engineering teams align on application knowledge. Externally, it serves as both a customer education tool and a recruiting pipeline, attracting individuals interested in entering the fluid power field. “We realized this wasn’t just important for Zemarc; it was important for the industry,” says Lucy Chen, Director of Marketing.

The program also plays a role in correcting misconceptions about fluid power, particularly in comparison to electric systems. While electrification continues to grow, Meyer notes that hydraulics still excel in applications requiring high force, precise control, and durability in harsh environments. This educational emphasis has become increasingly relevant as Zemarc works with aerospace testing facilities in regions such as Mojave, where hydraulic systems are integral to test stands and validation environments.

Zemarc’s newest growth initiative, the opening of a ParkerStore™ in Lancaster, California, represents a targeted expansion aligned with industry geography rather than simple footprint growth. The Lancaster–Palmdale–Mojave corridor has become a hub for aerospace manufacturing, testing, and space launch operations, creating demand for rapid, localized service.

Leading the new facility is Branch Manager Jannett Andrade, who describes the Lancaster location as fundamentally different from a traditional branch. “We’re targeting to open Q1 of 2026, with an open house and a full team blitz,” Andrade says. “One of our main goals is to establish ourselves in the Palmdale–Lancaster area as a ParkerStore.”

The 5,000-square-foot facility is being built to function as both a warehouse and a storefront, complete with a showroom and point-of-sale system. The goal is to encourage foot traffic while showcasing not only Parker products, but Zemarc’s broader hydraulic and pneumatic offerings.

Opening a ParkerStore is not a routine expansion; it reflects a level of trust from the manufacturer, which grants Zemarc responsibility for the territory. Chen emphasizes that the decision was made collaboratively with Parker based on Zemarc’s track record of technical capability, investment, and customer engagement.

One of the Lancaster facility’s primary value propositions is speed. The store is being equipped with hose assembly and cleaning capabilities, supported by dedicated inventory to enable rapid turnaround. “We already have a crimper on site, and that’s going to be one of our biggest value-add services,” Andrade says. “We’re investing in inventory so we can assemble hose assemblies quickly and keep customers moving.”

The location is designed to serve customers who “needed things yesterday,” particularly in aerospace ground support, testing operations near Mojave, general manufacturing, equipment rental yards, and municipal service providers such as street sweeper fleets.

In addition to reactive service, the Lancaster team will emphasize preventive maintenance, a critical but often overlooked component of operational reliability. Zemarc will offer free on-site inspections, helping customers avoid costly downtime. “If you don’t maintain your system, it’s going to get very expensive,” Andrade says. “You end up down for a month or two waiting for a part you could have pre-ordered if you had seen the issue coming.”

Certainly, the company’s ability to deliver under pressure has been reinforced by strategic vendor relationships, particularly with U.S.-based manufacturers capable of customization and fast turnaround. One such partner is DMIC, a valve and manifold manufacturer that has supported Zemarc through periods of extreme supply chain disruption.

From an engineering standpoint, DMIC’s flexibility has been critical. Meyer highlights their willingness to machine customized manifolds and specialty valves, capabilities that are often difficult to secure from larger, more rigid manufacturers. “Being able to quickly customize something to fit customer specs has been really helpful,” she says, particularly in space launch applications involving unusual gases, temperatures, or materials.

Chen adds that DMIC’s responsiveness during tariff fluctuations and pandemic-era shipping delays provided stability when lead times elsewhere became unpredictable. The manufacturer also pursued additional certifications at Zemarc’s request, supporting applications in process gas and biomedical environments that require stringent cleanliness standards. These partnerships enable Zemarc to offer alternatives when a single supplier cannot meet customer needs, an increasingly important capability as manufacturers hedge against uncertainty.

Another major evolution at Zemarc has been the development of its Zemarc Power Unit (ZPU) program. Introduced two years ago, the program was designed to address a growing demand for fast-delivery hydraulic power units without sacrificing customization. Initially, adoption was gradual; over the past year, however, interest has surged. Meyer notes that Zemarc has completed more power unit projects in the last year than in the previous five combined, driven largely by customers who need systems quickly and are willing to collaborate on specifications to reduce lead times.

Traditional aerospace customers often require highly specific designs, while space launch companies prioritize speed and adaptability, and Zemarc works with both, helping customers understand where compromises can accelerate delivery without undermining performance. “We’ve been able to find happy mediums with them,” Meyer explains, enabling faster deployment while maintaining quality.

