September/October 2011 Broom, Brush & Mop Magazine SERVING THE INDUSTRY SINCE 1912 BORGHI ZAHORANSKY BOUCHERIE BIZZOTTO GIOVANNI AUTOMATION SPECIAL FOCUS | MACHINERY 2011 Machinery Manufacturers Continue Innovations Borghi Zahoransky Boucherie Bizzotto Giovanni Automation Prices Causing Concern In Yarn/Mesh Market Jones Companies Lemieux Spinning Inc. Patrick Yarn Mills Jason Mills Sales Of Handles & Blocks Remain Steady PelRay Int. Zelazoski Wood Pds. FIMM USA Whitley-Monahan Handle Co. Amerwood Raw Material Price Fluctuation Remains A Challenge First Half Of 2011 Sees Import/Export Increases
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September/October 2011
Broom, Brush & Mop MagazineS E R V I N G T H E I N D U S T R Y S I N C E 1 9 1 2
BORGHI
ZAHORANSKY
BOUCHERIE
BIZZOTTO GIOVANNI AUTOMATION
SPECIAL FOCUS | MACHINERY 2011
MachineryManufacturers
Continue InnovationsBorghi
ZahoranskyBoucherie
Bizzotto GiovanniAutomation
Prices CausingConcern In
Yarn/Mesh MarketJones Companies
Lemieux Spinning Inc.Patrick Yarn Mills
Jason Mills
Sales Of Handles &Blocks Remain Steady
PelRay Int.Zelazoski Wood Pds.
FIMM USAWhitley-Monahan
Handle Co.Amerwood
Raw Material PriceFluctuation Remains
A Challenge
First Half Of 2011 SeesImport/ExportIncreases
World renown manufacturer
of specialized and custom yarns.LEMIEUX SPINNING INC. has been in the textile industry since 1906. The company opted out
for marketing high added value products. They rely on the latest technologies and the qualification of their personnel to offer top quality custom products and services worldwide.
Synthetic rayon and cotton blended yarn for wet or dust mop.
For more information:1-418-484-2169 | www.lemieuxspinning.com
Today’s producers of mops, brooms and brushes require the latestin innovations and automation to remain competitive. To answerthis call, machinery manufacturers spend considerable time and
money improving their equipment and customer service. Broom, Brush & Mop Magazine recently talked with several represen-
tatives of equipment suppliers to learn what is new with each company aswell as how they are helping their customers become more productive intoday’s global economy.
Focusing on new product development, building relationships andkeeping a close eye on customer service remain vital objectives forofficials at Borghi s.p.a., an Italian manufacturer of machinery
that can make all types of brooms, brushes and mops as well as compo-nent parts. “Today’s customers are very diligent about thoroughly studying what
type of machinery will work best for their companies before making aninvestment. It’s important they meet all therequired improvements in the manufactur-ing process,” Borghi USA PresidentCarlos Petzold said. “This is not necessar-ily new, but the intensity of how thorough-ly today’s machinery purchases are studiedhas gone up tremendously during the pastfew years. “Companies in the past had a set of core
products that they had manufactured fordecades. Today, they are looking to
improve their product offering. We, at Borghi, have developed a longunderstanding of past core products from customers and also have thetechnology in place to meet their new needs.” One major development that is scheduled to be completed during the
first part of 2012 is a new facility built adjacent to Borghi’s headquartersin Castelfranco Emilia, Italy. The facility will create a new headquartersfor three of Borghi’s partners: Techno Plastic s.r.l., manufacturers ofmachinery for the production of brush and broom monofilaments andstrapping bands; Unimac s.r.l., manufacturers of power brush manufac-turing machinery, metal handle manufacturing machinery and automationequipment; and Bellucci s.r.l., builders of custom industrial electricalcabinets. The facility will cover almost 70,000 square feet and create better syn-
ergy between the four companies, while also making it more convenient
for visiting customers, according to Petzold. “These companies will also be able to share technological develop-
ments by teaming up their engineering departments with the goal of intro-ducing new innovations,” Petzold said. “Having everyone in one spot willcapture all the benefits of each individual company at a more rapid andefficient pace. Customers will be able to get new ideas from each of thesecompanies while visiting one location.”Product innovation at Borghi remains critical as customers continue to
look for the most efficient ways to make a wide variety of brushes,brooms, mops and related products. To help answer this need, a complete-ly new brush manufacturing machine model was introduced by Borghi in2011 named JUPITER. This machine has been designed to make almost any type of staple-set
brush that Borghi has encountered during its long history. This includesproducing brushes over standard sizes found in various industry segmentssuch as sweepers, large diameter disks, and long lag brushes; and withany combination of flare angles.“These extra large brushes have always presented a challenge to create
from a 5-axis machine — until now,” Petzold said. He added that JUPITER delivers a great degree of versatility, while
also providing short change-over times. This allows manufacturers to pro-duce different types of brushes in shorter runs, fitting in well with today’sbrush making trends. Meanwhile, Borghi’s revamped STAR-R32 features an innovative
guarding system. The high-speed, 5-axis, double-head drilling and fillingmachine also includes quick-change capabilities from brush to brush. “The STAR-R32 has a completely new design with its frame and how
it’s built. There are now fewer parts involved, allowing for a cost sav-ings,” Petzold said. “Borghi constantly looks for ways to keep costs downwith its machinery, yet still provides cutting edge technology that will sat-isfy today’s versatility, productivity, reliability and safety demands.” Along with the new JUPITER and revamped STAR-R32, Borghi pro-
duces a wide variety of other equipment for the brush and related indus-tries, according to Petzold. He added that keeping up with advancementsin automation is critical when helping manufacturers compete in a globalmarketplace. “We at Borghi feel there must always be reinvestment in new technol-
ogy taking place for a company to be successful. Many of our customersunderstand this well. They put funds aside every year to invest in updat-ed equipment. Companies that don’t do this will eventually get leftbehind,” Petzold said. “All equipment breaks down over time, no matter
how well it’s maintained. You can become obsolete if you rest on yourlaurels and don’t invest in new machinery and technology.”He added the Borghi experienced a resurgence in business in 2010 after
the economic slowdown that took place in many parts of the world dur-ing 2009. “And 2011 is shaping up to be an even better year in North America for
Borghi. Although we still hear in the news a lot of information indicatingthe U.S. economy remains slow, the overall brush business seems to behealthy and strong — at least for the technology and services provided byBorghi and Borghi USA,” Petzold said. When it comes to customer service for North American customers,
Borghi USA, located in Aberdeen, MD, is staffed with experienced per-sonnel who can help process orders and provide technical assistance soonafter a request is made. “The rate at which people are willing to wait for something has great-
ly diminished with the advent of cell phones and the Internet,” Petzoldsaid. “Therefore, we are all about trying to provide instant reply when itcomes to providing spare parts. From the moment we receive an order, it’salready processed in the computer and a pick list is ready to be used in thewarehouse for quick delivery. “Regarding technical support, it depends on the level of intensity as to
how quickly an issue can be resolved. We work hard with Borghi’s sup-port staff in Italy, as well as Matt Tompkins, who is the technical sup-port director at Borghi USA. They provide a key role in technical sup-port for our customer base.”Petzold also helps with technical support as does Barbara Lewis, who
is Borghi USA’s accounts manager.“We are all crossed-trained to provide the highest level of service pos-
sible at Borghi USA,” Petzold said. As for the future, Petzold said Borghi continues to work on a global
basis to satisfy the various needs of the brush and related industries.
“Borghi, and its partner companies, are working hard to come up withthe next, best machinery that will make life easier for customers,” Petzoldsaid. “Many challenges remain the same. This includes minimizing costsand helping customers increase, or at least maintain, profit margins so thatthey can continue to be successful. “At Borghi and Borghi USA, we understand that the success of our cus-
tomers is what drives our own success.” He added the Borghi continues to reinvest in the company for future
growth. Officials also look forward to showcasing products during the2012 InterBrush exhibition, held May 9-11. The event is held every fouryears in Freiburg, Germany. “We strongly encourage people to visit InterBrush,” Petzold said.
“After the show, they might also want to consider coming to Italy to visitBorghi’s headquarters as well as our partner companies.”
Contact: Borghi USA, Inc., 903 Cirelli Ct., Aberdeen, MD 21001.
Reporting that business has been strong this past year with goodorders from all segments is The Zahoransky Group. The com-pany has been a leading supplier of brush making machinery,
injection molds and blister packaging machines since 1902. “While we’ve seen a nice recovery at all levels of our company, the
recent world economic crisis has no doubt left its mark,” ZahoranskyUSA CEO Frank Kigyos said. “During the crisis, Zahoransky took thetime to develop new technology, make operational improvements andstreamline certain internal processes. “In the long run, I am confident the changes made will help
Continued On Page 39
In 2011, Borghi s.p.a., of Castelfranco Emilia (Modena)Italy, started out the year with its “MORE THAN THIS”campaign during the ABMA annual convention. The mes-
sage was clear and Borghi promoted the fact that although it iswell known as a leader in the field of staple-set, anchor-set andtwisted-in-wire brush manufacturing machinery, the companyhas so much more to offer. Borghi’s new display at the ABMA Suppliers Display
had a message in its colorful graphic panels, whichBOLDLY stated:PASSION: You will fall in Love with the Production Tech-
nology and the Care and Service we provide. Then you will
understand the Passion we have for every single thing we do,because we do it with pride and joy;ECOLOGY: Each year, throughout the world, the technol-
ogy we provide to customers consumes 1.7 billion recycledplastic bottles, saving them from going into landfills. Eachyear we produce 250,000 Kwh of energy from the sun whichis 70 percent of our energy consumption. We are Eco-Friendly;and,INNOVATION: With Experience, Know-How, Capability
coupled with New Blood, Intelligence, Forward-Thinking andthe relentless pursuit of perfection, we are re-inventing andsolving your production needs.
BORGHISPECIAL FOCUS | MACHINERY
Borghi Of Italy … More Than Just Broom & Brush Manufacturing Machinery!
Borghi introduced the JUPITER in 2011, a completely new brush manufacturing machine model. The JUPITER is able to produce almost any flare angle for the tufts of fiber, into almost any shape of brush block.
Advertorial
TOGETHER FOR YOUR BUSINESS, We Offer Technology For:• Drilling and Filling for Brushes and Brooms;• Twisted-In-Wire Brushes;• Strip Brushes;• Mops;• Paint Brushes & Paint Rollers;• Flagging and Trimming;• Injection Molds;• Power Brushes;• Steel Wire Preparation;• Tube Mills;• Tube Plastic Coating;• Handle Assembling;• Extrusion of Synthetic Monofilament; and,• Extrusion of Strapping Bands.
Borghi, Unimac, Techno PlasticThen, to further emphasize the fact that Borghi,
Unimac and Techno Plastic are all together, Borghihas announced the groundbreaking for a newbuilding. Borghi will bring in house its three sistercompanies as a group, which will be housed intheir new 6,000 m2 facility (approx. 66,000 squarefeet) to be built adjacent to Borghi’s existing20,000 m2 headquarters (approx. 220,000 squarefeet) in Castelfranco Emilia, Modena, Italy.Unimac is a specialist in the production of power
brush manufacturing equipment and metal handlemanufacturing lines, while Techno Plastic is a spe-cialist in production lines for monofilament (syn-thetic brush fibers) and strapping bands as well asconcrete reinforcement fibers. The third companythat is part of the expansion, Bellucci, is a longtime supplierand partner to Borghi that builds custom electronic control cab-inets for use with industrial equipment.According to the company, even with so much going on at
Borghi, innovation cannot stand still. A completely new brushmanufacturing machine modelwas introduced in 2011,named JUPITER. The conceptof being able to make almostany staple-set brush thatBorghi has encountered in its60-plus years, all on one
machine, was the catalyst for this new design. JUPITER is able to produce almost any flare angle for the
tufts of fiber, into almost any shape of brush block, no matter ifthe brush block is 2 or 75 inches long. This is the goal that wasreached with the introduction of JUPITER. No machine is lim-itless in what it can produce, but JUPITER has come closer tothis challenge than any other staple-set brush machine, accord-ing to Borghi.Also introduced in 2011, the revamped Borghi brush
machine model STAR-R32 with its innovative guarding sys-tem that is ergonomically designed to make it easy and con-venient to run and work on, not to mention how appealing itis in appearance. The Italian flair for aesthetics is prevalentin the modern design. Furthermore, what is inside the machine is what really
counts. The STAR-R32 is a high-speed, highly versatile, cut-ting-edge, 5-axes of motion, double-head drilling and fillingmachine with quick-change capability from brush to brush. It isfully self-diagnostic and highly efficient with a very shortindex time.
Many other exciting devel-opments are in the works thisyear at Borghi, so be sure totake an interest in the myriad ofchoices that Borghi and its part-ners have to offer. Borghi…MORE THAN THIS!
The STAR-R32 from Borghi is fully self-diagnostic and highly efficient with a very short index time.
September/October 2011 BROOM, BRUSH & MOP PAGE 11
During the course of its storied 109-year history, theZAHORANSKY-GROUP of Germany has been a lead-ing global supplier of brush making machinery and injec-
tion molds. With the latest innovations, ZAHORANSKY contin-ues to demonstrate why it is the industry’s leading supplier ofmachinery and molds, according to the company. The following isa sampling of ZAHORANSKY’s latest developments for theindustrial and household brush making industries.
