18.5_OL FULL MAG

CASCADE DIE CASTING GROUP • PROFILE

CASTING THE NET called Interlake, giving the company a truly
WIDE national presence with facilities now in High
Point, N.C., Dallas, Texas, and Los Angeles,
With customers that range from Jeep to Bose, Calif., as well. For the next 14 years, the com-
the Cascade Die Casting Group die casts a large pany continued to evolve itself along with the
variety of die casting parts from a broad spec-
trum of industries, including: Cascade Die Casting produces casts in both
zinc and aluminum material forms as each
• Class A decorative castings; metal provides different advantages
depending on the industry.
• Mirror brackets and inner bases;

• Thin-wall electrical enclosures;

• Transmission/transaxle components;

• Engine covers;

• NVH brackets;

• Electronic heat sinks and housings;

• Compression/pump components;

• Power tool components;

• Medical and dental components;

• Seating frames and components.

west of Detroit, where the heart of America’s
automotive industry lies. “By setting up shop
in Grand Rapids, Ted was able to quickly grow
the company, taking the business from a small
supplier to a mid-size player in a relatively short
period of time and putting the Cascade name
on the national map.”

Shaping a Business

Several years later in 1985, Hohlman, seeing
the potential of his company in the face of
growing demand, made the decision to acquire
three additional casting plants from a company

INDUSTRY TODAY 99

PROFILE • CASCADE DIE CASTING GROUP

EXPERIENCE THE DIFFERENCE changing needs of the automotive market and
beyond, expanding their services to a number
FURNACE REBUILDS, RETROFITS, AND TURNKEY of other industries as well. “In 1999, however,
REFRACTORY WORK ARE OUR “SPECIALTY” we found that most of our customers had either
shifted to the east coast or were already there,
Specialty Foundry Products, Inc. and from a facility standpoint it simply didn’t
1130 Raimund Muscoda Road, Bessemer, AL 35020 make sense to continue to operate out of our
locations in Dallas and Los Angeles,” says Tor-
Ph- 1-205-424-0307 / Fax- 1-205-424-7005 chio, who’s been with the company since 1988.
Greg Brown, email: [email protected]
Ted Kostilnik, email: [email protected] And it’s been better off as a result, as Cas-
cade stands today as a corporation that employs
www.specfoundry.com nearly 250 individuals and generates over $36
million annually from its three zinc and alumi-
100 INDUSTRY TODAY num casting facilities in Grand Rapids, Mich.,
and High Point, N.C.. Although with this level

With customers ranging from Jeep to Bose
Cascade Die Casting offers a large variety of
die casting parts.

CASCADE DIE CASTING GROUP • PROFILE

“Here at Cascade, we provide the expertise needed in high pressure
aluminum and zinc die castings for the automotive and commercial

industries in North America,”

of success, the question begs itself, ‘Just what Class A decorative castings, to NVH brackets
kind of casting solutions does Cascade provide?’ and engine covers. “We’ll make the castings,
machine them, test them so they’re ready for
“Here at Cascade, we provide the expertise assembly and then send them off to a tier-1
needed in high pressure aluminum and zinc die supplier,” Torchio says, continuing, “and while
castings for the automotive and commercial in- nearly all our components are highly regarded,
dustries in North America,” he says, adding, if I had pinpoint a particular product we’re per-
“From the beginning of the process, to the end, haps known the best for, it’d definitely be our
we deliver the high-integrity, quality finish, and side view mirror bases, which we manufacture
value that our customers demand.” for both passenger cars and trucks.”

Automotive Ally In fact, Cascade is the leading manufacturer
of side mirror bases—the component that at-
With regards to the actual products they cast, taches a car’s side view mirror to the door and
Cascade can produce a wide variety of parts, holds it in place—for America’s automotive
including everything from mirror brackets and

INDUSTRY TODAY 101

PROFILE • CASCADE DIE CASTING GROUP

industry, and makes such components available own benefits for the industries it’s destined for.
in both zinc and aluminum material forms. “Zinc die casting products can last many years,
Torchio says that they provide many of their and beyond that customers are getting a prod-
casts in both versions, as each metal provides uct with a high yield and impact strength, ex-
different advantages depending on the industry tremely tight tolerance capability, and reduced
and the needs of theirs customer within such. casting cycle time,” he says, adding, “It really
offers the best value if we’re talking about Class
“The lightweight property of aluminum A and decorative applications.”
combined with its remarkable strength make it
ideal for increasing safety by reducing mass in Strategic Production
many applications, and its place in role cast-
ing is extensive,” he says, continuing, “It’s also The ability to perform both aluminum and zinc
recyclable, making it particularly well-suited die casting allows Cascade to meet the needs of a
for the transportation, medical, and electronics diverse set of customers, but none of this would
industries where ‘efficiency’ is demanded in a be possible without the company’s steadfast
number of different ways.” commitment to high-quality, reliable manufac-
turing that lies at the foundation of its success.
Zinc die casting, on the other hand, offers its

102 INDUSTRY TODAY

CASCADE DIE CASTING GROUP • PROFILE

“Supporting our ability to offer our assistance and services to our
customers from the first step in the process to the end, is a

manufacturing presence focused on quality and efficiency, anchored by
a talented and dedicated workforce.”