The ZPU program is supported by strategic inventory decisions at Zemarc’s Fresno facility, where commonly used components are stocked to enable rapid assembly. This approach reflects a broader shift toward responsiveness as a competitive advantage in manufacturing.

While sustainability is not positioned as a headline initiative, it increasingly factors into Zemarc’s engineering decisions, particularly through system footprint reduction and fluid selection. Custom manifolds, for example, allow engineers to consolidate components and improve energy efficiency over a system’s lifecycle. Meyer also points to a growing push for more environmentally sustainable hydraulic fluids, especially in coastal and water-adjacent applications such as space launch sites. These fluids can reduce environmental impact in the event of a spill but often introduce tradeoffs related to cost, viscosity, temperature sensitivity, and wear characteristics.

Rather than promoting one-size-fits-all solutions, Zemarc’s role is to educate customers on these tradeoffs and help them select fluids and system designs appropriate to their operating conditions.

Despite widespread enthusiasm for artificial intelligence across manufacturing, both Meyer and Chen are candid about its current limitations in fluid power engineering. The issue is not resistance to technology, but the lack of reliable data; much of fluid power knowledge exists as undocumented experience rather than published material, and existing textbooks are often decades old and fail to account for modern electrohydraulic and integration practices. AI tools, drawing from outdated or incomplete sources, struggle to distinguish between civil engineering hydraulics and mechanical fluid power applications. This reality reinforces Zemarc’s emphasis on documentation, internal education, and direct mentorship as the primary means of advancing expertise.

As the company enters its sixth decade, its strategy is defined less by scale than by depth. The Lancaster expansion, ZPU program, and educational initiatives all reflect a common theme: moving faster without losing rigor.

For Meyer, the most encouraging shift is the growing industry-wide recognition of the knowledge gap and the need to address it proactively. “We’re starting to see companies worry more about the long term,” she observes.

Zemarc’s approach suggests that the future of manufacturing will not be driven solely by automation or digital tools, but by organizations willing to invest in people and the difficult work of translating experience into shared knowledge. At 50, Zemarc is not simply reflecting on where it has been but actively shaping where fluid power goes next.

The post A Technology-led Approach to Serving Modern Manufacturing<p class="company">Zemarc Corporation</p> appeared first on Manufacturing In Focus.

But for that box to land on your porch (especially in one piece), a lot of steps needed to come together. And one step that probably never gets the attention it fully deserves is the conveyance system. When it comes down to production and packaging, it is conveyors that are crucial to keeping our supply chains moving.

Conveyors are much more than just a belt that products and packages ride along on; they are data-driven systems that monitor, label, and track inventory in real time. They also can weigh, divert, and inspect products as they ultimately get the package ready to go out for shipping.

It is also these systems that keep many businesses working, by reducing production bottlenecks and increasing the capacity of what a given business can produce. And conveyors work across diverse sectors, from food and beverage to healthcare to paper products.

These systems have grown in leaps and bounds over the past 40 years. One industry leader, Pack Air Inc., has been at the forefront of these changes and growth. “It’s very rare now for a customer to have a truly dedicated production line where there are no adjustments needed, just running one product all day long,” says Michael Sohn, General Manager for Pack Air Inc. “They need a conveyance system that can adapt from running individual wrapped products in the morning to a 12 pack in the afternoon and be capable of multiple other product configurations on the same line.”

To get a sense of how much this company has had to adapt to the innovations that have taken place in conveyance, we need to travel back to when Pack Air got its start: 1984. Back then, Van Halen and Prince were at the top of the charts and conveyor belts were pretty much just that—loops of rubber and fabric. They required a lot of maintenance and did little more than move an object from point A to point B.

Headquartered in Neenah, Wisconsin, Pack Air was innovative from the jump, starting with a focus on using air conveyors as a primary means for moving materials. While many companies at the time were fixed on the conventional rubber and fabric conveyors, Pack Air got its name from focusing on air conveyors. Air conveyors move objects along on a cushion of air, avoiding contact with a surface, something particularly important for delicate products. But these conveyors also had a good amount of power to move objects that can be very difficult to convey. For example, a single operator can easily maneuver a window or door assembly weighing 1,000 pounds on one of the company’s Air Tables.

The other major advantage of this kind of conveyance is that there are only two moving parts, the motor and fan, which means few things that can break down. In fact, many of these systems can last for over 30 years with very little maintenance.