Model Z.TIGER – Highest Staple-Set ProductivityZ.TIGER, the most advanced dual head carousel machine on the
market, according to ZAHORANSKY, guarantees highest produc-tivity through the unmatched combination of increased tufting speed
and extremely shortstand-still times.These improve-
ments, while benefi-cial for all brush pro-duction, are mostnoticeable in the pro-duction of small-ware products withlower hole-countswhereby fully auto-matic production
results in lower unit costs. With the Tiger, all aspects of the brush pro-duction can be automated, including block and filament loading feed-ing as well as the tufting and finishing operations. In this case, theonly manual labor required is an operator to pack finished brushes. For those in the market for a more flexible lower priced
machine, then the 3-station Tiger with drill and fill operations only,is the appropriate configuration. With quick change carriages andtooling, combined with the powerful Brush Designer software,companies can produce a wide variety of brushes and brooms withextremely short change-over times. Depending on the require-ments of a core business, the Tiger can be equipped with either 70or 100mm stroke filling tools. The 70-stroke system can run 9.5-inches long filament up to 600-plus rpm, while the 100-stroke sys-tem can run 12-inch long filament up to 500-plus rpm. Other advantages provided by the Tiger include its new ener-
gy efficient direct drive design which also makes for extremelyquiet operation, and the new servo drill system, which monitorsand prevents drill breakage by monitoring required drill forces.
Model Z.LYNX3Automatic Loop Handle Twisted Wire Brush ProductionZAHORANSKY’s latest addition to its machine lineup for the
production of industrial twisted wire brushes is the brand newZ.LYNX3. This fully automatic CNC-controlled machine for theproduction of either "looped handle" or "closed end" twisted-in-
wire brushes effectively reduces labor costs and achieves consis-tently high production quality of most twisted brush types, accord-ing to ZAHORANSKY. This guarantees a consistent high qualityand cuts costs per piece compared with manual operated or semi-automatic machines.LYNX3 benefits:• Consistent high quality production of either "looped handle" or
"closed end" twisted wire brushes;• Complete servo drive system providing maximum process
repeatability and control over twisting as well as core wire feed-ing, straightening, forming and cutting;• CNC controlled precision trimming device with HSS cutter for
automatic finishing;• Efficient and simple change over procedures enhanced by pro-
grammed servo settings for all critical processing movementsincluding brush twisting and core wire feed/form/cut;• Processing of all material types including synthetic, wire and
natural filament from either multi-strand spool system or pre-cutmaterial stock box;• User-friendly touch screen HMI including operating, data
acquisition, formula administration, brush programming andmaintenance screens; and,•High output with fully automatic production without an operator.LNYX3 specifications and features:• Soft stem wires from 1,0 to 3,0 mm; • Capable of twisting both nylon and wire filament;• Trimmed brush diameters from 6,0 to 110 mm (nylon) / 12,0
to 110 mm (wire);• Trimming length 20 to 800 mm;• Loop diameter
from 6,0 to 40 mm(noncircular shapesalso possible);•Machine housing
in accordance withEG safety standards;and,• The user-friendly
touch screen controlsystem for machineoperation and brushprogramming.
Model Z.LYNX2Automatic Closed-End Twisted Wire Brush ProductionAnother ZAHORANSKY workhorse for the industrial twisted
wire brush market is the proven Model Z.LYNX2 (formerly modelGA10). This fully automatic system includes as many as 6 servo-motors and is capable of producing continuous end brushes frommost wire and synthetic filaments as well as with some yarns.
Advertorial
ZAHORANSKYSPECIAL FOCUS | MACHINERY
The Z.TIGER is an advanced dual head carousel machine.
The Z.LYNX3 is designed for automaticindustrial twisted wire brush production.
Advertorial
The LYNX2 can twist soft wireup to 3mm in diameter and overallbrush lengths of approximately150mm. Optionally, the LYNX2can be set up to twist dual core-wire (i.e. single/double) and can beequipped with a servo controlledfinishing system, which includescut-off, trimming and grindingoperations. With the servo finish-ing system, trim diameters can beset as part of the CNC brush pro-gram, profiled and abrasive brush-es can be produced, and brushescan be cut off to precise lengths. The machine is built on a heavy-
duty frame fabricated from welded tube steel, guarded completelyaround and has an estimated output of 8 to 12 brushes/min whenusing guide shells and 4 to 6 brushes per minute when trimmed.
MODEL Z.WASPEconomical Abrasive Tufting
ZAHORANSKY says its proven abrasive stapling system hasbeen a huge successfor industrial brushmanufacturers in theUnited States andaround the world.The interchangeablepicking and tuftingsystem is now avail-able on the entireWASP family ofmachines.The WASP was
designed for producing industrial staple-set brushes and broomsincluding various configurations such as cylinders, domes, discs,strips, plates and more. ZAHORANSKY’s abrasive tufting system, developed in 2005
and since improved in 2009, has also been a huge success. ZAHO-RANSKY first introduced the system to local companies inGermany, but recent years several machines have been successful-ly placed in the United States and Canada. Most grades of abrasive filaments can be run on the ZAHO-
RANSKY system, which includes low-cost easy to change wearparts that are convenient to obtain or can even be produced “inhouse.” Since this system is interchangeable it can also be easilychanged over to our standard high-speed picking and tufting sys-tem for natural and synthetic materials in as little as 15 minutes.
SPECIAL NOTE: The Z.WASP with abrasive set-up and rotary disc carriage(option to add cylinder carriage), as seen at the ZUSA Open
House, is available for immediate installation. ContactFrank or Kevin Kigyos for demonstration.
Model Z.SAILFINAutomatic Twisting Of Medical & Dental Brushes
Z.SAILFIN is ZAHORANSKY’S latest machine model for theproduction of interdental, mascara and medical twisted wire brushes.
Incorporating the proven technology of the most recent DM modelswith its intelligent components, the Z.SAILFIN is a concept for thefuture with highest outputs of up to 60 brushes per minute.New servo motors replace the time consuming adjustment work
to enable fast change-over as well as the highest productivity.Important parameters including wire feed, straightening, andspreading, along with twisting time and brush diameter are allentered comfortably on the machine’s touch screen interface. Allprogrammed parameters can then be stored as a brush formula forsubsequent production requirements. With the KO 32 vision inspection system in place, downstream
processing is possible through integration of handle assemblymachines M6D/M6M as well as the profile trimming machineMCT. ZAHORANSKY says the Z.SAILFIN constitutes an excep-tional production concept which is able to meet the highest quali-ty and performance requirements from customers, both now and inthe future.
SAILFIN features & specifications:• Interdental, medical and mascara brushes ranging from 16 to
40 mm length;•Wire diameter between 0.18 mm and approx. 0.75 mm; • Optional brush length 16-80 mm with wire diameters of 0.3-
0.75 mm;• Filament length from 8 to 32 mm;• Brush diameter from 1.8 to
10 mm; • Reconfiguring to a contain-
er for shorter filaments isoptionally available; • Brush twisting system with
brushes per minute.SAILFIN advantages:• Optional integration with
assembly machines;• Real output up to 60 brush-
es per minute; • 50 percent faster conver-
sion time for complete sample change when compared to compe-tition;• Change-over time for the filament spools approximately 1/3
faster when compared to the competition;• Best trimming results due to twisting and trimming taking
place in same clamping; • Clean cut-off for brush stem during rotation for no burrs or
wire forking at the end of the brush;• Absolutely even filament distribution by means of vibratory
feeding;• Approximately 80 percent less wear and tear in comparison
with the competition; • Narrowest bending radii with thin wires (according with inter-
national test criteria); • Less space required (approx 4 sq.m.); and,• 1 Operator for 2 machines.
The Z.LYNX2 includes asmany as 6 servo-motors.
The Z.SAILFIN produces interdental and other
types of brushes.
The Z.WASP includes an interchangeablepicking and tufting system.
PAGE 14 BROOM, BRUSH & MOP September/October 2011
Advertorial
BIZZOTTO GIOVANNI AUTOMATION
SPECIAL FOCUS | MACHINERY
The story of Bizzotto began in 1957, whenthe founder,GiovanniBizzotto, turnedhisgarage into a small artisan shop dedicated
to the construction of smallmanualwooden brushmaking machines for local clients. Thanks to hispassion for mechanical equipment, innovativemachines and revolutionary technical solutionspermitted improvedqualityandan increase inpro-ductionofthearticlesforwhichthemachinerywasdesigned to produce.Today, due to constant technological
research and development, and putting to gooduse the precious experience achieved aftermany years of hard work, Bizzotto has evolvedto become one of the most original realities inthe mechanical, industrial sector. After half a century of dedication, passion and
care for the manufacturing industry, Bizzottocontinues toprovide revolutionaryandprofitabletechnical solutions to customers all over theworld.Understanding Customers’ Specific Needs
And Providing State-Of-The-Art Solutions—This is Bizzotto’s philosophy, a family-ownedcompany that has widened its horizons by pre-senting itself as a supplier of totally customizedmachinery for different industrial sectors. It hasfocused on quality with a complete partnershipwith the customer, which expresses itself in thecapacity to understand the needs of customers andprovide them with “made-to-measure” solutions.
Experience In The Sector, Complete AdviceAnd State-Of-The-Art Solutions. Is This
What You Are Looking For?Precise teamwork is what the Bizzotto
Company puts into the field to support cus-tomers in every step of the production processand to implement truly customized solutions.This support includes:The Solution Area —A complete staff, with
specific competencies that range from design toengineering, supports the customer in the eval-uation of possible product ergonomic and tech-nical improvements for which machinery andspecific automation is to be created. This con-sultation can be very useful since it is based onthe rich experience learned by the company.The Engineering Area —Once the final spec-ifications of the item to be produced or to beassembled are identified, the team of designers
and electronic experts apply the most suitabletechnical solutions and automations for themachinery. A sophisticated computer net allowsa strict cooperation between the differentdepartments. This guarantees a constant updat-
ing in any phase of the project and the applica-tion of the most innovative and reliable tech-nologies.Manufacturing — Each component of the
machine is produced with great care, both withinthe in-house specialized departments andwith thecooperation of reliable partners.After careful andaccurate controls, the final assembly of the partsand the testing take place.All of this is carried out in total observance
of safety standards that are in force, with partic-ular care taken to simplicity of use and of main-tenance. Finally, a team of highly qualifiedtechnicians attend to the installation and start-up of the machinery and any automation that isneeded. This is done all over the world.Assistance: The availability of a technical staff
for maintenance and service of machinery andautomation in every part of the world is immediate.
This is done in particular viamodemdirectly on theelectronic systemorvia the Internet, on IPnode, andtele-service supports (also with video conference)thatallowtheimmediate locationof theproblemandanypossible upgradeof themachine that canbecar-ried out.Spare Parts Service:Aspare parts warehouse
is provided with a computerized system for therecording and the control of the availability of anyspare part.This assures prompt retrieval and time-ly shipping to the customer.
Bizzotto Is Specialized In Three Main Sectors
Handle Machinery Sector: Sanders, chuck-ing machinery (i.e. doming, tapering, tenoning,threading, end boring, cross boring, etc.); paint-ing machinery (lacquering); labeling systems;and packing machinery for the production ofwooden handles.Complete machinery lines for the production of
metal handles, starting from the flat steel or alu-minumbandcoil, includingpainting lines,machinesforassemblingthevariousplasticinserts(hangertips,thread inserts,mop inserts, tapered inserts, etc.), bor-ing, deforming and cutting, as well as labeling sys-temsand machinesforpackagingwith theuseofdif-ferentsystems,evenrobotized.Woodworking Machinery Sector: Profiling
and shaping machines; boring and tappingmachines; and sanders for the production ofbroom and brush blocks, paintbrush handlesand similar items.Industrial Automation Sector: Customized
machinery for the preparation, positioning andassembly of particular products and accessories forthe cleaning industry (mops, floor scrubbers, deter-gent dispensers, velvet lint brushes for clothescleaning, adhesive lint brushes for clothes cleaning,toothbrushes/accessories, etc.,) automotive indus-try and the kitchen appliance industry.
BIZZOTTO GIOVANNI AUTOMATION srlVia Buonarroti, 67
35010 Paviola di S. Giorgio in Bosco (Padova) – Italy+39 049 9451067
Tufting Machines For Brooms, Household, Industrial And Personal Care Brushes And Toothbrushes
Boucherie’s Anchor Free Technology is available for the produc-tion of household and industrial brushes without the use ofanchors or staples. The filament and block can be made of differ-
ent materials.According to Boucherie, with two filling heads running continuously
at 650 RPM (1,300 tufts per minute), brushes with 138 tufts are produced
at the rate of 600 pieces per hour. The indoor broom thatwas demonstrated at the last InterBrush show in Freiburg,Germany, requires a mere 50 percent of the weight inpolypropylene of a regular brush block.Additionally, there are savings in filament waste since
no trimming is needed and, of course, there is no wire. Inthis world of high energy costs and petroleum basedmaterials, such savings cannot be considered to be trivial.These combined attributes have the potential to revolu-tionize the brush manufacturing industry.Boucherie’s TCU/CNC machines are capable of han-
dling brushes from nailbrushes to 24–inch brooms, all atspeeds up to 600 RPM or 1,200 tufts per minute.Boucherie’s modular concept, which permits a machine
to be reconfigured for vastly different brushes, has nowbeen well demonstrated. Moreover, these machines areavailable from being manually loaded all the way to fullyautomated production cells, equipped with fully auto-matic handle feeders and industrial robots.The TCU-CNC range of machines has been further extended by the
introduction of the TCU-SL/CNC and the TCU-T/CNC. The TCU-SLC/NC machine, with its unique fiber picking system and 95 mm
stroke, is able to run at speeds up to 1,000 tufts per minute even withfilaments as long as 420 mm (16 inches) unfolded. The TCU-T/CNCmachine, with long stroke filling tools that are lined with a ceramicmaterial, also comes with a sturdy carousel with heavy-duty support inthe drilling and filling stations. The machine is designed for arduousapplications with drill sizes to 12 mm, and with the use of heavy veg-etable fibers.With the single-header SCU-CNC, Boucherie enters the market to
produce machinery for making industrial brushes. The SCU will handledisk brushes as well as plate brushes, and can be convert-ed to a household brush machine in a matter of minutes.The SCU-S/CNC is an economically priced, yetextremely sturdy and versatile single header, for the pro-duction of all kinds of brooms and brushes up to 62 cm(24-inches) long in 1 operation and 1 meter (39-inches)long in 2 operations.