“Supporting our ability to offer our assistance success that doesn’t look to stop growing any
and services to our customers from the first step time soon. And the company isn’t sitting back,
in the process to the end, is a manufacturing but rather putting their weight behind it, evi-
presence focused on quality and efficiency, an- denced most recently by their decision to ex-
chored by a talented and dedicated workforce.” pand their facility in High Point. The move,
which features a $6 million investment and
Location is just as critical for Cascade, as while looks to create 25 new, full-time jobs over the
their aforementioned facilities in Grand Rapids, next two years and speaks to the company’s en-
Mich., are close to Detroit, their facility in High thusiasm about their future in the area.
Point is also in a strategic spot as well, given the
heavy concentration of America’s automotive “In addition to the deep-seeded automotive
supply chain in neighboring Tennessee. supply chain in Tennessee, many of the major
OEM’s are either shifting or opening up addi-
All of these aspects of Cascade Die Casting tional operations down south, and we felt an in-
Group have combined to create a snowball of vestment like this would greatly strengthen our
ability to support such going forward,” Torchio
says. He adds that while they considered open-
ing up a new location in a state down south or
even in Mexico, the assistance provided by the
High Point Economic Development Corpora-
tion was what ultimately led to them staying
and expanding their existing facility instead.

Keeping an eye on the future is key for any
company’s sustained success, and Cascade looks
to be aggressively addressing such, despite its al-
ready strong current position in the marketplace.
And with a corporate philosophy that takes an
uncompromising stance towards anything but
producing the best value, the name Cascade will
continue to serve and impact companies of all
types for many years to come.

INDUSTRY TODAY 103

PROFILE • SURFACE EQUIPMENT

104 INDUSTRY TODAY

SURFACE EQUIPMENT • PROFILE

2015 marks the 30th anniversary of the founding of Surface Equipment
Corporation, one of North America’s leading designers and fabricators
of pressure vessels and other process-related equipment. Based out of Kil-
gore, Texas, the company is recognized for not only their quality and
efficiency, but their ability to customize and successfully take on “out-of-
the-box” projects for their customers as well. Jeremiah Weekley, director
of sales for Surface Equipment Corporation, discusses the wide range of
services his company provides, the industries they impact, and why, in
recent years, bigger truly has been better. Steve Engelhardt reports.

INDUSTRY TODAY 105

PROFILE • SURFACE EQUIPMENT

urface Equipment Corporation began cator, who was later acquired by them.
back in 1985 when Bart Owens, a Having been acquired by a major manufac-
chemical engineer at the time, decided
to purchase a small fabrication shop in Kilgore, turer, Surface’s capabilities and overall footprint
Texas. Having already established himself as an grew significantly. “After the ITP acquisition,
engineer in the oil and gas industry, Owens got we really took on a new identity, as they inte-
his business started by doing work for local gas grated a lot of their pressure vessels designs into
companies in the area and quickly grew its rep- our workload and invested in a bigger facility
utation to the point that it attracted the interest so that we could compete at a higher level,”
of the ITP Group, an Italian-based global fabri- says Weekley, adding, “This period really de-
fined what has become backbone of Surface

106 INDUSTRY TODAY

SURFACE EQUIPMENT • PROFILE

Equipment Corporation’s offering today.” becoming an independent company once again,
Some years later, the ITP Group, amidst Surface was able to better hone in on our core
strengths, and it proved to be a smart move,
some financial trouble, decided to sell off Sur- as much of our business today lies within
face Equipment Corporation to local investors, fabricating mid and large size vessels for North
allowing it to evolve itself even further. “After

“Slug catchers have become a bit of a specialty with
respect to our offering, and when it comes to the size

we are capable of, the bigger the better.”

INDUSTRY TODAY 107

PROFILE • SURFACE EQUIPMENT

America’s natural gas sector.” “We don’t view ourselves as
merely a fabricator, but rather
Engineered Equipment as an innovative partner that
can take you through the entire
But to say that Surface simply fabricates pressure process from start to finish, deliv-
vessels wouldn’t do justice to the wide range of ering the solutions you need each
services and processes they are capable of, or
the quality they achieve within each and every step along the way.”
product they make. “We have a full engineering
staff capable of designing and fabricating a wide
range of products, including pressure vessels
and process related equipment like scrubbers,
dehydration systems, 2 and 3 phase equipment,
slug catchers, sand separators, amine systems
and other related equipment.”