“We still do use air,” Sohn explains. “We are unique in the conveying industry when it comes to all the different types of conveyance that we use—fabric belts, plastic chains, and metal chains—and we are one of the few that still uses air.”

But it was soon apparent to the company there was a need to branch out to meet manufacturing demand. That’s because conveyors were changing. From being long loops of belt that moved things along, they became integral pieces of the production line, tied directly to other manufacturing and production equipment. Then technological advances started to introduce smart capabilities like self-monitoring, high-speed cameras to identify damaged goods, and more autonomy through integrated robotics. Indeed, there’s a level of sophistication in this field that many consumers simply wouldn’t know about.

Conveyors have also played a significant part in Industry 4.0 developments, which have seen the rise of automation and smart machines. These developments came about alongside the advent of COVID and the subsequent “Great Resignation” or “Great Retirement,” which saw up to 50 million people leave their jobs between 2021 and 2022, making businesses look at new ways to automate.

“Prior to COVID, roughly 50 percent of our mechanical projects had some electrical scope to them. Today it’s probably closer to 80 percent that have electrical components,” says Sohn. That is to say, customers are automating to make up for the reduced number of workers available.

Since its early days, Pack Air focused on engineering and the technical aspects of customers’ facilities. But since 2019, the company has seen a notable uptick in technical support much earlier in the process, and in some cases, Pack Air provides technical expertise for customers that used to be available to them in-house.

An example of this is EVO, one of Pack Air’s solutions that can be adapted to almost all conveyance applications through an adjustable guide rail that allows for very quick changeovers from a single point with either a hand wheel or an automated motor. So, customers making a changeover from one product to another can do it in a matter of minutes instead of what used to take up to a full day.

But it’s not just selling conveyors that sets Pack Air apart from others in the industry; it is how the team arrives at a solution for each customer they work with. Pack Air’s customers are not experts in conveying, packaging, and material handling; they are experts in producing paper, food, beverages, and all other kinds of consumer and industrial goods. But without that critical step of conveying their products, the whole process would break down. That’s where Pack Air comes in. The company focuses on the root problem the customer is trying to solve, and this may not always be what they wrote in their spec.

As Sohn points out, “If you walk in some place and you say, I have these conveyors for sale and we’ll try to fix your problem by using one of our existing solutions, well, that’s not what we do.” Instead, his veteran engineers and technicians listen at length to the customer’s challenges and develop a unique system in response. “I want the customer to tell me their problems—what works with their existing system and more importantly, what doesn’t work, and how we can change that.”

A recent project for Pack Air was for a cheese manufacturer handling one-pound and three-pound bags of cheese. “They originally came to us looking for a one to three diverter. The cheese is already in the bags, and they were heading toward a strapper,” Sohn explains. “So, they take the individual bags and strap them together as value packs in either two or three packs.”

Pack Air was not making the drop filler or the strapper. Those pieces of equipment were provided by others. “But we were responsible to connect them and do our diverting operation. That requires us to be very familiar with how other manufacturers design their equipment as well,” Sohn notes.

At first, this may sound straightforward, but, like many projects Pack Air gets involved in, there are hurdles to get over. That included redesigning equipment into a very specialized piece of machinery, because the floor space needed a specific path to handle the packaging in a very confined space. “We essentially combined two machines, a one to three servo diverter and a right angle transfer, into a single machine that fit their layout, fit their rate, and did the job.”

And that is a big part of what makes Pack Air special. It is almost like engineering improv; the team is able to create custom solutions by taking standard product lines and fusing them together in a way that meets its customers’ exact needs.

Reaching a creative solution like this doesn’t just happen. It’s a process that starts early on, by understanding the customer’s process and listening to what they need to do. In the above case, “we actually said, ‘wait a minute, I don’t think this works,’ and we started asking more questions.” The questions led to the successful outcome. “The client needs to understand how important those questions are upfront,” says Sohn.

Looking ahead, he foresees an increasing need for specialized advice and a growing demand for more automation. “We always had to consider how a mechanical device was going to be controlled, but we weren’t always responsible for designing a control system,” he shares. Ten years ago, many customers would do that themselves, but that expertise is not available at a customer level like it once was. “What’s different today is that those experts are gone in the larger corporations, and they are looking to us for that responsibility.”

It is a challenge that Pack Air is only too eager to meet.

The post Conveyor Systems That Make Manufacturers More Agile and Efficient<p class="company">Pack Air Inc.</p> appeared first on Manufacturing In Focus.