Toothbrush Production Lines And Work Centers
Boucherie has developed a variety of toothbrush manu-facturing equipment. Production machines range from thevery affordable TB3-A/CNC, through the TB3-TS andTB3-FS, which are economically priced, full productionlines for less demanding applications, to the highly auto-mated and sophisticated TB3-FM and TB3-FM/L.All of these single header machines now run at contin-
uous speeds up to 1,000 tufts per minute. For the highestproduction, Boucherie offers the double headed TB3-
A2/CNC, TB32-FM4/CNC and TB42-FM/CNC numerically controlledmachines, which will produce up to 50 finished brushes per minute.
BOUCHERIESPECIAL FOCUS | MACHINERY
The TB3-FM/L high speed machine comes with compact orientation of cascade handle feeder with multi-station finishing machine.
The TCU-CNC is a high speed machinewith ergonomic-friendly features.
boucherie Latin AmericaKra. 104 No. 11-25 Apto 102Puerto de HierroCali, ColombiaPhone 57-2-333-6873E-Mail [email protected]
USA INC.
SCU-CNCBoucherie has pushed the envelope once again when it comes to flexiblemachinery : the SCU-CNC can be converted from scrubbing brushes to toiletbrushes, or from 24” brooms to tank cleaning brushes in a matter of minutes.It speaks for itself that, just like any other Boucherie machine, the output ofthe SCU-CNC is extremely high and the reliability is unsurpassed.
> available as a manually loaded machine or with any customized automation level
> single, double or triple fibre box> variety of quick-change brush holder turrets available> turret change with click-on system> anchor- or staple filling tools> user friendly computer interface with touch-screen> 3D software “WinBrush” for easy CNC program
creation or modification> compact footprint with excellent accessibility
QUICK AND EASY, VERSATILITY AT ITS BEST
A
PAGE 20 BROOM, BRUSH & MOP September/October 2011
The AFT/HH
The AFT/CNC
Boucherie Contact InformationBoucherie USA Inc.
John Williams - President8748 Gleason RoadKnoxville, TN 37923Phone: (865)247-6091Fax: (865)247-6117
Boucherie’s Anchor Free Technology now allows for the production of different types of brushes without the use of anchors or staples.
IDM Machine
The IDM is a compact carousel machine for the high-speed pro-duction of inter-dental and mascara brushes. With the new two-steptwisting, it is now possible to produce up to 60 high quality brush-es per minute, even while using the smallest wire sizes, since thebrush remains in the same clamp throughout the whole productionprocess.The IDM is available in versions with spool feed of the nylon, or
with fiber boxes for pre-cut filaments. An integrated vision systemfor the automatic inspection of finished brushes is also available.
Injection Molds
Boucherie produces single component molds; multi-componentmolds with manual or automatic transfer; and multi-component,high cavitation, valve gated, hot runner stack molds. Boucheriemolds are used to produce a wide range of consumer, medical andengineering products.
Packaging Machines
Form, fill and seal blister packaging machines are available inheat seal and high frequency seal versions for toothbrush and per-sonal care brushes. They may be operated as stand-alone machinesor integrated into one or two tufting machines.For the packaging of items like interdental brushes and tooth-
brushes in double-sided blister packs, the BM-A/DS was recentlyintroduced.
Brief History
Boucherie USA Inc., has been selling Boucherie brush machines,sophisticated multi-component injection molds and packagingequipment in North, Central and South America for over 30 years.
Anchorless Toothbrush Production Lines And Work Centers
In the field of machinery for the oral care industry, with the introduc-tion of the AFT/CNC machine, Boucherie clearly established a leadershipposition in anchorless technology.The AFT/CNC is the first machine for tufting toothbrushes without
using anchors, according to the company. Block tufts, strip tufts and var-ious combinations of tuft angles widen the range of design options for thetoothbrush heads.The AFT/CNC features automatic handle feeding, Windows-based
CNC controls, with pre-endrounding of bristles. No trimming is required.AFT technology may now be used to manufacture toothbrushes withtapered filaments. Available, too, is a less automated version of thismachine: the AFT/SD line, in which the handle and bristle in-feed areaccomplished manually. The AFT-IMT was the world’s first commercially available in-mold
technology for the production of toothbrushes, according to Boucherie.Pre-endrounding filaments are picked and arranged in their final config-uration prior to being transferred into a mold, where the brush head andhandle are over-molded to produce the finished product.
Boucherie continued from page 18
To better serve you• 8-colorPrinting
Available
By Rick Mullen, Broom, Brush & Mop Associate Editor
As the U.S. economy strains to bounce back from the recent reces-sion, executives from four manufacturers of yarn and/or knitmesh — representing one Canadian and three U.S. companies —
discussed how their businesses have fared during the past year.When interviewed recently by Broom, Brush & Mop Magazine, all
four executives expressed concerns about raw material prices. TheAmerican companies, in particular, are also keeping a wary eye on whatis happening in Washington, D.C., concerning economic issues.
Since 1936, Jones Companies, Ltd. (JCL), of Humboldt, TN, hasfocused on supplying the floor cleaning industry, with a primaryfocus on the mop segment, with yarns made with recycled post-
industrial and post-consumer fiber.JCL also manufactures yarns and products for other industries as well,
including antimicrobial, rayon blend, cotton blend and cellulose/synthet-ic blend yarns. JCL manufactures proprietary blend yarns to meet a cus-tomer’s application needs, from wet mops to high twist dust mops.“It has been a challenging year for many people,” said JCL Vice
President of Sales Andrew Dailey. “We have had to deal with extreme-ly volatile increases in raw material costs,particularly related to the cotton market.This has presented some challenges for usand the industry as a whole.”Dailey said the cause of spiking cotton
prices is explained by a very basic“Economics 101” law — high demand,coupled with a limited supply, means high-er costs.“Last year, the total pounds of cotton
generated worldwide was low,” Daileysaid. “This was primarily due to weather catastrophes and flooding thatoccurred in India and China, and somewhat in Pakistan. The governmentof India stepped forward to protect the country’s supply of cotton andplaced restraints on the amount that could be exported. Therefore, theglobal supply somewhat shifted and that, on top of the fact that the yieldfor the harvest was lower, took valuable bales of cotton out of the market-place.”High cotton prices were further exacerbated when speculators got into
the act.“The situation with speculators somewhat mirrored what happened
with the oil industry after Hurricane Katrina when oil prices were artifi-cially inflated because of speculators,” Dailey said.Dailey explained the speculators are typically investors who are not the
people who normally deal in the cotton market. Rather, they are just in themarket to make a profit, but otherwise have no stake in the industry.“For example, it would be like if I bought a barrel of oil. I couldn’t do
anything with it except to try and resell it for a profit,” Dailey said.“Likewise, speculators moved into the cotton fiber marketplace and thathelped to drive up the prices of cotton at a very rapid rate.“The good news is there is some indication that the extremes, at least,
will be disappearing, even though I don’t think we will see a completereturn to 2009 raw material cost levels.“The overall economy is such that there have been some good periods
of the year that have been steady. Other periods, especially during typicalslow times around the summer holidays and vacations, have been slowerthan we would have liked.”One of JCL’s foundational principles is its commitment to innovation.
Through research and development efforts, JCL has added technologythat allows spinning of a broader range of raw materials.In recent years, JCL has also expanded its lines of alternative substrates
for use in conventional cut-end and looped-end wet mops. Among theproducts in this category is the company’s nWET (nonwoven edge trim)fabric yarn. According JCL, nWET is an alternative material that meets orexceeds the performance requirements of conventional economy spunyarns. The material is a blend of rayon and polyester, with a soft texturesimilar to the nonwoven fabric found in baby wipes.“Rising fiber costs have created an opportunity for people to look more
seriously at alternatives,” Dailey said. “Our nWET line is certainly one ofthose opportunities that has stepped up and we are seeing it grow. “nWET fabric yarn may be limited to some specific applications in the
marketplace, such as foodservice or any type of disposal situation wherethe mop is used a limited number of times and then thrown away.“Mop manufacturers have responded well to nWET. The product per-
forms extremely well. It has a tremendous amount of absorption and doeshave some durability. The down side is, an nWET mop doesn’t look likea conventional mop.”Dailey compared nWET with other popular floor cleaning tools that
have come into the marketplace in recent years that do not look like con-ventional mops, but have been well accepted by consumers.Last year, representing what the company calls a “rejuvenated commit-
ment to the cleaning industry,” JCL launched a line of carpet bonnets, dis-posable dust mops, microfiber towels, microfiber tube wet mops andmicrofiber mitts. This group of products, called the NEXT GENERA-TION line, is part of the company’s strategy for the future, which includesa multi-faceted approach targeting innovative, value-added and perform-ance tested products.“NEXT GENERATION products are doing very well, and this line
continues to grow,” Dailey said. “One objective with these products is tooffer items to manufacturers that they may or may not have. If they dohave these types of products in their lines, they generally are importedand come with fairly high stocking inventory levels.“I think mop manufacturers expect Jones Companies to be innovative
Andrew Dailey
Raw Materials Prices Causing Concern
For Yarn/Mesh Makers
September/October 2011 BROOM, BRUSH & MOP PAGE 23
and bring new items to the marketplace, whether it is new fibers or newprotections such as antimicrobial fibers. Mop companies have an expec-tation that they can source these types of yarns from Jones. As a result, wemust be, not only reactionary, but also proactive in our exploration ofwhat is the next best thing.”JCL’s AM™ anti-microbial yarns are based on the natural antibacterial
properties of silver, according to the company. AM yarns are spun withfibers infused with silver nanoparticles. Silver ions are non-leaching,environmentally friendly, non-toxic, non-allergenic and are safe forhuman contact. AM yarns are ideal for wet and dry mopping applicationsin foodservice, health care and commercial facilities with limited launder-ing capabilities. AM yarns resist the growth of destructive microbes thatcause mop odor, yarn discoloration, yarn staining and fiber breakdown.“We recognize that the consumer marketplace changes,” Dailey said.
“There are ideas and products that we want to continue to explore, and wewould like to be in a position to supply new and innovative products tothe mop industry.”Along with offering environmentally friendly products such as the AM
line, JCL also operates its own landfill.“One benefit of our landfill operation was we were able to be involved in an
erosion project,” Dailey said. “We utilized what we were carrying to the landfill toshore up some areas where erosion was occurring. We restored land where thereare currently crops growing and cattle grazing.“We didn’t get involved in the erosion prevention project because we
thought it was going to bring us additional customers. It was just some-thing that we did as good stewards of what we have.”When it comes to customer service, cultivating relationships has been
the foundation of this effort with both customers and suppliers. JCL’s mis-sion, according to company literature, is “to be people oriented, serviceminded, quality driven and profit motivated. But, at no time should theseaspirations sacrifice the dignity of the individual: be it associate, cus-
tomer, supplier or owner.”Part of the company’s customer service effort is to assist customers
with timely inventory management. JCL has also ramped up its e-com-merce capabilities.Looking down the road, Dailey said he is “optimistic” about the future.
Dailey also said he sees indications that more offshore manufacturingmay return to the United States.“One of the things on our minds constantly is the ability of the U.S.
manufacturer of mops to compete on a global scale,” Dailey said. “Wefeel very strongly that in the next couple of years we will see productsbeing produced in the United States for U.S. market consumption that willmaintain a competitive advantage.“We have also been reading and hearing more about the situation in
China, where they are going to continue to have a challenge feeding theirown population. We are seeing the potential of having the same acreagethat would have been involved in growing commodity fibers possiblybeing shifted to grow vegetables. This could provide some revitalization ofU.S. cotton farming, which would be beneficial to the mop industry.”
Lemieux Spinning, Inc., of St. Ephrem, QC, is a leading NorthAmerican manufacturer of yarns for cleaning supplies for institu-tional or commercial use, such as wet and dust mops.
“The company also offers yarns for top-of-the-line tufted, braided andwoven carpets, which are used in aircraft and other luxurious projects,”said Lemieux Spinning President Serge Lemieux. “Our array of prod-ucts also includes top quality yarns used in the filtration industry, andhigh performance yarns used as protective knits.“Lemieux Spinning has been in the textile industry since 1906. The
company opted out for marketing high added value products. We rely onthe latest technologies and the qualification of our personnel to offer topquality custom products and services worldwide.”The company was founded by J.A. Lemieux, who was dedicated to
offering first-rate service and high quality products. J.A. Lemieux’s son,Clément Lemieux, took over the reins of the company in 1945. SergeLemieux took over from his father, Jean-Paul Lemieux, who had beenpresident from 1986 to 2007. Serge Lemieux’s brother, Marc, is the com-pany’s general manager.The company’s mission statement reads:
“Lemieux Spinning is committed to offerits customers products of higher value thanthose of competitors. This commitment isachieved because of careful manufacturing,high quality products and a personalizedcustomer service. Thanks to continuousinnovation and constant cooperation withthe client, (Lemieux Spinning) can createunique custom products to fit the clien-tele’s specific needs.”Sales at Lemieux Spinning were up during the past year, but there were
challenges dealing with the high cost of raw materials.“Raw material costs have increased on a monthly basis for about a year,
and this has created a shortage of good fibers for mop yarns,” Lemieuxsaid. “These escalated costs forced us to adjust our prices. Unfortunately,we were unable to adjust at the level of raw material costs — the marketwouldn’t bear it.”Lemieux Spinning’s main product categories include:n Industrial and technical yarns — Applications include industry,
filtration and high performance;n Specialized yarns— Applications include knitting and weaving;
nWool yarns and blends— Applications include manufactured tuft-ed carpets, braided rugs or woven carpets. Also in this category is thecompany’s Eco-Natural Collection, which presents a range of qualityyarns produced in natural wool. According to Lemieux Spinning, by using wool from a selection of
British breeds and other wool types and blends, these yarns offer superi-or eco advantages to the carpet manufacturer. The wool is shorn annuallyand is fully sustainable and biodegradable without harm to the environ-ment; andn Synthetic and cotton Yarns— Applications include cleaning prod-
ucts.“We are planning to launch a new product, which will differ from the
original mop yarn,” Lemieux said. “Currently, we are sending samples toour customers. We will be able to talk more about the new product in thenear future.”When it comes to customer service, Lemieux Spinning’s philosophy is
the company is a “business partner” with customers. Incoming calls arefielded by a live person and any corrective action needed to solve a prob-lem is done in a timely manner. Personalized service is paramount as eachcustomer has an express phone line into the company.“What is really helping us to remain competitive is our ability to offer
complete service right to the customer’s dock,” Lemieux said. “We areincluding in our price a worldwide door-to-door delivery, plus all customslogistics.”Traditionally, Lemieux Spinning has kept abreast with the latest in
automation and technology, allowing it to lower production costs andenhance efficiency. This makes it available for the company to keepprices as competitive as possible.“Automation and new technologies have always been our top priori-
ty as a means to produce yarns at the lowest cost possible, without com-promising our excellent quality,” Lemieux said. “The challenge moving
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PAGE 24 BROOM, BRUSH & MOP September/October 2011
Serge Lemieux
forward is to provide our customers with added value products. This isour mission for the upcoming years. We believe innovation is the futurefor our company. Our Research & Development Department is workingvery hard to create new and refreshing products.”In looking ahead, Lemieux expressed optimism concerning the mop
manufacturing segment.“We are pleased to see that mop manufacturers continue to be strong in
their markets, even with aggressive competition coming from offshore,”he said. “We feel one of the primary reasons for the success of these com-panies is their commitment to high standards in offering quality prod-ucts.”