Weekley says that while they ensure the same
quality and durability in each and every one
of their products, perhaps their most popular

WISHING A HAPPY ANNIVERSARY equipment to manufacture are their slug catch-
TO SURFACE EQUIPMENT! ers. And this says a lot, given the fact that slug
catchers are responsible for the critical storage
Edmonton Exchanger fabricates a full range of pressure vessel of significant amounts of liquids within natural
component sizes, and features the most extensive one-stop gas pipelines. “Slug catchers have become a bit
pressure vessel head forming and shell rolling capabilities in of a specialty with respect to our offering, and
North America. when it comes to the size we are capable of, the
www.edmontonexchanger.com bigger the better.”

108 INDUSTRY TODAY Surface offers three different configurations
of these systems: single barrel horizontal, fin-
ger harp style, or double barrel harp style, with

SURFACE EQUIPMENT • PROFILE

each slug catcher is designed for specific appli- an enhanced alternative to larger buffer vessels.
cations. Single barrel horizontal catchers are Finally, finger type catchers provide an eco-
designed for small particle separation (10 mi-
crons) in areas where there is more liquid and nomical way to catch large slugs as well, and
lower gas flow. deliver predictable particle separation in sizes
of 50 microns and up. Because of their massive
Double barrel harp style catchers are designed size, these slug catchers are fabricated in sec-
for applications where there are high gas flow tions, and assembled in the field at the actual
rates and potentially large slugs, and provide project site. “All of these models have become
in high demand in recent years, with Surface
Surface Equipment fabricates mid and large delivering models for over 20 projects within
size vessels for North America’s natural gas the last three years alone.”
sector.

INDUSTRY TODAY 109

PROFILE • SURFACE EQUIPMENT

Fabrication Innovation with regards to our SLV facility, we can handle
just about any equipment demand, with a ca-
All of Surface’s slug catchers—and every other pacity that extends up to 700,000 pounds and
piece of equipment by extension—are fabri- anywhere between 14 and 16 feet in diameter
cated under the roofs of what has now grown depending on the project.”
to three separate facilities in Kilgore. “We have
divided our work into three different units, With this kind of capacity and process capa-
Surface Large Vessel (SLV), Surface Medium bility, Weekley says that one of Surface’s true
Vessel (SMV), and Surface Production Units differentiators amongst their competitors is
(SPU),” he says. their ability and willingness to take on “out of
the box” type projects. One concrete instance
Weekley adds that most of their major proj- of this came when the company took on a proj-
ects are handled at their SLV facility, with ect with Chesapeake Energy a few years ago,
smaller equipment fabricated at the other two. who was in need of a pressure vessel that was
“In our SMV facility, we have up to an 80,000 actually larger than anything Surface had ever
pound capacity and up to 8 feet in diameter
and delegate smaller, volume-based projects Work is divided into three units; Surface Large
to our other two shops,” he says, adding, “But Vessel (SLV), Surface Medium Vessel (SMV)
and Surface Production Units (SPU).

110 INDUSTRY TODAY

SURFACE EQUIPMENT • PROFILE

BIRD’S EYE VIEW: DOING BUSINESS WITH SEC

At Surface Equipment Corporation, each project begins with a project execution plan (PEP) that
outlines the equipment design, fabrication, and quality control process. Engineers can design
and model, complex processing systems including those with integrated ASME pressure vessels.
They can perform hydrostatic testing with pressures up to 13,000 psi supervised by an ASME
authorized inspector. Their in-house health, safety, and environmental representative ensures
that safety is built into the design and fabrication of all pressure vessels and processing systems.
They have assembled a team of expert engineers, designers, and fabricators to ensure that
every job they do is completed to the highest quality and safety standards with the most mod-
ern design and manufacturing tools available. They also have an international reach, and are
certified with the A2 stamp, Manufacture License of Special Equipment for China. Extensive
certifications include ASME Section VIII Division I & II, National Board of Boiler and Pressure
Vessel Inspectors U, U2 and R Stamps and AWS.

INDUSTRY TODAY 111

PROFILE • SURFACE EQUIPMENT

done before. “Chesapeake needed a vessel that order a million dollar trailer to deliver it, and
ultimately topped out at 500,00 pounds—a needed to temporarily shut down the interstate
piece of equipment whose weight exceeded not in Texas in order to effectively transport it,” he
only the capacity of our facilities, but most oth- says, adding with a laugh, “and you can be sure
ers in the region as well.” that out there, the whole event certainly turned
quite a few heads.”
He says that despite the colossal size of the
vessel, Surface took on the challenge, first But beyond the company’s open minded-
building it in two halves within their SLV ness towards projects, this particular example
shop and then completing final assembly out- demonstrated the commitment and depend-
side after renting a crane to lift the pieces of ability that Surface Equipment Corporation
equipment out. “The project was so big that brings to each and every partnership it enters
the freight company shipping the vessel had to into with a customer. And with the company

112 INDUSTRY TODAY

SURFACE EQUIPMENT • PROFILE

growing its presence in multiple sectors, in-
cluding offshore equipment manufacturing, a
fast expanding base of customers are coming to
understand this in many different ways. “We
don’t view ourselves as merely a fabricator, but
rather as an innovative partner that can take
you through the entire process from start to fin-
ish, delivering the solutions you need each step
along the way.”