LasX’s new PhotonX Lab, which opened in September 2024 at its headquarters, is intended to be a research and development hub for rapid, intelligent laser materials processing. To this end, the space boasts a variety of equipment including short-pulse infrared (IR) and ultraviolet (UV) lasers, high-power ultrashort pulse IR and green lasers, high-speed scanners, motion control, and low and high-powered carbon dioxide lasers, among other gear.

“PhotonX enables our engineers and customers to collaborate closely on next-generation applications across packaging, medical and life sciences, and aerospace and defense. The goal is simple: provide a space where new ideas can be proven quickly, evaluated rigorously, and scaled efficiently,” explains LasX President Ryan Falch.

The lab will enhance LasX’s ability to prototype, then test and validate various laser processes to reduce risk for customers, speed the passage of breakthrough products to market, and upgrade manufacturing performance, he adds.

There is no shortage of other developments beyond the PhotonX Lab. Probably the biggest single change since we last spoke in September 2023 for Manufacturing in Focus is “the expansion of our laser materials processing capabilities through the introduction of new LasX equipment platforms,” says Senior Development and Engineering Manager Ethan Dinauer, son of company Chief Executive Officer and Co-founder William Dinauer. “Over the past year, we have added near-IR, green, and UV laser technologies with nano-, pico-, and femtosecond pulse durations, delivering higher precision, faster processing speeds, and improved material compatibility,” he explains.

These changes have enabled LasX to deliver cleaner edges, tighter tolerances, more robust turnkey systems, and improved multi-material processing.

LasX’s new equipment platforms are designed to support three of the company’s main markets: fast-moving consumer goods (FMCG) and packaging—a category that includes everything from packaged foods and beverages to soap, shampoo, and toothpaste—medical and life sciences, and aerospace and defense.

While the company also serves the graphic arts, textiles, and automotive sectors, the three segments cited above “offer the highest growth rates… FMCG and packaging continues to represent a significant growth engine, driven by the demand for atmospheric control, easy-open features, mono-material packaging solutions, and direct-to-package laser marking,” Falch tells us.

For the packaging segment, he points to the new LaserSharp® Marking solution, unveiled in November 2024. Developed in partnership with consumer products giant Procter and Gamble, the LaserSharp Marking system offers multiple benefits: consistent, top-quality results even during high-speed production; design flexibility, even in areas that can be hard to reach; permanent, high-resolution surface marking; and a digital configuration that offers maximum agility in response to changing graphics and text.

LaserSharp Marking is also ecofriendly since it doesn’t use traditional shrink label and pressure-sensitive adhesive (PSA) materials, inks, or anything else typically utilized for label applications. LaserSharp Marking can thus reduce waste while bolstering clients’ sustainability initiatives, which is all the more reason why LasX is confident that the system will be a success.

“Within packaging, LaserSharp Marking is positioned to become one of the most dominant application categories in 2026, supported by major brand-owner initiatives around sustainable printing, variable data, and inkless marking,” Falch explains.

At the time of our previous feature, the company was gearing up for the launch of the Proton λ laser process controller (the second part of the product’s name refers to “Lambda,” a letter in the Greek alphabet). The controller has since been launched and proven to be highly successful, offering high-speed laser processing and superb resolution, and facilitating new raster applications (a type of pixel-based laser marking). Proton λ also provides fast laser marking (a process that places indelible images on materials) and can be incorporated into the company’s existing laser equipment lineup. “Since the introduction of the Proton λ controller, we have continued to strengthen our LaserSharp process control ecosystem,” Falch notes.

The company has also expanded “its portfolio of equipment platforms,” he continues. “These platforms serve as starting points for application-specific solutions across scoring, perforating, micro-machining, laser marking, and surface modification.”

These achievements are somewhat par for the course for a company that has been ahead of the curve for decades. LasX was founded in 1998 to fill a perceived gap in the manufacturing sector: “the lack of a flexible modular option for laser material processing” as the company’s website puts it. A year after LasX launched, it began to design and build industrial laser processing modules (LPMs), which are critical for processing flexible materials. LasX’s LaserSharp® Processing Module is key to its materials processing capability, along with intuitive LightGuide operator software.

Recent “software enhancements in LightGuide have improved recipe control, diagnostics, and integration with automation and vision systems,” Falch points out.

In 2022, LasX released a machine platform called FreshFocus, a pioneering laser system that perforated and laser scored packaging to make it both breathable and easy to open. Breathable food packaging has tiny holes that allow in oxygen, extending shelf life.