Patrick Yarn Mills, of Kings Mountain, NC, was founded in 1964by H.L. Patrick to manufacture synthetic mop yarns for the jan-itorial market. Today, the company has expanded its capabilities to
become a global supplier of yarns for filtration, protective wear, gaskets,geo-textiles, composites and other technical textile applications in a widerange of industries.“Patrick Yarns was built on customer partnerships and product innova-
tion, coupled with investment in the latest manufacturing and processingtechnology, all focused on providing our customers with innovative andprofitable solutions,” said Patrick Yarns President Gilbert Patrick.“This has been the bedrock of our company’s success and we plan to con-tinue on this path. That said, we don’t cater to every industry or to who-ever calls with an order. We choose our partners and help them find solu-tions for their growth.”
The Patrick family’s tradition of rising to challenges and commitmentto community and success are deeply ingrained in the Kings Mountainarea. Their ancestors fought in the Battle of Kings Mountain, which isconsidered a decisive battle in the Revolutionary War.Continual innovation and investment in technology has proven a suc-
cessful combination in these ever-changing economic times.“Business for 2011 has been good, yet challenging,” Patrick said.
“With the unprecedented rapid spike in raw materials earlier in the year,our team was challenged to absorb, re-engineer or pass on raw materialincreases in a fashion that kept our customers competitive, while keepingus at sustainable margins.”Patrick explained that raw material issues, particularly pricing, have
been a fact of life in the industry up and down the supply chain.“Unfortunately, with the increasing demand for raw materials in
emerging markets like China and India, not to mention the manipula-tions of Wall Street, I think this new volatility in raw material pricingwill probably become the new normal in this economy,” he said.Patrick Yarns product offerings in the mops/janitorial category include: n MicroPOWER® wet mop: Through their research in the field,
Patrick Yarns discovered using microfibersin wet mops made of typical yarn construc-tion delivered disappointing results. Thistype of mop exposed delicate micro denierfibers to abrasive floor surfaces creatingsnagging, fraying, breaking and splittingthe fibers. This approach greatly reducesperformance and increases labor costs.With MicroPOWER®’s patent pending
technology, the micro denier fibers arespun within the center of the yarn, thus
protecting them from the abrasiveness of floor surfaces, and providing apowerful wicking ability. Liquids distribute evenly and quickly through-
out the yarn structure, resulting in superior performanceand durability;n MicroPOWER® dust mop yarns: According to the
company, most dust mop yarns have been constructed ofstandard fiber blends with conventional deniers or diame-ters. Patrick Yarns’ MicroPOWER® technology blends thewedge-shaped micro denier fibers within the yarn mass.This multitude of small wedge-shaped nylon fibers givesthe yarns more fiber surface area, which producesincreased cleaning performance; andn FiberTAC® mop yarns:According to Patrick Yarns,
rough, non-slip tile floors used in today’s fast food restau-rants and consumer oriented businesses are a big challengeto the professional cleaning industry. The naturally abra-sive surface of these floors quickly shreds and destroysconventional mops. FiberTAC® patented technology usesa blend of fibers engineered for enhanced cleaning per-formance and then tacks them together to minimize linting,shedding and unraveling of the yarns.Patrick Yarns’ capabilities now go way beyond mop and
cleaning yarn products.“We recently completed a major installation of modern
spinning equipment for proprietary yarns focused on pro-tective and environmentally friendly fashion wear,”Patrick said. “Our family of X13 and X14 performanceyarns for cut protection is doing very well. Also doing verywell are our eco-friendly Earthspun® yarns, which aremade from recycled PET (RPET) plastics found in sodaand beer bottles, X-rays, and food trays, combined withrecycled cotton or other eco-friendly fibers.”Sustainability and the environment are key components
of the company’s manufacturing mission.“We just commissioned the largest privately held solar
Plus working together tomake THE PIE BIGGERTHE PIE BIGGERTHE PIE BIGGER
PAGE 26 BROOM, BRUSH & MOP September/October 2011
Gilbert Patrick
PAGE 28 BROOM, BRUSH & MOP September/October 2011
power installation within the Piedmont Region of North Carolina. As acorporation we have always worked diligently to be environmentallyfriendly. Today, all our yarns are exceptionally friendly, and, as we like tosay, they are ‘Spun by the Sun™.’”
According to a news release from Patrick Yarns, the new solar installa-tion generates 140,000 kWh (kilowatt hours) per year of clean photo-voltaic power — equivalent to the power generated by 11,310 gallons ofgasoline or 234 barrels of oil, and enough to power 14 average-sizedhomes.
Patrick Yarns also has highly efficient lighting and motors in place. Thecompany says it produces no greenhouse gases in its processes, and isworking toward a zero landfill goal.
Indeed, the company has a history of introducing innovative productsand practices into the marketplace and remains committed to this strate-gy as it moves forward.
“As a company, we continue to stress innovation, partnership, state-of-the-art-manufacturing processes and a manufacturing team with a ‘cando’ attitude,” Patrick said. “This company vision and message shouldcontinue to separate us from other yarn providers that want to sell from aprinted sales sheet of available yarns. Our clients need us to provide solu-tions, and that is what our team delivers.
“It goes without saying, many manufacturing companies must becomemore savvy in processing and distribution. However, just doing what youhave been doing and thinking you can do it faster or more automated andstay competitive is writing a death warrant for your company in this mar-ket. In today’s global business environment, you have to add innovationto the equation if you are to have a successful long-term business plan.
“We are a significant supplier in a multitude of global markets andwe continually invest in R&D and capital equipment to stay ahead.Interestingly enough, what we learn in one market, such as protectivewear or performance apparel, can extrapolate to other areas such as
janitorial, fiber optic, geo-textile yarns and much more. With the rapidadvancement of new fibers and technologies, the future advancements weforesee are exciting.
“Our company faces the same challenges as many other manufacturersin the United States in that we see no clear path, direction or policies per-taining to energy, health care, taxes or other employment costs comingfrom Washington, D.C.,” Patrick said. “As manufacturing in this countrysuffers, so does our economy, our communities and our nation as a whole.
“Until Congress addresses unfair trade issues, our economy will strug-gle, employment will struggle, and our deficits will continue to balloon.We need Congress to supply U.S. industry with a level playing field, sowe can create jobs and wealth here in America, and not ship more jobsoverseas than we are creating here.
“There are two ways people can help determine the direction our coun-try takes — with the ballot on Election Day, and how they spend their dol-lars. It’s not much more to buy American, which supports companies andcreates jobs here.
“Challenges notwithstanding, I still foresee a good future for boththe mop yarn and mop companies that have invested wisely and prac-tice good business sense. As unemployment continues to be an issue,I think we will continue to experience a resurgence of demand for U.S.made products.”
Contact: Patrick Yarn Mills, P.O. Box 1847, 501 York Road, KingsMountain, NC 28086. Phone: 704-739-4119; Fax: 704-739-9276.
Website: www.patrickyarns.com.
Originally founded as an apparel company in the mid 1970s,Jason Mills, LLC, of Milltown, NJ, has evolved into a leadingproducer of knit mesh for the mop industry, serving a wide range
of manufacturers throughout the United States, Canada and Europe.“We are a manufacturer/convertor of knit industrial textile products,”
P.O. Box 330065Fort Worth, Texas 76133 USA
Brand Handles and DowelsHonduran and Domestic Pine
said Jason Mills President Michael Lavroff. “We service many different niche mar-kets including the wet mop industry. Our niche within the industry is supplying cus-tomers who require a heavier abrasive fabric.”
The company also focuses on industrial and custom fabric applications and isan industry leader in dye processing, finishing, slitting and dye cutting on bothstock and custom fabric. Jason Mills also manufactures and distributes varioustypes of sports netting, bird netting and agricultural shade cloth. Lavroff, whohas more than 25 years experience in the textile industry, purchased the compa-ny in 2007.
“Sales have remained steady as compared to about this time in 2010,” Lavroff said.“However, wet mop/squeegee sales are off as compared to the same time frame of lastyear.
“Certainly the U.S. growth rate is extremely disturbing, as is the global economy.The proposed KORUS FTA (The Republic of Korea-United States Free TradeAgreement) will only make textile manufacturing more challenging.”
As its name implies, the KORUS FTA is an agreement between the United Statesand the Republic of Korea. The treaty was first signed June 30, 2007, with a renego-tiated version signed in early December 2010. The agreement has yet to be ratified bythe National Assembly of South Korea or the United States Congress.
According to the Office of the United States Trade Representative, “Under theKORUS FTA, nearly 95 percent of bilateral trade in consumer and industrial productswould become duty free within three years of the date the FTA enters into force, andmost remaining tariffs would be eliminated within 10 years.
“For agricultural products, the FTA would immediately eliminate or phase out tar-iffs and quotas on a broad range of products, with almost two-thirds (by value) ofKorea’s agriculture imports from the United States becoming duty free upon entryinto force.”
For the mop segment, Jason Mills primarily offers the 5-inch harness or saddle thatgoes on the base of a mop. The company sells 5-, 1 1/4- and 1 3/4-inch mesh fabric.The company’s fabric is consistently about 3.5 ounces per square yard. The mesh isthe abrasive part of the mop. It is run to a crisp finish and it serves to encircle thesponge and create an abrasive fabric.
According to the company, Jason Mills continually strives to be innovative and for-ward-looking in its manufacturing processes.
“One goal for 2011-2012 is the elimination of formaldehyde in the finishingprocess,” Lavroff said. “The challenge will be to maintain the stiffness of the materi-al that our customers and the market have come to expect. To date, there has not beena cost effective replacement to the melamine. In addition, a product line of fabricmade from recycled polyester is something that has been in development.
“Also, as a convertor, our greatest asset is our production software. Having a firmunderstanding of our cost structure — from yarn procurement through fabric slitting— allows us to price accordingly.”
As Jason Mills moves forward, there are challenges to be overcome. One of themore immediate challenges is the spiking costs of raw materials.
“Raw material costs, yarn in particular, have gone up exponentially,” Lavroff said.“Supply has not been a huge problem, but costs have become a major headache,with some yarn deniers increasing 40 to 50 percent in a very short period. In addi-tion to raw material costs, imports and macro manufacturing growth are the great-est challenges.
“Unfortunately, mop supply is trending slightly downward for this year. Wehope it doesn’t go the commodity route like the laundry bag. Our success willcontinue to come from product diversification, value added specialty finishing,such as antimicrobial and fire resistance, and the development of technical fab-rics and textiles.”
In the effort to remain competitive during the recent recessionary economy, manycompanies ratcheted up their customer service efforts. As customer service at JasonMills has historically been a top priority, the company also intensified its efforts inthis area, and continues to do so.
“Currently, we are doubling down on our sales efforts, attending more tradeshows,seeking more rep involvement and establishing a greater online presence,” Lavroffsaid.
Contact: Jason Mills, LLC, 440 S. Main St., Milltown, NJ 08850. Phone: 732-651-7200; Fax: 732-651-7222.
By Rick Mullen, Broom, Brush & Mop Associate Editor
When Broom, Brush & Mop Magazine spoke recently withexecutives representing five U.S. companies that supplyblocks and handles to the broom, brush and mop industry, two
primary themes emerged. One was that sales of blocks and handles aresteady or steadily improving, but are still down from pre-recession times.
A second underlying theme had to do with recent events in Washington,D.C., concerning economic issues, which have caused some anxiety anduncertainty in the business world.
Serving manufacturers of brooms, brushes and mops worldwide,PelRay International, LLC, of San Antonio, TX, sources sup-plies from 5 continents and from more than 20 countries.
PelRay’s inventory includes wood handles, made with hardwood andpine, and metal handles that are powder painted and plastic coated. In
addition, the company offers mop andbrush hardware and mop yarns.
“Our business has been steadily improv-ing,” said PelRay CFO Bart Pelton.“Business has been recovering here the pastcouple of years and it seems, most months,it is getting a little bit better. It is certainlybetter than last year at this time.”
Pelton said perhaps some of the doomand gloom over the economy that is some-times portrayed in the national media is alittle misleading.
“You can spend too much time watching the news on TV. Sometimesyou just have to go with what your customers are telling you and how youare doing,” Pelton said. “I think the economy is doing a little better thanadvertised. It is not back to where we were in 2007 and early 2008, butbusiness seems to be improving steadily. You just have to continue tomanage your business better and work harder. Working harder andsmarter is key in competing in a soft economy.”