With a highly skilled team of engineers every
job is completed to the highest quality and
safety standards.

INDUSTRY TODAY 113

PROFILE • VON ROLL

114 INDUSTRY TODAY

VON ROLL • PROFILE

Von Roll is a name that has been with us for over 200 years, and the
company has used this period of time to elevate and establish itself as one of
the world’s leading designers and manufacturers of electrical and thermal
insulation products, systems, and services for a number of different indus-
tries. Although the company has operations all over the globe, a major hub
of its success today lies within the United States market and its 20-year
presence here . Jonathan Roberts, General Manager and COO of Von Roll

USA, sits down to talk about an expanding level of success, and
sheds light on the factors behind his company’s ability
to deliver industry-leading insulating materials
on an annual basis. Steve Engelhardt reports.

on Roll roots stretch back to 1803
with the founding of the Eisenwerke
der Handelsgesellschaft der Gebrüder
Dürholz & Co. (Ironworks of the Commer-
cial Firm of the Brothers Durholz and Co.).
The name Von Roll came about when seven
years later the firm was taken over by Von Roll
& Cie, a newly formed venture by Ludwig

INDUSTRY TODAY 115

CONGRATULATIONS VRI

20th Anniversary

A great partner, past, present and future!

Coil Manufacturing, Inc.
940 Alton Parkway, Birmingham AL 35210
Toll Free: 1-w80w0w-2.9le9-g26e4n5dFcaxo: m(20p5a) 8n3i8e-s5m99n0 .wcwowm.cmicoil.com

VON ROLL • PROFILE

Von Roll is one of the world’s leading designers and manufacturers of electrical and thermal
insulation products serving a range of industries.

Freiherr von Roll and Jacob von Glutz. This self as a company and made the decision to ac-
marked the beginning of what would become quire Schweizerische Isola-Werke AG from the
an extremely diversified industrial company US-based Essex Group to enter into the global
and for the next 170 years or so the company electrical insulation market. Working to estab-
continued to grow, reaching an organizational lish partnerships with the industry leaders over
size of more than 10,000 employees by 1970. the next decade, including a deep-seated one
with General Electric (which continues today),
U.S. Arrival the company made the decision in 1995 to set
up an official presence in the world’s biggest
Following the economic crisis that plagued market—the United States—and bring their
much of the developed world during the mid- insulation business to the next level.
1970s, Von Roll decided that, in the wake of a
strong steel market rebound, it would evolve it- This decision was paired with the company’s

INDUSTRY TODAY 117

PROFILE • VON ROLL

purchase of GE and subsequently, Alstomin-
sulating materials division, which gave them
increased market presence and product tech-
nology, that paved the way to their initial and
sustained success in the U.S and the strengthen-
ing of their European presence. “After these ac-
quisitions, Von Roll began introducing unique
lines of insulation products, developed within
their research laboratories, which are capable
of testing insulating materials according to
international standards,” says Roberts, noting
his company’s global identity. Core business
product lines at the Schenectady site include
mica-based electrical insulation, liquids in the
form of resins and vanishes and flexible lami-
nates. In 2007, Von Roll continued to invest
in its core liquids business and purchased the

118 INDUSTRY TODAY

VON ROLL • PROFILE

COIL MANUFACTURING INC. well established and recognized John C. Dolph
company, located in Monmouth junction, NJ.
Coil Manufacturing Inc. (CMI) is a leading manufac-
turer of form wound coils to North America’s appa- Since then, the company has utilized its di-
ratus repair industry and beyond. Founded by six verse portfolio to provide leading insulation
employees in 1993 by current President Randy Rutter solutions for high and low voltage applica-
and VP Wendell Herrington (Ret), the company has tions, across a number of different industries,
grown to over 80 full-time employees and boasts an primarily focused on rotating machines and
expansive customer base of over 500 repair shops transformers.
throughout the United States, Canada, and South
America. The Mica and Resin Advantage
Headquartered in a 32,000-square-foot facility in
Birmingham, Ala., CMI offers its customers both the Although Von Roll offers a number of differ-
process capabilities and regional proximity to handle ent materials and solutions, including adhesive
a number of different needs. Between its AC and DC tapes, braided products, resins and varnishes,
departments, the company is able to manufacture all Roberts says that one of their “claim to fame”
stator coils up through 7,200 volts, as well as produce is their mica-based products. To clarify, the
large DC field coils and AC synchronous rotor coils, term “mica” is used for a group of minerals that
rotor bars, and DC armature coils. show perfect cleavage, sheets of silicate that can
CMI is certified in ISO 9001:2008-ANSI/ISO/ASQ Q9001-
2008 and presently engaged in longstanding rela-
tionships with industry leading insulation and wire
vendors like Von Roll. CMI brings an inherent com-
mitment to delivering first-rate quality and customer
support to each and every partnership it enters into.
Between its employee experience, operational effi-
ciency, and comprehensive service, CMI has the
industrial presence to deliver a wide variety of coil
solutions to their customers, when they need them.
www.cmicoil.com