In 2012, LasX established a life sciences group with ISO 13485 certification. The group has full-service contract development and manufacturing organization, currently focused on applications involving thin-film laser converting and microfluidic technology.

Earlier this year, LasX announced it had made significant microfluidic modifications to biosensor electrodes produced by global medical equipment manufacturer, Linxens Healthcare. The modifications were intended to “enhance the functionality of our electrodes, enabling real-time continuous blood parameter measurements and expanding diagnostic possibilities,” explained Linxens in an article posted on the LasX website.

And LasX’s European branch, founded in 2016 and based in Germany, continues to thrive. “LasX has strengthened its European engagement by adding Clive Jacobs, Director of Global Strategic Partnerships, to lead key account development across the region,” says William Dinauer. “Clive works closely with our European Solutions Engineer, Hendrik Kleinfeldt, to support both the FMCG and packaging markets with a particular focus on our LaserSharp Marking initiatives.”

For LasX, leading-edge solutions are only part of the equation. The company has long emphasized the importance of excellent customer service. Among other measures, its ClearCut® service program offers a lifetime of enhanced customer support in the form of training, remote assistance, discounts on labor and parts, equipment performance checks, and upgrades to software. The benefits of ClearCut include optimized performance, avoiding unpleasant surprises through preventive maintenance, accelerated training, software upgrades, and a comprehensive maintenance plan.

Plans are afoot to make ClearCut even bigger and better. “Soon, we intend to expand the ClearCut program to offer on-site process support to help customers optimize recipes, validate materials, and accelerate production readiness and on-site and virtual operator training, allowing teams to become fully proficient faster,” says Falch.

LasX also offers a global solutions team made up of experts who assist clients in various ways. Sometimes, this assistance is focused on a specific project involving laser material processing or new manufacturing methods. Other times, the collaboration is broader-based and involves large firms that need outside help because their own internal development teams do not have the laser expertise.

The team is highly active and on an expanded mission. “The team now operates within a more focused execution model, aligning resources to our primary markets and adding new business development personnel to ensure we remain deeply connected to customer needs,” says Ethan Dinauer. “The global solutions team strengthens responsiveness, improves cross-functional collaboration, and ensures that every customer benefits from experts who understand both their industry and their long-term production goals.”

This strong emphasis on customer support reflects the company’s determination to be more than just an industrial laser systems provider. The idea is to provide solutions, which means offering as much assistance as needed. This inclusive, far-reaching approach has helped LasX stand out from competitors.

“LasX is unique because our equipment and contract manufacturing solutions combine intelligent laser processing, turnkey automation, and precision engineering into a single, performance-guaranteed ecosystem,” states William Dinauer. “The LaserSharp Processing Module and fully integrated LasX equipment platforms are engineered around each customer’s exact application. This includes process development, system design, automated material handling, vision/SPC (statistical process control), and lifecycle support, all delivered with the high reliability required for demanding commercial production environments.” It’s a formula that has served the company well since the beginning and will continue to fuel innovations in high-performance laser materials processing.

The post A New Lab and New Opportunities for this Leading Laser Company<p class="company">LasX</p> appeared first on Manufacturing In Focus.

Engage Technologies is the parent company of Squid Ink, which specializes in the manufacture of industrial inkjet printers and high quality inks; Eastey, a leading manufacturer and supplier of heavy-duty shrink packaging equipment and automated case-sealing systems; and American Film and Machinery (AFM), which provides reliable shrink sleeve labeling equipment, shrink sleeves, and tamper-evident bands.

Through these entities, Engage Technologies develops new products, solutions, and efficiencies for manufacturers everywhere with comprehensive packaging systems—which include coding and marking solutions for traceability, case sealing and shrink packaging equipment, shrink sleeve labeling solutions, and automation systems—that set the bar for technical, financial, and environmental performance.

Investing in success
Engage Technologies Corporation’s success is no lucky accident. Over the last decade, the company has more than doubled in size, capacity, and impact through strategic investments in its physical presence in Minnesota. With a new Eastey production facility in Big Lake Industrial Park, HVAC upgrades at its Brooklyn Park headquarters, and more than a million dollars of investment at its Squid Ink facility in the last six months alone, company leadership continues to identify ways to bolster capacity and streamline efficiency and throughput. “We’ve invested heavily in all of our plants, in particular our Squid Ink fluids production facility,” CEO David Mylrea shares.