Doing business on a global scale has its own set of unique challengesincluding dealing with fluctuating currency rates, environmental con-cerns, supply chain issues and pricing, as well as various governments.PelRay’s managers and sales staff have more than 100 years combinedexperience in the industry and are experts in doing business with foreignmarkets.
Perhaps the most popular source for hardwood handles coming into theUnited States is Brazil. Brazilian tauri hardwood is prized by many U.S.
handle makers and importers. PelRay primarily imports hardwood han-dles from Brazil. Therefore, the company keeps a close watch on the cur-rency rates of the U.S. dollar against the Brazilian real.
“The Brazilian real had been on an upward trend most of the year untila few weeks ago,” Pelton said on Sept. 20. “From June of last year to Julyof this year, the real went up about 22 percent, which has been reflectedin handle prices. The real peaked July 26 at 65 cents, and since has fallento 56 cents.
“This 15 percent drop is the result of the Brazilian Central Bank takingsteps to stop the appreciation of the real. However, the decline brings itback to where it was a year ago. I have not seen this decline result in anylower prices, at least not yet. It is certainly going to keep any increases
from happening for awhile, and we could even see prices back downsomewhat.”
Another factor affecting the price of Brazilian hardwood handles is,ironically, that country’s fairly strong economy. This has resulted in anincrease in construction in that country, which, in turn, has increased thedemand for lumber.
“As a result of the local economy doing well, prices of logs and lum-ber in Brazil have gone up, not just in American dollars, but also inBrazilian currency,” Pelton said. “Now we can sell U.S. made hardwoodand pine handles for about the same price or less than Brazilian hardwoodand pine. We have developed some domestic supplies of handles that weare now using. As a result, we are importing slightly fewer handles fromBrazil. Pine handles out of Honduras are still cheaper than Southern yel-low pine handles, but they are also not as good in quality.”
Another source for hardwoods that PelRay has explored in the past isthe Indonesian market. As with Brazil, there are currency rate issues tomanage.
“Although prices from Indonesia have been attractive, we haven’timported any hardwoods from Indonesia recently, because the quality has
Bart Pelton
Sales Of Handles & Blocks Remain SteadyBut Suppliers Have Nervous Eye On Washington
“Prices … in Brazil have gone up. Now wecan sell U.S. made hardwood and pine
handles for about the same price or lessthan Brazilian hardwood and pine. We
have developed some domestic suppliesof handles that we are now using.”
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PAGE 32 BROOM, BRUSH & MOP September/October 2011
not met our standards,” Pelton said. “Also, there have been some con-cerns about complying with the Lacey Act with the Indonesian hard-woods.”
The Lacey Act combats trafficking in “illegal” wildlife, fish, andplants. The 2008 Farm Bill (the Food, Conservation, and Energy Actof 2008), effective May 22, 2008, amended the Lacey Act by expand-ing its protection to a broader range of plants and plant products. TheLacey Act now, among other things, makes it unlawful, effective Dec.15, 2008, to import certain plants and plant products without animport declaration, according to the United States Department ofAgriculture (USDA).
PelRay also deals in FSC (Forest Stewardship Council) handles. FSCis an independent, non-governmental, not-for-profit organization estab-lished to promote the responsible management of the world’s forests. It isa certification system that provides internationally recognized standard-setting, trademark assurance and accreditation services to companies,organizations, and communities interested in responsible forestry, accord-ing to www.fsc.org. FSC is represented in more than 50 countries.
“Currently, we have both FSC pine and Eucalyptus available. It is notin great supply, but there is some available,” Pelton said. “We import ourFSC handles from Brazil. The biggest challenge is the pricing is not com-petitive with the domestic wood at this time. However, there are still somepeople who are buying FSC handles. The mill that we work with has beenFSC certified and one of our sister trading companies has received FSCcertification.”
PelRay also imports metal handles from Italy, which brings the U.S.dollar rate versus the euro into play.
“The euro, in spite of all the problems in Greece, has held its value sur-prisingly well,” Pelton said. “It has been volatile, but it hasn’t been per-sistently weak. It has traded down as low as $1.29, and it has also beenalmost as high as $1.50.
“Since the end of August, the euro has been weakening. It has beendown to $1.46 to $1.37. These prices are competitive, but not overwhelm-ingly competitive. You can save a little money importing from Europe,but it is not a huge savings. There are other places to import metal han-dles from, but Italy is by far the largest resource.
“Steel prices jumped up earlier in the year, but at the moment theyseem to be stable. None of the mills are complaining about the cost ofsteel, which means it is not going up.
“It would be nice if the people who are running the economy inWashington, D.C., and on Wall Street realized a stable dollar is probablybetter than a weak dollar or a strong dollar. If there were a little more sta-bility, I think the economy would be better.”
PelRay’s customer service philosophy is “have what the customerwants, when he or she wants it.” This commitment to customers hasserved the company well over the years and continues to be a hallmark forthe business.
In dealing with imports from overseas, much planning is required asturnaround times on imports can be weeks or even months. However, theuptick in companies seeking to do business back in the United States andother factors have made PelRay’s task of getting supplies to customerswhen they need them a little easier.
“It is still the name of the game here to keep customers happy and towin more business by having the right products and the right price at theright time,” Pelton said. “Transit and lead times are shortened consider-ably when doing business domestically. I am happy to say we are fillingorders faster and more accurately and with better quality than we were atthis time last year.”
To further enhance the company’s customer service efforts, Peltonannounced the company has hired Raul Gonzalez as the company’sfreight and logistics manager.
“I feel positive about the future,” Pelton said. “There is an ongoingmarket for cleaning products and it is not going away. From what I amseeing, domestic manufacturers are getting more competitive in the glob-al marketplace than in recent years. I think our manufacturing sector is
going to be OK.“When products are ‘made in the USA,’ it is so much easier to stay sup-
plied and to supply customers with what they want, when they want it. Isee a comeback for domestic suppliers.”
Contact: PelRay International, LLC, 610 Lanark Drive, Suite 202, San Antonio, TX 78218.
Zelazoski Wood Products, Inc., of Antigo, WI, is a leading U.S.manufacturer of broom and brushblocks. ZWP also makes other
wood items such as cutlery racks, furnitureparts, special wooden parts, baseball bats,game calls, fishing lure bodies and theoccasional farm related item.
Business at ZWP during the past severalmonths has been sort of a good news/badnews story, according to ZWP SecretaryBen Zelazoski. The good news is the brushblock business has been steady. The badnews is, while business has been steady, ithas also been down somewhat — what Zelazoski called “not a goodsteady.” However, the company’s ability and flexibility in handling small-er, specialized projects has been beneficial in staying competitive duringthe slow economy.
“People are still pretty cautious,” Zelazoski said. “We are looking atways to trim prices. We haven’t hired anybody for a while, but we haven’tlaid anyone off either. We are kind of holding our own. It is a long wayfrom where we were 15 years ago. We are only running with about halfthe people, but most of the overhead is still there. It is kind of hard tomake a profit this way.
“What concerns me the most is what is happening in Washington, D.C.We are all fighting budget crunches. In Wisconsin, the federal govern-ment has cut back funding to the states and the states have cut back to thecounties and cities. This can mean reducing the fire department, the policedepartment and other support people in a community. I think we could allfunction much better if Washington would just make up its mind and giveus a game plan.
“I’m hoping U.S. manufacturers will take a look at the actual cost ofthe products that they are importing. If they do, we will be better off andif our government ever decides to buy U.S. products instead of going off-shore, that will help too.”
As the economy turned for the worse when the recent recession tookhold, ZWP took an aggressive approach to increasing its overall sales andbranched out into machining plastics; imprinting, such as hot stampingand branding; and finishes, such as tinted lacquer and stains.
“We found that we can accomplish much of the plastic machining withthe same cutters and machines that we use to machine wood,” Zelazoskisaid. “We are doing more with specialty items. Up here, there is a lot ofice fishing and so we made a board for ice fishing tip-ups. It is the firsttime we have made this product and it is doing OK.”
Antigo is located in northern Wisconsin about 70 miles northwest ofGreen Bay in close proximity to regional forests and the area’s lumber
Ben Zelazoski
“I’m hoping U.S. manufacturers will take alook at the actual cost of the products that
they are importing. If they do, we will be betteroff and if our government ever decides to buy
U.S. products instead of going offshore, that will help too.”
— ZWP Secretary Ben Zelazoski
PAGE 34 BROOM, BRUSH & MOP September/October 2011
industry. As the economy went south, mills in the area closed and fewerpeople were engaged in logging. The result was ZWP had to look forother sources of wood, especially beech, primarily in Kentucky andTennessee, which increased costs. However, the situation has changed forthe better and there is, at least for now, an ample amount of wood beingcut in the north.
“The mills that are still around are producing pretty well. The supply,for the time being, is doing OK,” Zelazoski said. “I am hoping that theshortage of northern hardwood bottomed out in the past year or so, but Idon’t know for sure. I just heard that one of the large paper mills in thearea has filed for bankruptcy.”
Several years ago, those involved in the wood industry in central andnorthern Wisconsin, including ZWP, began a project to build the WoodTechnology Center of Excellence in Antigo. The purpose of the center isto train and acclimate people to wood processing and to help provideskilled workers in related fields.
The $3 million project, a joint effort with the wood industry, LangladeCounty and Northcentral Technical College of Wausau, WI, received a$1.2 million grant from the Federal Economic DevelopmentAdministration. Ground was broken for the facility in the summer of2010. According to local news reports, the project is expected to eventu-ally create 430 jobs and generate $14 million in private investment for thecommunity. Today, construction is complete and the center is conductingclasses.
“It is going great,” Zelazoski said. “Historically, during the summer,the National Hardwood Lumber Association has run three classes a yearfor lumber graders out of its headquarters in Memphis, TN. A couple ofyears ago, they started running one class in the summer in different partsof the country. We were able to host their class here this year and we had16 students. We are also starting our first wood technologies class. Wehave full enrollment and, in fact, there is a waiting list of students whowant to take the class.
“We hired a great instructor for the class. He is young, but he has a lotof experience. I think students will learn a lot from him. I’ve learned alot from him already. The center is going to be a real asset, both to thewood industry and to our local area. It will attract people to the area.Some people will look for jobs in the area. While they are here they willeat and sleep and participate in other activities, which will help the localeconomy.”
Another positive sidebar to ZWP’s story the past couple of yearsinvolves Major League Baseball. While ZWP has traditionally madewooden baseball bats, the company began working in conjunction with acompany called RockBats, founded by Roland Hernandez, a wood scien-tist and baseball enthusiast. As result, ZWP began making major leaguequality baseball bats. Last season, some Milwaukee Brewers playersbegan using bats made by ZWP.
When the story broke in the local news media in the spring of 2010, itstirred up some excitement and boosted community pride. This season,with the Brewers perched at the top of the National League’s CentralDivision as of late September, some of the Brewers have been usingRockBats from time to time, and one player has been swinging a RockBatexclusively.
“There are also some of the Colorado Rockies players using RockBatsthis season,” Zelazoski said.
Research has found that a baseball hit by a “broken in” metal compos-ite bat comes off the bat at much higher velocities than if it were hit by awooden bat. New rules concerning the construction of metal bats are call-ing for metal bats to behave more like their wooden counterparts, prima-rily for safety reasons.
“This is the last year that metal bats can have more ‘pop’ than woodbats,” Zelazoski said. “We are seeing more people showing an interest inwood bats, which will hopefully help sales. RockBats is a small part ofour business, but one that has sparked a lot of interest.”
As the economy slogs along for now, Zelazoski remains optimisticabout the future
“We will be here in some shape or form,” he said. “There are not manyU.S. wood producers left. Orders are smaller and they are more involved.I think there will always be a market for these value-added type orders.
“When people don’t have much money to spend, they make that brush,or broom last just a little bit longer.
“Things could be better, but I have seen them a lot worse. We will rideit out. We are Americans — we will make it.”
Amanufacturer of metal handles for brooms, mops, push broomsand other applications, FIMM USA, of Arcola, IL, came intobeing following the purchase of Handles USA last year by
FIMM ITALIA S.p.A. Handles USA was a division of The ThomasMonahan Company, of Arcola. FIMMUSA is housed in the same facility inArcola that was the home of Handles USA.
FIMM USA also manufactures metaltubing for yard implements, such as rakesand shovels, and for other products, includ-ing curtain, shower curtain and draperyrods. The company offers several diametersof metal tubes with various finishes as wellas telescoping handles.
“After a year and a half of ownership,FIMM officials have fully integrated theirphilosophies,” said FIMM USA Sales Consultant Jim Monahan, whowas the former vice president of Handles USA.
In addition to Monahan, FIMM USA officials include PresidentEnrico Spinelli and Executive Manager Fabio Meli.
Along with its locations in Italy and the United States, FIMM ITALIAalso has metal handle operations in Mexico (FIMM MEXICO) andChina (FIMM CHINA). FIMM ITALIA is part of the Spinelli Group, amachinery manufacturer.
“We are working on improvements in the molding operation of specif-ic caps and threads,” Monahan said. “The company had implementedsome new technology to improve efficiency in the molding of caps andthreads, while offering customers new designs. Becoming more efficientand providing customers with excellent customer service is an ongoinggoal.”
The retention of much of the former Handles USA staff has resulted ina smooth transition to the new ownership, and has also helped in the areaof customer service.
“FIMM USA continually strives for plant efficiency, which involvesmaking long runs and quick changeovers,” Monahan said. “The companyworks with suppliers and customers to plan ahead to allow customers to
Jim Monahan
“It used to be steel mills were very reluctantto shut down blast furnaces because theywanted the production. But now, it seems
like the big companies are much moreknowledgeable on inventory levels and they
don’t seem to mind shutting down a blastfurnace to stop over production. In this way,
the steel companies try to control the market a little more than they were able
to in the past.” — FIMM USA Sales Consultant Jim Monahan
September/October 2011 BROOM, BRUSH & MOP PAGE 35
make blanket orders or long-term commitments.This, in turn, makes it available for FIMM USA toreap the benefits of the long runs and efficient pro-duction. This can translate into lower pricing forthe customer.