INDUSTRY TODAY 119

PROFILE • VON ROLL

be transformed into a continuous paper-like corporated the new paper and products into
product and offers unmatched performance in our overall product line when we acquired the
insulation technology. “General Electric devel- insulation division,” he says.
oped a mica paper solution in the 40s and t
proceeded to design a new generation of insu- Roberts says that Von Roll’s commitment to
lating materials, based off of this new technol- mica based products, starts with mining, fol-
ogy. Acquiring the GE technology augmented lowed by very specialized methods of produc-
Von Roll’s overall line of mica paper manufac- ing paper from the mineral and finishing with
turing capabilities, which had been developed the production of highly specialized mica tapes,
by the Schweizerische Isola-Werke AG during
the same period as GE’s innovation. We in- Products include mica-based electrical
insulation, liquids in the form of resins and
vanishes and flexible laminates.

120 INDUSTRY TODAY

VON ROLL • PROFILE

rigid and flexible mica plates as well as mica Both motors and generators utilize mi-
ancillary parts. It’s this vertical integration that ca-based tapes and resins together in the insu-
makes Von Roll a market leader in the high lation systems design. Von Roll is unique in the
voltage motor and generator arena. “We utilize industry, in that they create, through chemical
two of the primary types of mica, phlogopite reactions, their own specific polymers to pro-
and muscovite, for a variety of applications, de- duce an extensive line of reactive resins to be
pending on the required thermal and electrical used in conjunction with the mica tapes, which
characteristics. In addition to products designed allows them to design unique electrical insulat-
for motors and generators, we also supply spe- ing systems. By understanding the exact chem-
cific materials designed for high temperature istry in the mica tapes and the resins used by
induction furnaces, automotive gaskets, cable their customer’s vacuum pressure impregnation
insulation to maintain circuit integrity during (V.P.I) process, Von Roll can assure chemical
fire conditions and heater plate, used as a stand- compatibility between the resin used to bond
off insulation, found in household appliances the mica tape together and the impregnation
like a regular toaster.” resin, supplied by Von Roll and subsequently

“This move demonstrates such, as not only are we tangibly upgrading
our operational capabilities, we are also sending a very strong message
to our partners and customers about our long term commitment to the

market here and our place in it.”

INDUSTRY TODAY 121

PROFILE • VON ROLL

All Von Roll’s facilities adhere to international class at which these materials can be used.
standards.
Expanding Footprint
added into the mica tape through the custom-
er’s V.P.I process. In addition, in their test Overall, Von Roll’s mica, liquid and flexible
laboratories at the Schenectady site, Von laminate products offer an advantage built
Roll can combine these materials and es- upon quality, completely integrated insulation
tablish through the use of internationally systems, technical support and an overall higher
recognized testing standards, the thermal level of performance than other options in the
market., This speaks to the company’s com-

122 INDUSTRY TODAY

VON ROLL • PROFILE

mitment to its customer base and to growing WHAT IS MICA?
and improving itself whenever possible. In fact,
Roberts says they recently unveiled a number of The dictionary defines mica as “A class of
new materials at the 2015 EASA Convention silicates having a prismatic angle 120°, emi-
in San Antonio, most notably, their new version nently perfect basal cleavage, affording thin
of their Corona Protection Package, a thin tape- tough laminae or scales, colorless to jet black,
like material that serves as a critical component transparent to translucent, of widely varying
within a high voltage insulation system. “When chemical composition, and crystallising in the
thinking about the space between an insulating monoclinic system”.

In brief, mica is a generic term applied to a
group of a complex aluminosilicate minerals
having a sheet or plate like structure with
different chemical compositions and physical
properties. All micas from flat six-sided mono-
clinical crystals with a remarkable cleavage
in the direction of the large surfaces, which
permits them to split easily into optically
flat films, as thin as one micron in thickness.
When split into thin films, they remain tough
and elastic even at high temperature.

What makes micas so important to command
such a unique position? Because it had been
gifted with exceptional values. It possesses
some of the most outstanding combination
of chemical, physical, electrical, thermal and
mechanical properties, which are not found in
any other product.

material and the iron slot of a motor or gen-
erator, you need a thin semi conductive layer
that provides intimate contact between both to
normalize the electric field between the two,
which is exactly what this does,” he says, add-
ing, “That’s important, because if there’s a gap
between the insulation and the steel slot, a

INDUSTRY TODAY 123

PROFILE • VON ROLL

That’s important because if there’s a gap between the insulation and
steel, a voltage spark can occur which can sabotage everything. With

this, you eliminate this gap and mitigate any stressors and spread
them elsewhere.”