Investments include a new pail filler to optimize efficiency across the ink manufacturing operation, as well as new forklifts and hydraulic pallet lifters. Additionally, a new ink mill for grinding pigments was a costly but value-rich investment. What used to take days is achieved in hours, yielding a more consistent quality and better pricing for customers, a win for everyone.

According to Chief Operating Officer Dan Pint, these improvements are the result of the Kaizens the company conducts yearly to identify process improvements, which also extend to customer service. “We did a big Kaizen on customer service last year, which helped identify several opportunities and improved our process there. So, it’s not just in the manufacturing area, but also in the office to help us improve efficiencies everywhere,” he says.

Further, Engage Technologies is investing in IT upgrades and training to improve operational efficiency across its footprint, identifying ways to integrate new technologies and automation into its facilities.

“Bigger, faster, stronger”
To be sure, Mylrea and the team at Engage Technologies expect great things. “As technology evolves along with access to artificial intelligence, everybody’s looking for ways to be more efficient. ‘Bigger, faster, stronger’ not only speaks to the National Football League, but also the packaging industry,” he says. Big changes in next-generation printing and packaging systems are in the pipeline, he tells us, and October’s Pack Expo 2026 is sure to be action-packed.

Through its own feedback channels and trade shows such as Pack Expo, Engage Technologies monitors industry reaction to ensure that it meets market needs while remaining competitive with the best possible products and innovations at the best possible price. This is also true of the company’s commitment to the environment, such as its high-resolution printing system that can serve as a labeling replacement, effectively replacing the need for labels, adhesives, and other consumables by printing directly onto the surface, resulting in superior resolution and less environmental impact.

Engage Technologies is also navigating an increasingly complex market due to the imposition of tariffs, but thanks to extra inventory, strong relationships with suppliers, and new sourcing agreements, it has shouldered the brunt of the uncertainty so its customers don’t have to.

Raising the bar
Of course, product development is a continuing characteristic of Engage Technologies’ engineering, and its equipment is designed for efficiency and is built to last. “We’re always looking to develop and release new products,” says Chad Carney, Vice President of Marketing and Corporate Communications. “Last year we released six new products—three packaging and three coding and marking products—and this fall, five new products.” The new releases included some real game changers for the industry.

One such innovation is Squid Ink’s CoPilot Max LT, which features a 2.8” print height per printhead and offers 360 dots per inch (DPI) resolution compared to the industry standard of 180, and does so at an impressive print speed of up to 440 feet per minute.

With oil, solvent, and UV ink capabilities and long throw capability up to 12 millimeters versus the industry standard of five millimeters or less, the design is such that it protects the printhead, compensates for poor material handling, and results in improved print quality, truly revolutionary for industrial ink jet printing which typically needs to be closer to the surface being printed on.

As Carney notes, “We’ve been able to integrate new technology that allows the user to print from up to a half inch away from the product, which is really revolutionary for an inkjet.” This helps manufacturers compensate for contingencies or imprecisions in their process while still achieving 360 DPI at up to 440 feet per minute.

Ribbons redundant
Similarly, Squid Ink’s SQ-UVT Laser Marking System has been designed to replace thermal transfer overprint (TTO) for flexible film and single-serve packaging. The laser marking system leaves a permanent mark without the need for consumables like ribbons, reducing the need for inventory orders and downtime for ribbon changes, breakage, and wrinkling, bringing lower ownership costs and optimized uptime.

Eastey’s ECB25A is another innovative product that will change the way Engage Technologies’ customers operate. With no tray or supportive material needed, this shrink-wrap bundling system for multi-packs of unsupported products helps to control weight, process, and costs. The ECB25A can wrap bundles up to 11” tall and 20” wide at up to 25 bundles per minute, thanks to a servo-controlled pusher and seal bar that enable precise movement and throughput.

“We’re using cutting-edge technology,” says Carney. “It has a large, full-color touchscreen with remote access, so if the user needs to troubleshoot it from afar, they can. We can actually dial into that system from our facility, if needed, or distributor service personnel can do that and help the client troubleshoot whatever they’re dealing with.”

Likewise, Eastey’s VSA1825 Auto L-Sealer/VST1710 tunnel for fully automated shrink wrapping can wrap and seal products up to 7” in height and with a seal area of 18 x 25”, running up to 35 products per minute. Available in painted or stainless steel base, it can be used for food applications and many others that require a simple setup and reliable throughput at a competitive price, making it a highly popular selection for manufacturers across sectors.