“FIMM USA has heavily invested in upgradingequipment and improving production capability inboth the metal tubing and finishes, and also for themolding operation for parts.
“The company is working hard to gain newbusiness and to take costs out of the system bybeing more efficient in providing on-time serviceto customers, along with top quality products.”
As a domestic supplier, FIMM USA is able tofacilitate just-in-time deliveries of handles to cus-tomers who are trying to keep their inventories aslow as possible as a cost-cutting measure. Also, asa domestic company, FIMM USA is able to sparecustomers some of the hassles of importing fromoverseas, among which are fluctuating currencyexchange rates.
“Obtaining handles domestically takes a lot ofthe risks out of the ordering process,” Monahansaid.
A company may have a need to change the spec-ifications of an order, such as the color of the han-dles, etc., after the initial order is placed. As ordersfor overseas containers are many times mademonths in advance, this kind of last-minute adjust-ment to an order is not possible, Monahanexplained.
“A company can be much more flexible if it isworking with a domestic supplier,” he said.
In the current economic climate, raw materialprices have been a challenge the past severalmonths.
“Prices in the oil, steel and plastic resin mar-kets jumped considerably. However, at themoment, it looks like steel and plastic priceshave stabilized,” Monahan said. “Plastic resins,which are involved with the finishes of end fit-ments, and the cost of steel are the company’stwo main raw materials.
“It has been a difficult year as far as pricing isconcerned, and there have been some increases.FIMM USA is hoping it can hold the line on pricesso no more increases will be forthcoming.”
FIMM USA uses a specialty steel called “fullhard light gauge steel,” which is very strong for thethickness required for the company’s handles. Inpast years, full hard light gage steel has been some-what difficult to find in inventory.
“Full hard light gage steel is still a little difficultto find. Domestic production in the steel industryhas seen a lot of peaks and valleys,” Monahan said.“It seems like the steel market is now controlled bya few of the giant steel mills. In the past, we havehad many more options of where we could buysteel, as there were many regional manufacturersin the market.
“It used to be steel mills were very reluctant toshut down blast furnaces because they wanted theproduction. But now, it seems like the big compa-nies are much more knowledgeable on inventorylevels and they don’t seem to mind shutting down
a blast furnace to stop over production. In this way,the steel companies try to control the market a lit-tle more than they were able to in the past. In theold days, they just produced. If they couldn’t sellthe steel, they just cut the price until it did sell.”
While Monahan expressed concerns about thestate of the economy and the political climate inWashington, D.C., he is optimistic about the futureof FIMM USA.
“FIMM USA is doing very well,” Monahansaid. “Company officials are optimistic the compa-ny will remain very competitive in the metal han-dle market with the modernization of the plant andthe emphasis on production technologies and effi-ciencies.
“Moving forward, we think the economy couldplay into FIMM USA’s hands because of the fluc-tuations in the currency exchanges and the ever-present concerns about ocean freight and leadtimes from overseas. Company officials haveinvested in the plant to reinforce their optimism.”
Contact: FIMM USA, 202 N. Oak St., Arcola, IL 61910.
Phone: 217-268-5753.Web site: www.fimmusa.com.
The Whitley-Monahan Handle Co., ofMidland, NC, offers hardwood and soft-wood handles for the broom, brush and
mop industry in partnership with The ThomasMonahan Company, of Arcola, IL.
Whitley-Monahan imports most of its raw mate-rial from Brazil, which is the leading source oftauri hardwood for handle manufacturing in theUnited States.
“The wood handle business has been steady, butnot quite as strong as it has in previous years,” saidWhitley-Monahan Sales Manager JimMonahan. “There have been price increases as aresult of ocean freight charges. In addition,exchange rates with Brazil have been a major fac-tor as the dollar has changed considerably againstthe Brazilian real. This has caused some fluctua-tions in raw material prices, which have beenpassed onto customers in the United States. Thereare other sources of wood for handles in the world,but Brazil is by far the dominant supplier to theUnited States.”
With the rainy season approaching in SouthAmerica, there is always a concern that the weath-er may impact the availability of tauri coming outof Brazil.
“The rainy season is beginning in the next fewmonths in Brazil, but it looks like there is anample supply of tauri available this year,”Monahan said. “There is a lot of wood stockedunder cover, so I don’t think there will be muchof an issue with shortages. I don’t think we willever see wood shortages out of Brazil. There areplenty of logs in the pipeline and Brazilian millsare working; however, they certainly could bebusier.”
While Brazilian tauri remains the mostpopular raw material for the manufacture ofwood handles, Monahan said there has been
PAGE 36 BROOM, BRUSH & MOP September/October 2011
an increased interest for “made in the USA” products in the pastyear.
“People in marketing departments are looking for an edge against theircompetitors and it looks like ‘made in the USA’ is starting to gain a littlemore momentum,” Monahan said. “Whitley-Monahan offers domesticpoplar, which is a hardwood, and also domestic Southern yellow pine, asoftwood. Poplar is typically a little higher priced than the tauri and pinesoftwood is a little cheaper. These domestic woods offer alternatives toend-users looking for ‘made in the USA’ handles.”
As sustainability and other environmental issues have become marqueeissues in recent times, Monahan reported that there has been an emphasisplaced on these factors in Brazil. In recent years, at the behest of environ-mentalists and the Brazilian government, there is an increased awarenessconcerning the responsible cutting of trees in that country.
Whitley-Monahan has also done its part in making sure its suppliers arelegally logging and replanting the forests.
“Our major suppliers in Brazil are fully complying with governmentregulations concerning the cutting of tim-ber and are following the reforestationprocess,” Monahan said.
While Brazil is a primary source forhardwoods, Honduras supplies much of thepine, a softwood also used in making han-dles. Amerwood, of Fort Worth, TX,deals in the Honduran pine market.Amerwood Division Manager Wayne
Pringle reported that handle imports fromHonduras are slightly down from this timelast year. Weather can play a major role in
the Honduran market this time of year, as it is the hurricane season andthe start of the rainy season in Central America.
“There are places getting rain every day now, and that affects the dry-ing capability of squares that are used in the production of handles,”Pringle said. “August and the first half of September weren’t too bad asfar as shipping, but I think we are going to see it slow down, and we hopeand pray we don’t have a hurricane.
“The demand for wood handles slowed somewhat during the summermonths, but as things get a little tight during the rainy season, we canexpect it to pick back up toward the end of the year. Raw material priceshave been fairly steady except for some increases in ocean and inlandfreight costs.”
Whitley-Monahan is able to offer many options to customers includingthe processing of Brazilian tauri and domestic hardwoods and softwoodsat the Midland plant.
“As a domestic supplier, we can accomplish quick turnaround timesand supply small quantity orders,” Monahan said. “We have the capacityto gear up for surges and promotion business that comes unplanned or notin time to order the raw materials.
“We have had several customers visit our facility and they wereimpressed with our machinery. We are taking steps to constantly upgradeand modernize our equipment and to become more efficient in the pro-duction of wood handles.
“If a customer needs a specialized handle or specialized packaging orlabeling, we can meet the need. We will also work with customers to setup a program to either maintain inventory for them or develop a releaseschedule to ship as they request.”
While there are always challenges in good times and bad in the busi-ness world, one obvious challenge is the current economy and how eco-nomic issues are being played out in Washington, D.C.
“There is a lot of uncertainty right now. There is a lot of focus onWashington and what is going to happen there,” Monahan said. “It wouldbe nice if the politicians in Washington would check the politics at thedoor and all work together to get something done.
“I am hoping that in the next few months, with the committee that isreviewing cost reductions and programs to reduce the national debt,
that people gain a little more confidence that Washington does func-tion.
“I am also hoping the government makes a better atmosphere for taxincentives for the small business people, which probably includes muchof the brush and mop industry. I think Washington has to give us someincentives so small business people will feel more confident and startinvesting in the future.
“It seems like a lot of people are in kind of a defensive mode right nowand are just kind of holding on. Their attitude is, we are going to hunkerdown and see what is going to happen over the next few months.
“One of these days, people are going to have to get aggressive andmake some investments and try to grow their businesses. We are hopingthat government will give us a game plan that will encourage people toinvest. I think it would mean better business for everybody involved inour industry, from the suppliers to the manufacturers to the end-users.”
While the economy certainly has a way to go and, in the meantime,poses some serious challenges ahead, Monahan and Pringle remain opti-
mistic about the future.“We feel, given the times in which we live, people need a good quali-
ty supplier,” Monahan said. “They need a supplier they know they cantrust for quick turnarounds and long-term planning to work on programsthat will reduce prices.”
Monahan is also encouraged by evidence that consumers are showingmore interest in “made in the USA” products.
“Several customers have told me that inflation and pricing in China areon the increase and there are concerns that China may not be the futurelow-cost producer,” Monahan said. “Furthermore, there are indicationsthat some people who are deciding whether to ‘make or buy’ are comingback to the United States to manufacture products here rather than buyingoverseas.
“Hopefully, there is wave of momentum building that will encouragepeople to look hard at ‘made in USA.’ Whitley-Monahan stands ready, asa domestic supplier of handles.
“We are in an economic battle and we are confident that America willunite as it has in the past and establish some programs that will help thesmall businessman and promote job growth, which will mean more busi-ness for everybody.”
Pringle added, “I feel pretty good about the future. We need a spurt inthe economy. Right now, it is on cruise control, but I don’t see it gettingmuch worse.
“Amerwood doesn’t employ a lot of people in the United States,but it impacts a lot of people, including Hondurans who are workingin the wood processing factories there. We impact customs people,the shipping business, trucking — it just goes all down the line. Youwould be surprised how much a small business can influence otherbusinesses.”
Contact: The Thomas Monahan Company, 202 N. Oak, P.O. Box 250, Arcola, IL 61910.
“Amerwood doesn’t employ a lot of peoplein the United States, but it impacts a lot of
people, including Hondurans who areworking in the wood processing factories
there. We impact customs people, theshipping business, trucking — it just goesall down the line. You would be surprisedhow much a small business can influence
other businesses.”— Amerwood Division Manager Wayne Pringle
Wayne Pringle
PAGE 38 BROOM, BRUSH & MOP September/October 2011
By Rick MullenBroom, Brush & MopAssociate Editor
U.S. government trade figures for the first half of 2011 indi-cate raw material imports were up in both categories outlinedin this issue, compared to the first half of 2010. For June 2011,raw material imports were also up in both categories outlined,compared to June 2010.
Import totals for the first half of 2011 were up in two of thethree finished goods categories outlined from the same timeperiod in 2010. In June 2011, two of the three categories out-lined recorded decreases, compared to June 2010.
RAW MATERIAL IMPORTSBroom And Mop Handles
The import total of broom and mop handles during June2011 was 2.4 million, up 9 percent from 2.2 million for June2010. During the first half of 2011, 11.7 million broom andmop handles were imported, up 22 percent from 9.6 million forthe first half of 2010.
During the first half of 2011, the United States received 5million broom and mop handles from Brazil.
The average price per handle for June 2011 was 74 cents, up4 percent from the average price for June 2010 of 71 cents. Theaverage price for the first half of 2011 was 79 cents, up 11 per-cent from 71 cents for the first half of 2010.
Metal HandlesThe import total of metal handles during June 2011 was 3.6
million, up 20 percent from 3 million for June 2010. Duringthe first half of 2011, 17.9 million metal handles were import-ed, up slightly from 17.8 million for the first half of 2010.
During the first half of 2011, Italy shipped 7.7 million metalhandles to the United States.
The average price per handle for June 2011 was 66 cents, up32 percent from 50 cents for June 2010. The average price forthe first half of 2011 was 69 cents, up 41 percent from 49 centsfor the first half of 2010.
FINISHED GOODS IMPORTSBrooms Of Broom Corn
Valued At Less Than 96 CentsImports of brooms of broom corn valued at less than 96
cents per broom during June 2011 totaled 40,680, compared to2,448 brooms imported during June 2010. During the first halfof 2011, 94,560 brooms of broom corn were imported, up 90percent from 49,968 brooms imported during the first half of2010.
All the brooms were imported from Mexico.The average price per broom in June 2011 was 76 cents,
down 10 percent from 84 cents for June 2010. The averageprice per broom for the first half of 2011 was 80 cents, down5 percent from the average price for the first half of 2010 of 84cents.
Brooms Of Broom Corn Valued At More Than 96 CentsThe United States imported 725,689 brooms of broom corn valued
at more than 96 cents per broom during June 2011, down 15 percentfrom 853,922 for June 2010. During the first half of 2011, 4.3 millionbrooms of broom corn were imported, down 10 percent from 4.8 mil-lion imported during the first half of 2010.
Mexico shipped 4.2 million brooms to the United States during thefirst half of 2011, while Honduras sent the remainder.
The average price per broom for June 2011 was $2.31, down 2 per-cent from the average price for June 2010 of $2.35. The average priceper broom for the first half of 2011 was $2.42, down 2 cents from theaverage price for the first half of 2010.
ToothbrushesThe United States imported 73.8 million toothbrushes in June 2011,
down 5 percent from 77.3 million imported in June 2010. During thefirst half of 2011, 445.3 million toothbrushes were imported, an increaseof 2 percent from 435.5 million imported during the first half of 2010.
China sent 302.2 million toothbrushes to the United States during thefirst half of 2011.
The average price per toothbrush for June 2011 was 23 cents, up 2cents from the average price for June 2010. The average price for thefirst half of 2011 was 22 cents, up 1 cent from the average price for thefirst half of 2010.
EXPORTSExport totals for the first half of 2011 were up in one of the two cat-
egories outlined, compared to the first half of 2010. In June 2011, oneof the two categories outlined aslo reported increases in exports, com-pared to June 2010.
ToothbrushesDuring June 2011, the United States exported 7.6 million tooth-
brushes, down 10 percent from the total recorded in June 2010 of 8.4million. During the first half of 2011, 48.9 million toothbrushes wereexported, down 6 percent from 52 million exported during the first halfof 2010.