124 INDUSTRY TODAY

VON ROLL • PROFILE

voltage spark (corona) can occur, which can and a consistent display of innovation over the
lead to a catastrophic failure of a high voltage years, Von Roll’s entry into the North Amer-
machine. With this corona protection layer, ican marketplace, twenty years ago, has been
you mitigate the electrical stress and prevent one largely characterized by consistent success.
the inception of the destructive corona energy. ” For this reason, in January of this year the
company announced a $21 million expansion
In addition to the new, enhanced Corona of their manufacturing plant in Rotterdam,
Protection Package, Roberts says they also N.Y.a move that spoke to their need for grow-
introduced a new insulating tape at the con- ing in their infrastructure, to accommodate
vention. “This tape is designed for traction increased demand. As part of the Schenectady
motors and utilizes new materials integrated strategic transformation and expansion plan,
with arimid fibers that makes it much more Von Roll is also consolidating the New Jersy
user friendly and efficient.” Roberts adds that facility to the NY site. Optimization of the Von
beyond their own product development, Von Roll sites and investments into their infrastruc-
Roll often works intimately with their part- ture and manufacturing equipment represents
ners like, Alstom and General Electric to assist a key global success element. In this context,
them with their advanced insulation develop- the consolidation of the American Liquids
ment programs . activities into the Schenectady site is a significant

With industry leading insulation systems

INDUSTRY TODAY 125

PROFILE • VON ROLL

126 INDUSTRY TODAY

VON ROLL • PROFILE

step towards integrating their manufacturing
capacities. By combining these operations, Von
Roll improves the overall utilization, produc-
tivity and competitive position, while stream-
lining their overall services. Von Roll’s liquids
business is one of their core business activities,
where they fully intend to invest efficiently
and grow significantly. The equipment invest-
ments, and creation of a single larger center
of competence for liquids in North America,
allows increased focus on product and process
innovation which are key to future success.“We
are extremely competitive as a company, and
we know one of the best ways to remain on top
is to adopt the best practices and equipment for
optimum efficiency and productivity,” Roberts
says, adding, “This move demonstrates that
we are tangibly upgrading our operational ca-
pabilities and sending a very strong message
to our partners and customers about our long
term commitment to the market and our stra-
tegic place in it.” The move was also moti-
vated by the company’s desire to consolidate
its resin and varnish manufacturing operation
from its facility in New Jersey. Roberts says
that all 155 jobs at the Schenectady site will be
retained, in addition to 18 new positions that
will be created in the near future.

It’s an exciting time for Von Roll, as the
company is hitting a new stride in 2015. “We
are an international company with a singular
identity, and we bring a tremendous amount
of knowledge and industry know-how to de-
liver unique solutions for each of our custom-
ers in the markets we serve.” he says.

INDUSTRY TODAY 127

PROFILE • NOR-CAL BEVERAGE COMPANY

128 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

Nor-Cal Beverage Company, a family-owned and operated business based
in California, provides contract manufacturing services for specialized
drink lines, as well as equipment solutions for customers ranging from
convenience stores to biotech labs. In addition, Nor-Cal produces and
markets Go Girl® sugar-free energy drink. David Soyka reports on Nor-
Cal’s most recent evolution as an independent bottler that has invested
heavily in new technologies to broaden its product lines to better serve its
customers.

INDUSTRY TODAY 129

PROFILE • NOR-CAL BEVERAGE COMPANY

aya Angelou said that, “Stepping tributorship. “It was a very good partnership
into a brand new path is difficult, for us, dating back to 1967, and we had grown
but not more difficult than re- that segment of our business,” explains presi-
maining in a situation.” dent and CEO Shannon Deary-Bell. “But we
The history of Nor-Cal Beverage Company wanted to concentrate on further developing
certainly attests to this. Over the course of its
78 year history, this California family-owned
company evolved from a small soft-drink
bottler to the largest independent beverage
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the industry. They have also made some tough
decisions about the direction of their business,
many of which required starting down a new
path.
The most recent case in point was the de-
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130 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

INDUSTRY TODAY 131

PROFILE • NOR-CAL BEVERAGE COMPANY

132 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

our production and contract manufacturing to develop new SKU’s and, in particular, their
capabilities (a business it first entered in the need to package tunnel pasteurized products.
1980s), and we had to make some hard choices
about how we wanted to allocate our resources. This manufacturing upgrade expands the
Therefore we decided to sell the distributor- Anaheim facilities’ capabilities for hot-fill, cold
ship to a local beverage distribution company. or ambient fill and tunnel pasteurized products
They hired most of our sales, delivery and ad-
ministration staff and the transfer closed last PROPERTY & CASUALTY
December.” EMPLOYEE BENEFITS