And finally, AFM’s latest AutoBandit and Manual Bandit systems round out Engage Technologies’ newest offerings. The automatic tamper band applicator replaces hand-applied pre-form bands using automatic or semi-automatic machines that can run up to 30 products per minute (depending on size).

Each of these unique products helps reduce labor and costs in terms of both time and consumables, with less inventory to maintain and greater productivity.

Best in class—and culture
Engage Technologies isn’t just best in class when it comes to its packaging solutions; it is best in culture, which has been validated time and again with the recognition of being named a Top Workplace in Minnesota for five consecutive years by the Star Tribune, based on employee feedback.

“We’re working really hard to improve this culture of not just serving customers, not just looking outward, but also looking within the company to see if there are things we can do internally to improve,” says Mylrea.

These accolades and internal efforts to boost the work environment through competitive wages, benefits packages, and a deeply rooted commitment to innovation help secure the top talent needed to drive the company’s activities, including those product development and process investments that test every boundary. From Carney’s perspective, there is a genuine pride in excellence that permeates the company: “We all know as employees that we can make an impact on the customer experience every day, and we all take pride in making that a positive experience.”

This also helps to position Engage Technologies as an employer of choice in a highly competitive talent market, able to attract the caliber of mechanical and electrical engineers and others who can help the company grow its product offerings and market penetration.

Looking ahead, it will likely be more of the same for Engage Technologies—more innovation and continued excellence, whether that be from a product development, performance, or service standpoint. In doing so, this company will continue to make its mark on the packaging industry.

The post Great Products Go Further with the Right Engagement Strategy<p class="company">Engage Technologies Corporation</p> appeared first on Manufacturing In Focus.

When he decided to go his own way in his own company in 2013, Applegate researched everything from available web addresses to search terms and marketing. Although undecided on a company name, he knew he didn’t want ‘plastic’ to feature because it was too generic. “But if somebody understands the term ‘injection molding,’ they know what they’re buying,” he says.

For his Texas-based, regional service business and contract molder, Applegate acquired several URLs with ‘Texas’ in the name before selecting the one that fit his vision and mission: Texas Injection Molding. A plus was that the name would suit a company that was to be marketed through the internet rather than a sales force, a decision of his that would prove extremely successful.

“We have had more inquiries than capacity, and that’s how we’ve continued to grow: build more buildings, buy more machines, and expand more than 10 times in the first decade,” says Applegate. “That strategy has been great, and not having outside sales resources is a unique aspect of the business.”

Although CEO from the start, Applegate’s recent transition to “Chief Encouragement Officer” came after Texas Injection Molding received investment from private equity firm Blackford Capital last November. The influx of capital will enable the company to expand further and access Blackford’s wealth of experience “in identifying and integrating acquisitions,” the company says.

Says Blackford CEO Martin Stein, “We have been impressed with Texas Injection Molding’s engineering capabilities, tooling, and resources, and are excited to partner with the team as they take advantage of the many opportunities available in Texas today. We will look to support the business growth across Texas and other high-growth regions across the country by leveraging our industry and regional experience with Lubbock, Texas-based Industrial Molding Corporation. We’re thrilled to have another investment in Texas, and we’re excited to grow this fantastic business and team.”

Texas Injection Molding’s current management team will remain in their roles, and Applegate is eager to embrace his new position. When he originally purchased the company, Applegate’s dad, Steve, was his greatest champion. Confident in his son’s abilities, Steve not only supported his son morally but also financially, offering to invest 10 percent in the business. Jeff was initially reluctant to accept because of the possible risk, but Steve insisted. “It was wonderful, because not only was it a good financial investment for him, but it gave us something to share and talk about,” says Jeff. “He was my chief encourager.”

Although retired, Steve dedicated his time to helping his son, researching information about injection molding, markets, potential customers, suppliers, and more. “Anybody who knew him knew he was a chief encourager, building other people up. My job description is to help customers and employees prosper personally and professionally. I moved from a coach to a cheerleader, and that’s where Chief Encourager comes through.”

As a sign of his appreciation, Jeff bought business cards for his dad, planning to give them to him for Christmas 2020. Sadly, he never got the chance, with Steve passing away during the pandemic just two weeks before Christmas. The cards bore the title he awarded his father: “Chief Encourager.”

A few years later, when Applegate invited Blackford Capital to come and help grow the business, Jeff took over his dad’s title and became Chief Encourager to the company himself.