The United States exported 19 million toothbrushes to Canada dur-ing the first half of 2011.
The average price per toothbrush for June 2011 was 58 cents, down3 percent from the average price for June 2010 of 60 cents. The aver-age price per toothbrush for the first half of 2011 was 59 cents, down18 percent from 72 cents for the first half of 2010.
PaintbrushesThe export total of paintbrushes during June 2011 was 200,188, up
4 percent from 192,289 paintbrush exports recorded for June 2010.During the first half of 2011, 1.2 million paintbrushes were exported,up 21 percent from 994,556 during the first half of 2010.
Canada imported 825,665 paintbrushes from the United States dur-ing the first half of 2011.
The average price per paintbrush for June 2011 was $8.15, down 24percent from $10.79 for June 2010. The average price for the first halfof 2011 was $9.55, down 20 percent from $11.87 recorded for the firsthalf of 2010.
First Half Of 2011 Sees Import/Export Increases
improve productivity and make us a more competitive and quality-driven company.”
The Zahoransky Group currently operates out of seven facilities locat-ed in Germany, Spain and India — with its headquarters in Todtnau-
Geschwend, Germany. Additional sales and service facilities are
located in the United States, Shanghai andHong Kong. Zahoransky USA (ZUSA),headquartered in Sugar Grove, IL, wasformed in 2006 as a wholly-owned divisionof Zahoransky Germany, and is headed byofficers Frank and Kevin Kigyos. Othermembers of the ZUSA team includeService Manager Jack Kee and PartsManager Bobbie Springborn.
ZUSA held an open house in May for customers and supplier col-leagues to showcase new products available to the marketplace. FrankKigyos was pleased with the event’s turnout.
“We feel this strong showing was a good indicator that the U.S. MainStreet economy is ready for recovery,” Frank Kigyos said. “We are alsovery excited about some of our new machine offerings. For example, theLION-2114 is a single-head staple-set machine, providing 4-axis controlfor high speed drill and fill of brush blocks up to 16-inches long (32-inch-es long in two operations), and stock lengths up to 12.5-inches long.
“What I really like about this machine is that it comes complete withdouble stock box, quick change clamping plates, filling tool, and suctionunit at a surprisingly low price.”
He added the machine is ideal for producing short-runs and should beviewed as a bargain when one considers the multitude of brush styles thatcan be produced.
Other machines that Frank Kigyos highlighted were Zahoransky’sLynx2 and Lynx3 for the automatic production of industrial twisted-in-wire brushes.
“The Lynx2 is designed to produce ‘closed end’ brushes, while theLynx3 has been designed to produce ‘looped’ handle twisted-wire brush-es. Both machines are essential to any custom or industrial twisted-wirebrush operation,” he said.
In an effort to help household brush manufacturers better compete withdemands for high volume/low margin production, Frank Kigyos addedthat Zahoransky has developed a new method for molding pre-coredblocks. This makes tufting machinery less expensive and far more pro-ductive than the traditional drill and fill machines, he said.
Customer service also remains essential for those involved with TheZahoransky Group and ZUSA.
“We have made it a priority at ZUSA to provide customers with domes-tic after-sales service for all product lines,” Frank Kigyos said. “With bothKevin (Kigyos) and Jack (Kee) providing mechanical and electrical serv-ice for our twisted-wire and staple-set product lines, we are well on ourway to achieving this goal.
“In the future, we will continue to train and add qualified staff so thatthe vast majority of technical services provided in the United States willcome from Zahoransky USA.”
Zahoransky will exhibit its latest machinery developments for the pro-duction of personal care, household and industrial brushes and broomsduring the 2012 InterBrush.
According to Frank Kigyos, “Our goal during the event will be todemonstrate why Zahoransky is the ideal partner for providing value-added brush manufacturing solutions. To achieve this, we plan to demon-strate innovations that are the result of world class engineering, machinebuilding, software programming and customer service.”
Contact: Zahoransky USA, Inc., 1981 Bucktail Lane, Sugar Grove, IL 60554.Phone: 630-466-1901; Fax: 630-466-1902.
Providing high-tech products and new developments has alwaystaken center stage at GB Boucherie, a major focus that will con-tinue in the years ahead.
“Newly developed technologies from Boucherie give our customersthe tools to be innovative themselves, and only innovation can give acompany sustained growth,” Boucherie USA President John Williamssaid.
GB Boucherie, of Izegem, Belgium, has been in business buildingmachinery for the brush making industry since 1928. The company buildsstaple-set machines for the household/industrial market, advancedmachines for making toothbrushes, and stapleless machines for both theoral care and household markets. It also builds both single- and multi-material molds for a variety of industries.
“We are currently working on several new developments, as well asimprovements to existing machines, to be showcased during the 2012InterBrush exposition,” Williams said. “Boucherie has always been acompany that has showed the newest trends in brush making machinery.In the past, this has included the carrousel machine, 5-axis controlled
brush making machines for householdbrushes, the high speed continuously run-ning turret machines for toothbrushes, andmore recently, anchorless brush technolo-gy.
“Our focus remains on technology, andwe will continue to push in that direction.”
With today’s production batches fromcustomers trending smaller, Boucheriealso places a strong focus on making auto-mated machines that are more flexible and
easier to change over. “We are always happy to provide customers advice as well on how
their product lines can be designed to streamline production,” Williamssaid.
He reported that business has been “excellent” for Boucherie duringthe past year. According to Williams, concerns remain over the health ofthe world economy, but many companies see a need to develop new prod-ucts even during these uncertain times.
“For example, stapleless products continue to play an important role,”Williams said. “The need for cost improvements drive automation in thedeveloped world. Automation seems to become more important as well incountries where labor costs were low but are now rising.
“There are three domains where we try to take the lead — flexibleautomation, product cost reduction and product innovation throughanchorless technology.”
Along with producing highly automated equipment, officials atBoucherie take pride in the level of service the company offers after itsmachines and molds have been delivered. Williams said Boucherie willcontinue to provide quality customer service, whether in response torequests for spare parts or technical and service issues.
Among the challenges facing Boucherie, as the company moves for-ward, are succeeding in a time of high labor costs and being able to con-tinually find highly skilled workers in Europe. He noted, however, thatBoucherie enjoys close and personal relationships with customersthroughout the world. This helps build a feeling among the company’swork force that Boucherie is a leader in the industry, and helps in attract-ing new employees as well.
“With the economy slowing down again, there are certainly other chal-lenges ahead, but as long as we keep improving our products and supply-ing customers with improved tools that respond to their needs, there will
September/October 2011 BROOM, BRUSH & MOP PAGE 39
Machinery Manufacturers continued from page 8
Frank Kigyos
John Williams
Continued On Page 49
Domestic Merchandise1404902000 Broomcorn (Sorghum Vulgare Var. Technicum)Used Primarily In Brooms Or In Brushes, Whether or Not
In Hanks or BundlesJune Year To Date
Country Net Q/Ton Value Net Q/Ton ValueHondura 3 12,278
France 6 23,328 32 120,960
Germany 1 3,020
Croatia 1 9,330
TOTAL 6 23,328 37 145,588
9603100000 Brooms & Brushes, Consisting of Twigs or OtherVegetable Materials Bound Together, With or Without Handles
June Year To DateCountry Net Q/Dozen Value Net Q/Dozen ValueCanada 2,814 133,961 18,242 677,170
Mexico 251 8,271 456 17,718
Salvadr 104 3,444
Hondura 80 2,626
Nicarag 12 2,851
C Rica 324 7,498
Panama 68 3,196 723 27,025
Bahamas 156 49,200 590 155,674
Jamaica 486 14,255
Dom Rep 21 6,956
Dominca 5 2,859
Colomb 267 9,388
Venez 5 5,940
Chile 2 3,597 32 8,310
Brazil 517 23,345
Uruguay 8 3,260
U King 263 17,448 7,094 908,899
Ireland 1,886 38,748
Nethlds 269 2,953
Belgium 46 4,520 386 15,722
France 140 29,443
Germany 683 30,086
Poland 378 15,556
Russia 4 2,689 4 2,689
Spain 4 4,719
Portugl 18 9,675 18 9,675
Kuwait 117 3,446 117 3,446
S Arab 1,746 47,097
Qatar 100 9,260
India 16 5,376
Phil R 1 2,709
Macau 100 4,375 100 4,375
China 989 28,014
Kor Rep 294 14,873
Hg Kong 1,749 35,512
Taiwan 131 4,320
Japan 1,298 62,839
Austral 1,178 38,845 3,323 111,745
Guinea 24 5,382
Angola 11 2,808
TOTAL 5,017 279,223 42,633 2,364,565
9603210000 ToothbrushesJune Year To Date
Country Net Q/No. Value Net Q/No. ValueCanada 3,332,685 1,596,748 18,982,284 9,767,072
Mexico 1,290,124 469,624 8,959,361 3,450,840
Guatmal 1,071 10,475
Belize 84,672 60,760
Salvadr 20,760 37,654
Hondura 25,869 102,270
Nicarag 250 3,490
C Rica 135 4,728 575 9,228
Panama 283,334 257,820 883,426 977,629
Bahamas 5,939 28,266
Jamaica 3,456 6,365 37,320 23,405
Cayman 808 7,147
Haiti 1,358 7,577
Dom Rep 13,192 14,257 227,961 149,458
Antigua 3,960 3,283 16,321 18,931
S Lucia 546 5,586 546 5,586
Grenada 120 4,128 1,303 16,234
Barbado 67,810 48,735
Trinid 8,751 45,141 71,246 200,150
N Antil 1,869 12,792
Curaco 9,000 6,437
Aruba 8,156 18,449
Colomb 15,432 10,425 138,855 209,543
Venez 10,800 13,365 371,885 327,911
Guyana 360 5,145 1,152 17,096
Ecuador 28,551 13,522
Peru 40,176 14,448 120,402 71,753
Chile 976 14,249 52,552 60,666
Brazil 126,070 59,817
Paragua 828 8,469
Uruguay 9,341 86,616
Argent 153,485 122,673 642,403 662,960
Finland 12,000 5,480
U King 372 3,802 234,293 451,525
Ireland 432,000 143,675 4,660,451 1,572,420
Nethlds 37,817 168,225
France 6,528 2,872 16,122 17,233
Germany 25,213 256,049 604,708 1,831,727
Austria 29,718 18,210
Slovak 618 3,508
Hungary 609,384 327,180 2,856,712 1,474,064
Switzld 400 4,867
Poland 15,320 14,033
Russia 2,984 30,525 5,084 44,427
Ukraine 5,760 15,030
Italy 5,873 60,099
Turkey 5,540 10,244
Lebanon 1,240 2,547
Kuwait 72,918 36,037
S Arab 16,811 9,720
Qatar 1,188 12,150
Arab Em 141,446 108,622
India 188,160 373,830 716,160 1,424,574
Thailnd 5,904 5,713 8,783 35,175
Vietnam 5,591 57,200
Malaysa 3,662 37,470 8,702 46,817
Singapr 47,377 36,617
Indnsia 67,392 17,588 74,634 63,511
Phil R 21,840 52,553 44,240 110,694
China 827,801 469,388
Kor Rep 401,629 215,236 3,278,011 1,618,864
Hg Kong 579,885 245,346 3,437,595 1,698,936
Taiwan 31,200 12,103 249,720 113,051
Japan 38,943 49,372 244,685 280,766
Austral 52,266 44,486 296,386 344,681
N Zeal 3,300 7,009
Mauritn 2,000 2,900 2,000 2,900
Rep Saf 4,320 9,894
TOTAL 7,626,894 4,408,685 48,873,268 28,661,183
9603290000 Shaving Brushes, Hairbrushes, Nail Brushes,Eyelash Brushes & Other Toilet Brushes For Use on the Person
June Year To DateCountry Net Q/No. Value Net Q./No. ValueCanada 334,843 246,269 2,121,066 1,569,417
Mexico 411,265 105,583 4,100,434 1,364,625
Guatmal 586 5,358
Hondura 72 6,732
PAGE 40 BROOM, BRUSH & MOP September/October 2011
EXPORTSJune Exports By Country
C Rica 4,890 23,542
Panama 2,000 15,800
Dom Rep 3,735 31,603
Trinid 4,561 44,000 19,462 188,097
N Antil 1,511 2,638
Colomb 58,884 33,464 1,768,030 546,518
Venez 478,245 137,903 646,052 182,401
Surinam 2,916 7,097
Ecuador 3,263 21,079
Peru 180 4,140 520 11,960
Chile 8,582 12,460
Brazil 592,750 127,973 989,830 230,240
Paragua 20,640 8,333
Argent 940,000 190,430
Sweden 5,379 49,187
Norway 4,510 43,422
Finland 375 3,428
U King 4,654 28,150 66,403 260,266
Ireland 1,108 13,751
Nethlds 571 9,780 3,914 38,205
Belgium 17,772 170,407
France 20,915 71,773
Germany 7,416 32,350 65,461 322,494
Austria 2,078 19,000
Czech 648 2,592
Switzld 412 3,770 1,736 15,882
Lithuan 1,344 3,116
Ukraine 2,600 12,731 3,284 18,982
Spain 1,201 10,980 4,129 34,951
Italy 62 6,000 41,108 52,353
Turkey 6,250 32,867 6,300 40,367
Arab Em 569 18,264 6,099 95,118
India 60 5,268 4,130 15,943