A change of an even greater magnitude is a PERSONAL INSURANCE
$25 million retooling of its Anaheim facility. RISK MANAGEMENT
Situated on 20 acres this facility was originally LOSS CONTROL
built to process concentrated orange juice and HUB International
was once owned by Bing Crosby and the Co- www.hubinternational.com
ca-Cola Company. Deary-Bell says that the in-
vestment stemmed from our customers’ needs Christopher J. Angelo

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pressurized volumetric filler located in the [email protected]
Nor-Cal Beverage Anaheim Ca. facility;

above: Go Girl Sugar Free Energy Drink is
owned and produced by Nor Cal Beverage
Co., Inc. Since its release date, Go Girl
Energy has grown to nine western states and
five flavors with no end in sight.

INDUSTRY TODAY 133

PROFILE • NOR-CAL BEVERAGE COMPANY

in a variety of can sizes. These new capabil- future lines. This includes a new dual-pass
ities are in addition to their current produc- RO water treatment system, energy saving
tion lines, which include chilled paper, chilled equipment and a complete recycling center.
plastic, aseptic, glass, PET, can and several tea In August 2015 we produced our first saleable
brewing processes. product on our new can line.

Currently, the two contract manufacturing End-to-End Solutions
facilities produce over 50 million cases of qual-
ity beverages annually. In addition, Nor-Cal has restructured its
warehouse/distribution network. “We have a
“We invested some $50 million in upgrad- 250,000 sqf. distribution center in Fullerton
ing our plant in West Sacramento back in and a 500,000 sqf. distribution center in West
2007 to meet our customer’s needs,” Sacramento. Both distribution centers offer
re-pack capabilities for our customers. We
Similarly, at our Anaheim facility we are provide our own transportation service, rather
implementing the latest technologies to im-
prove the efficiency and productivity of our Pictured right: Dual Pass R/O Water Treatment
processing, filling, packaging and labelling ca- System from GE Osmonics.
pabilities. We have also invested heavily in our
infrastructure to accommodate this line and

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134 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

INDUSTRY TODAY 135

PROFILE • NOR-CAL BEVERAGE COMPANY

ALL IN THE FAMILY

Nor-Cal Beverage was founded by Roy Deary in 1937 with four employees. Today it is in its third generation
of ownership. In addition to Shannon Deary-Bell at the helm, her father Don Deary is chairman of the board;
nine family members work for the company and two are active board members. It’s not surprising, then,
that Nor-Cal is a founding member of The Family Business Association, which represents California’s some
1.4 million businesses and provides incentives to create jobs and invest in the state.
The company employs 500 (and ramps up to around 650 during seasonal upswings). The majority of
employees have more than 20 years of experience. Deary-Bell notes this is well above national employment
averages, and attests to both employee dedication to a family business, as well as the family’s dedication to
develop and support the people who work for them. “They’re part of the extended Deary family,” she says.
She also points out that despite the company’s heavy investment in the latest technologies to handle pro-
duction, quality control and logistics, a real person always answers the company phone. “When customers
call, they can expect us to provide an answer as quickly as we can,” she says. “We pride ourselves on great
customer service, delivered with integrity. It’s a family tradition.”

136 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

C&L REFRIGERATION – IN THE than rely on third-party logistics suppliers.
BUSINESS OF COOL This enables us to provide a truly end-to-end
solution for our customers, a unique capability
As one of the largest and most com- that distinguishes us from our competition.”
prehensive Industrial Refrigeration con-
tractors in the Western United States She adds, “Nor-Cal is not typically your low
we meet the heating, ventilation, air cost provider. But we offer a range of capabili-
conditioning and refrigeration needs of ties that achieve the highest technical qualities,
customers in California and Southern backed by the most extensive expertise of any
Nevada and are proud to count the co-packer. In fact, we are the only ISO-certified
Nor-Cal Beverage Company as one co-packer in our territory, which is of signifi-
of them. With a commitment to cus- cant value to our customers and sets us apart
tomer service and a dedication to tech- from other co-packers. Our FSSC 22000:2010
nical excellence we deliver innovative, certification as well as thorough quality man-
responsive solutions that are second agement systems and processes ensure we meet
to none. For information on our full or exceed FDA standards for quality and food
range of capabilities visit our web site at safety, Hazard Analysis and Critical Control
www.clrefrigeration.com. Points (HACCP). Product traceability and

Pictured: Nor-Cal’s corporate offices are
located in West Sacramento, Ca. They also
own and operate a food service “Equipment
Solutions” business unit and brand owners of
the “Go Girl Energy” beverage.