Rooted in quality
ISO 9001:2015 certified, Texas Injection Molding currently operates 33 plastic injection molding machines from 55 to 1,350 tons. Serving a range of sectors including recreation and outdoors, food and beverage, medical and pharmaceutical, business electronics, energy, industrial, and safety, the company operates three shifts, five to seven days a week. Energy, construction, commercial and home components, and components for the air conditioning industry account for a considerable part of the business, and the company has also seen some re-shoring, with manufacturers bringing components back to America—and Applegate expects to see more.

“I feel that now is the most optimistic I have been about manufacturing returning to the United States,” he says. “You are seeing it in the news, the commitments to invest in the U.S.”

Along with some foreign companies in automotive moving manufacturing to America—especially in the economically inviting southern states with their available labor, lower taxes, and other incentives—Applegate has seen investment in data centers, solar power manufacturing, and other industries. “That’s where we see the opportunities for us to expand beyond Texas and do what we do in areas where there is growth,” he says.

Building a reputation for quality products and timely, professional services, Texas Injection Molding primarily serves industrial OEMs and suppliers of components to other manufacturing companies. On the smaller side of things, the company’s components include grommets or bushings of just a few grams in weight, while larger products include lane delineator curbs bolted to the ground weighing 10 to 15 pounds, large caps covering underground storage tanks holding natural gas or propane, and restaurant grease traps.

Other products include airflow regulators for the air conditioning sector, small valves for soda dispensers, nozzles used on pump ends to thicken food for patients, blow molding of sharps containers for used needles, water meter covers, and even decorative nameplates for companies like Amana and Goodman.

Points of difference
What differentiates Texas Injection Molding from its competitors is that this is much more than just a molding business. Many molding outfits offer nothing more than just ‘shoot and ship’ (which is what it sounds like). In contrast, more than 80 percent of Texas Injection Molding’s products undergo additional operations like assembly, printing, welding, and machining, Applegate estimates. The company even performs contract manufacturing, combining other components, such as springs and screws, with their own molded parts to provide customers with fully manufactured products, including combined subcomponents, which are assembled and packaged in customer boxes. “Contract manufacturing is a differentiator for us,” says Applegate.

And, in addition to injection molding, the company provides a number of value-added services. One example is weighted exercise vests; the company manufactures small plastic containers, fills them with measured lead shot to add weight, and welds on the top.

“We’re pretty entrepreneurial—looking at opportunities, figuring out how much value we can add, and asking how we can be more than just a plastics supplier,” Applegate shares. “‘Can we be a strategic partner in manufacturing your product? How much can we do to support you?’ We find places where we can create additional value and be more than a supplier of single products.”

Indeed, customers often approach the team with designs, and the company will offer design for manufacturing services. These include suggesting ways to save money, the most suitable materials—whether nylon, ABS, or polycarbonate—and suggesting a radius instead of sharp corners, where suitable, to make products stronger. The company also works with recommended expert designers in injection molding.

The place for people
The company has a staff of about 200, many of whom are long-timers. And while skills are certainly important, Applegate says that in an intensive operation like this, respect for one another is paramount. Manufacturing around 450 different parts using approximately 120 different materials, and running about 30 different products every day, Texas Injection Molding is a fast-moving operation responsible for millions of parts every month.

“If I can get my employees and team to respect and care for each other, they will care for everything else, including the building and the products they’re producing,” says Applegate. “Dedicated people stay because they feel they are cared for, part of a team. When things get tough, they will stick around. The difference between a good company and a great company is the culture.”

This dedication saw the company win Plastic News’ Best Places to Work 2025 award. For the award, employees were surveyed through an independent company and discussed everything from work environment to opportunities for advancement, compensation, benefits, culture, and how they compare to industry peers.

Building for the future
Operating from a 90,000-square-foot location, Texas Injection Molding continues to grow and plans to add three more machines in 2026. With the help of Blackford Capital, the company intends to expand in the southwest and southeast, essentially building a regionally positioned injection molding resource to cover the entire southern half of the United States.

“Our strategy is people, process, and technology: have great manufacturing processes; give them the technology to do their jobs,” Applegate says.

“But the differentiator is when you can wrap people, process, and technology in culture, where people genuinely respect and care for one another. Then you’ve got something special.”

The post Made in America With a Big Helping of Encouragement<p class="company">Texas Injection Molding</p> appeared first on Manufacturing In Focus.