INDUSTRY TODAY 137

PROFILE • NOR-CAL BEVERAGE COMPANY

recall programs are also in place. Our rigor-
ous practices enable us to meet the standards
for packaging organic, all natural, and kosher
products. This demonstrates our commitment
to ensure we deliver the highest quality service
and products that our customers can get.”

Socially Responsible

As a deeply rooted 78 year old California
based company, Nor-Cal understands the im-
portance to protect and preserve the climate
and environment. We work closely with local
and state government to conserve natural
resources and minimize our impact on the
environment.” Deary-Bell says.

Another example of Nor-Cal’s sense of so-
cial responsibility, as well as an example of

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Bay Area. We staff over 150 employees
throughout California, with multiple facilities
to better service our customer’s needs. Our
customer base is made up of many Industries
including wineries, food & beverage
companies, major distribution centers, and
a variety of manufacturing companies
throughout California.

138 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

another path that has branched in unexpected
directions, is its Go Girl line of sugar-free en-
ergy drinks. The brand was created in 2005
for calorie- and fitness-conscious women, with
a portion of profits donated to breast and
ovarian cancer research and related causes and
foundations. While the original intent was to
eventually take the brand nationwide, it re-
mains distributed for now within Nor-Cal’s
western territories. “It’s been an interesting ex-
perience for us as a manufacturing company to
extend ourselves as a marketing and branding
company,” Deary-Bell says. “And we definitely
have had a few stumbles along the way. We
learned there’s a big difference between know-
ing how to make something and knowing how
to sell it. However, we remain committed to

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INDUSTRY TODAY 139

PROFILE • NOR-CAL BEVERAGE COMPANY

the brand and we look forward to continuing
its mission to raise awareness and funds for
cancer prevention and treatment.”

Nor-Cal also provides equipment and main-
tenance solutions to the food service, retail in-
dustries, healthcare, biotech and institutional
industries. This includes sales and service of
beverage refrigeration equipment and sup-
plies, ice-making machines, freezers, coolers,
fountain systems, draught and glycol systems.
“It remains a good, dependable business for
us,” Deary-Bell says. “It will continue to be an
important part of our portfolio.”

Contract -packaging, however, is the largest

Pictured left: Nor- Cal operates state of the
art blending systems in both of their plants;

above: Nor-Cal provides a variety of
secondary beverage packaging options to
their customers in both plants.

140 INDUSTRY TODAY

NOR-CAL BEVERAGE COMPANY • PROFILE

A $25 million manufacturing upgrade expands the Anaheim facilities’
capabilities for hot-fill, cold or ambient fill and tunnel pasteurized

products in a verity of can sizes. These new capabilities are in addition
to their current production lines, which include chilled paper, chilled

plastic, aseptic, glass, PET, Can and several tea brewing processes.

business unit in our company. “Our customers industry to figure out how they can best satisfy
are constantly inventing new SKUs and they ever-changing tastes and the desire for some-
need a co-packer that can quickly and effectively thing different from yesterday’s trend.”
supply their needs,” Deary-Bell says. “These
are interesting times for the beverage industry. Health consciousness is another factor driv-
Millennials in particular are not as brand loyal ing product development. “The trend right
as people in older generations. It used to be you now is flavored water” Deary-Bell notes. “There
drank one brand of cola and you were pretty is tremendous potential to fill numerous niches
much loyal to that brand. However, Millenni- in the beverage market, and we are more than
als are always looking for something new and capable to help our customers fulfill their cus-
different, and they want immediate satisfaction tomer demands. We live up to our motto—
from it. That presents a big challenge to the Nor Cal delivers the right product at the right
cost at the right time.”

INDUSTRY TODAY 141

ADVERTISER’S INDEX VOLUME 18 • ISSUE 5

A J
Acme Marine ..............................................................72 James Tool Machine & Engineering, Inc.................. 98
ADFORS ......................................................................86 John. O. Bronson Co.................................................133
Alcan.......................................................................... IFC
K
B Kuraray America.........................................................86
BASF Corporation .......................................................46
Buck Algonquin...........................................................79 M
Buhler Leybold Optics.................................................61 Marine Fasteners.........................................................75
Bykowski Equipment and Engineering Co............. 135 Mobil.........................................................................OBC
Monster Beverage Corporation.............................. 132
C
C&L Refrigeration......................................................130 N
Coil Manufacturing, Inc...........................................116 Noroo Bee Chemical America.................................. 62
CVC Thermoset Specialties...................................... 118
O
D Oakland Pallet Company, Inc................................ 138
DCD Technologies......................................................98
VIDEO
E
Edmonton Exchanger...............................................108 S
Enovation Controls......................................................74 Sentry Equipment & Erectors, Inc............................ 134
Exel North America.....................................................62 Simas Floor & Design Company.............................. 139
Specialty Foundry Products, Inc.............................. 100
G
Golden Gate Air Freight.............................................50 T
Thoma Technologies, Inc........................................... 61

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142 INDUSTRY TODAY

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