Thailnd 2,715 24,830 16,488 150,785
Singapr 200,230 72,281
Phil R 1,390 12,403
China 5,776 52,832 41,304 377,728
Kor Rep 684 6,255 4,272 34,157
Hg Kong 5,616 13,517 8,457 43,897
Taiwan 405 3,700
Japan 48 5,837 183,445 84,795
Austral 2,220 31,844 16,359 149,343
N Zeal 8,325 27,306
Ghana 283 10,878 283 10,878
Nigeria 144 2,655
Rep Saf 1,792 102,429
TOTAL 1,921,865 1,005,485 11,373,176 6,761,924
9603300000 Artists, Writing and other Brushes for CosmeticsJune Year To Date
Country Net Q/No. Value Net Q/No. ValueCanada 550,167 1,315,587 2,629,735 5,730,749
Mexico 26,350 97,736 322,350 1,104,951
Salvadr 8,869 14,874
Hondura 19,187 41,390
C Rica 1,295 4,777
Panama 41,679 114,269
Barbado 23,186 85,550
Colomb 7,079 17,019 9,235 26,249
Venez 1,919 9,888
Ecuador 3,771 7,281 3,771 7,281
Chile 3,976 9,813
Brazil 210,695 194,665 594,908 542,954
Paragua 13,644 50,342
Sweden 17,402 66,841
Norway 521 4,036 7,719 30,206
Finland 22,644 86,199 60,459 225,726
Denmark 536,096 1,980,360
U King 97,144 559,244 510,777 2,260,624
Ireland 996 3,674
Nethlds 808 8,375 11,090 52,294
Belgium 19,958 73,637
France 54,542 230,631
Germany 1,145 4,225 19,832 69,727
Austria 4,178 13,017
Slovak 151 9,527
Switzld 5,459 22,929
Estonia 829 8,363 2,822 15,716
Latvia 575 8,579
Poland 34,913 128,818 48,370 178,468
Russia 6,564 30,965
Ukraine 54,915 77,260
Armenia 6,103 22,518
Kazakhs 8,609 101,616
Spain 1,750 2,739
Italy 1,096 4,045 39,928 147,318
Greece 11,160 14,910
Israel 38,869 143,410
Arab Em 3,412 25,119 9,138 46,243
India 2,680 4,001
Thailnd 4,434 22,844
Vietnam 900 9,696
Singapr 1,831 15,144
Indnsia 1,150 4,243 3,105 11,456
Phil R 6,000 5,662 42,000 39,634
China 10,056 37,102 65,344 241,094
Kor Rep 28,322 139,373
Hg Kong 15,985 60,404 54,946 227,077
Taiwan 100 4,500 5,158 24,790
Japan 18,728 69,102 56,933 189,987
Austral 7,876 29,059 84,539 315,286
N Zeal 4,017 15,059
Rep Saf 25,076 92,523
TOTAL 1,020,469 2,670,784 5,530,501 14,919,986
9603402000 Paint RollersJune Year To Date
Country Net Q/No. Value Net Q/No. ValueCanada 205,255 476,696 1,105,210 2,418,303
Mexico 18,572 53,956 173,522 497,301
Guatmal 1,800 2,712
Salvadr 3,864 4,657
Hondura 3,450 11,698
C Rica 10,020 8,568 15,731 115,400
Panama 11,087 17,014
Bermuda 1,056 2,818 17,826 28,675
Bahamas 20 3,210
Jamaica 5,800 5,993
Haiti 1,000 5,400 6,256 13,600
Dom Rep 11,541 81,770 18,601 211,053
St K N 249 4,369
S Lucia 1,042 7,800
S Vn Gr 2,316 2,760
Trinid 7,000 7,924
Colomb 239 4,198
Venez 11,664 32,633
Ecuador 745 13,073
Peru 720 17,634 1,371 29,065
Chile 27,766 36,678
Paragua 174 3,050
Argent 72 3,456
Sweden 39 3,175
Finland 841 2,673
Denmark 3,711 19,159
U King 5,734 41,380
Ireland 5,942 47,828
Nethlds 3,278 15,530 13,285 74,211
Belgium 203 3,569
France 692 7,846
Germany 857 9,543 38,267 136,332
Switzld 930 2,647 19,527 42,815
Russia 2,460 5,711
Israel 651 11,428
S Arab 226 3,975
Qatar 610 3,972
Arab Em 14,664 20,306
Bahrain 780 3,712
India 5,508 24,896 7,609 61,763
September/October 2011 BROOM, BRUSH & MOP PAGE 41
Thailnd 176 11,176
Singapr 2,018 3,600 2,018 3,600
Indnsia 13,356 69,333
China 3,855 67,660
Kor Rep 108 2,719 1,947 34,989
Hg Kong 2,620 51,673
Japan 674 4,039 3,140 20,418
Austral 15,826 179,571 137,594 1,135,383
N Zeal 3,422 13,443 8,059 31,135
Rep Saf 117,596 81,142
TOTAL 280,785 902,830 1,821,407 5,470,986
9603404020 Paint PadsJune Year To Date
Country Net Q/No. Value Net Q/No. ValueMexico 1,023 7,263 45,550 81,321
Nicarag 423 3,000 423 3,000
Panama 47 5,910
Bermuda 1,010 7,166
Dom Rep 252 6,581
Barbado 166 3,215
Peru 1,173 3,127
Argent 715 7,448 715 7,448
Sweden 12 2,676
Finland 4,000 6,640
Belgium 1,120 2,560
Romania 728 5,171
Kuwait 1,761 12,500
S Arab 1,800 6,131
Malaysa 1,310 9,300
Singapr 2,144 8,340
China 1,500 4,860
Kor Rep 1,030 7,310 71,398 520,645
Austral 36,351 76,968
TOTAL 3,191 25,021 171,460 773,5599603404050 Paint, Distemper, Varnish or Similar Brushes
(Except Brushes of 9603.30)June Year To Date
Country Net Q/No. Value Net Q/No. ValueCanada 141,288 1,077,030 825,665 5,734,633
9603908030 Push Brooms, 41 CM or Less in WidthJune Year To Date
Country Net Q/No. Value Net Q/No. ValueMexico 8,592 33,019 15,412 56,769India 1,224 2,670Sri Lka 44,106 176,557 159,912 560,577China 17,548 64,194 288,660 1,172,559Taiwan 420 3,453TOTAL 70,246 273,770 465,628 1,796,028
9603908040 Other Brooms, NESOIJune Year To Date
Country Net Q/No. Value Net Q/No. ValueCanada 75,018 124,804 497,060 942,501
Mexico 443,358 595,645 2,303,477 3,734,477
Guatmal 20,940 22,259 100,689 109,213
PAGE 46 BROOM, BRUSH & MOP September/October 2011
Salvadr 107,232 125,869
Colomb 126,911 240,020
Brazil 41,340 53,240 205,100 250,289
U King 2,060 28,299
Germany 15 3,621
Czech 58,632 50,177 237,816 240,533
Lithuan 250 5,397
Spain 9,152 25,305 40,856 77,834
Italy 79,669 150,528 513,684 886,921
Israel 1,320 2,865
India 2,655 9,868 23,750 44,069
Bngldsh 60 2,700
Sri Lka 141,112 206,584 692,616 1,104,368
Thailnd 8,100 12,850 53,350 89,937
Vietnam 5,900 8,156 42,810 59,711
Phil R 80 2,414
China 526,731 1,611,559 3,039,411 8,433,906
Kor Rep 105 13,450 2,705 18,261
Taiwan 4,437 27,810
TOTAL 1,412,712 2,884,425 7,995,689 16,431,015`
9603908050 Brooms, Brushes,Sqeegees, Etc., NESOI
June Year To DateCountry Net Q/No. Value Net Q/No. ValueCanada 2,046,806 12,451,865
Mexico 2,798,134 15,745,632
Guatmal 6,115
Salvadr 22,567 150,474
Hondura 1,050,410 7,330,564
Dom Rep 207,526
Colomb 89,594 483,086
Brazil 64,845 311,289
Sweden 19,001 90,629
Norway 16,691
Finland 45,679 124,077
Denmark 148,830 1,075,057
U King 81,055 327,415
Nethlds 300,775 1,377,516
Belgium 133,830 691,295
France 14,540 62,544
Germany 248,217 1,221,828
Austria 2,252
Czech 96,609 500,167
Switzld 30,523 81,243
Estonia 2,718
Latvia 25,052
Lithuan 52,133 196,215
Poland 33,637 221,210
Russia 5,880
Spain 52,276 525,381
Italy 622,742 2,744,340
Slvenia 13,850
Romania 15,792 145,167
Turkey 10,788 36,220
Israel 4,903 165,582
India 44,732 315,251
Pakistn 380,963 2,463,525
Sri Lka 338,209 1,811,787
Thailnd 395,842 2,263,382
Vietnam 95,049 232,416
Malaysa 34,999 133,491
Indnsia 21,957 258,994
Phil R 4,573 4,573
China 30,916,379 175,645,494
Kor Rep 236,418 1,396,530
Hg Kong 560,932 4,769,998
Taiwan 1,444,821 7,175,008
Japan 75,218 453,899
Austral 97,469 425,507
Egypt 5,124 74,960
TOTAL 42,636,371 243,763,695
September/October 2011 BROOM, BRUSH & MOP PAGE 47
Large Solar Installation In PlaceAt Patrick Yarn Mills
According to Patrick Yarn Mills, provider of technical and earth-friendly yarns, the company has commissioned one of the largest private-ly-owned solar installations in the North Carolina Piedmont region.
The new solar installation generates 140,000 kWh (kilowatt hours) per
year of clean photovoltaic power — equivalent to the power generated by11,310 gallons of gasoline or 234 barrels of oil and enough to power 14average-sized homes.
“We’re excited to be generating our own electricity from the sun,” saidGilbert Patrick, president of Patrick Yarns. “We’ve been committed tosustainability for years, and this is another step toward helping create abetter planet for future generations and a better environment for our com-munity. It also provides our customers with environmentally sound, Spunby the Sun™ solutions to their textile requirements.”
The public can monitor how much electricity the system generates viasolar through a web application at www.patrickyarns.com/monitor.
The photovoltaic system installed by Argand Energy Solutions wasmade possible by a grant from theNC Energy Office. All of the sys-tem’s major components qualifyfor funding under the “BuyAmerican” provision of theAmerican Recovery and Rein -vestment Act signed into law in2009.
Patrick Yarn Mills also manu-factures a line of eco-friendly tex-tile products known asEarthspun® yarns, which are made from recycled PET (RPET) plasticsfound in soda bottles and combined with recycled cotton or other eco-friendly fibers. According to the company, all its facilities use highly effi-cient lighting and motors, produce no greenhouse gases in its processes,and are working toward a zero landfill goal.
Patrick Yarns officials say its commitment to creating jobs in the com-munity is well documented. Time magazine highlighted the company asa rare U.S. textile manufacturer thriving in a global economy.
Visit www.patrickyarns.com for more information.
Correction:In the story featuring Ha-Ste Manufacturing in the September online
eNews issue of Broom, Brush & Magazine, it should have said:n Looped-end wet mops: Ha-Ste says its looped-end wet mop line
includes products for all situations, from high intensive laundering togeneral purpose use. The MicroKleen line alone is available in 114 dif-ferent combinations of style, color and banding.
Patrick Yarn Mills’ new solar installation generates 140,000 kilowatthours per year of clean photovoltaic power.
Raw Material
Raw Material Price Fluctuation Remains Challenge For Suppliers
Harrell Kerkhoff, Broom, Brush & Mop Editor
The fluctuation in raw material prices continues to be a challengefor many companies doing business in the United States, includ-ing those involved in the supply and production of brushes, mops
and brooms. Four company representatives were recently asked about the status of
various raw materials they work with on a daily basis. The general con-sensus is that many of these materials are readily available. Pricing, how-ever, if often less stable. Hoge Brush Company Manager David Zwiep, of New Knoxville,
OH, reported that the wood the business uses comes from domesticsources. The company, which produces such products as brushes, blocksand push brooms, is a division of Hoge Lumber Co.
“We make wood blocks for ourselves and a variety of other companiesusing hard maple, ash, sycamore and a variety of other wood species.Some of this wood comes in the form of logs, which we saw and dry,”Zwiep said. “We are a pretty traditional company, using the same style ofblocks from the same wood species over the years.”
He added that the current lumber market remains on the weak side.This is due, in part, to today’s slow construction business in the UnitedStates.
“Supplies for wood are tight. Our suppliers are reacting to the sameconditions as seen with the construction market. There is a lot of contrac-tion taking place in the lumber business as this market remains down andthere are not as many customers right now,” Zwiep said. “Wood prices,however, haven’t reacted as much as one would think. In fact, in somecases, supply is so tight that prices have gone up.”
Along with blocks, Hoge Brush Company also produces various typesof brushes that require either natural and synthetic fiber. Zwiep reportedthat prices for many types of fiber have increased.
“This is true for both natural and synthetic fiber. These price increasesare not dramatic jumps, but ongoing,” he said. “The good news is there isplenty of supply available.”
When asked about the state of overall business as of late, Zwiep report-ed that a soft market continues although there are some bright spots aswell.
“With brushes, there remains a lot of pressure from imports. Many peo-ple are also waiting to see how the national political climate plays out,”he said.
Because it provides deep drawn metal stampings, handle ferrules andbroom caps for the brush, broom and mop industries, the status of suchraw materials as copper, bronze, aluminum and stainless steel strip is veryimportant for Line Mfg., Inc., of Walcott, CT.
“All these raw materials seem to be readily available with normaldelivery times for the most part,” Line Mfg., President BruceGarthwait said. “The same holds true for the drawing oils and lubricantsthat we use.”
He added that today’s price of steel continues to experience greatervariations than in the past.
“It goes up when the price for commodities goes up and there is greaterdemand, and then drops again when demand decreases,” Garthwait said.“Our major costs are associated with raw materials. This includes thelubricants we use. Our next major cost is labor.”
Overall, Garthwait reported that recent business activity has been spo-radic.
“You just never know. We get orders that make us busy, and then busi-ness gets slower. It’s been going back and forth. There is really no conti-nuity or major backlogs right now,” he said.
Reporting on recent broom corn and yucca fiber activity for the produc-tion of natural brooms was R.E. Caddy & Co. President RichardCaddy, of Greensboro, NC.
A total of 339 short tons of broom corn was imported into theUnited States during the first seven months of 2011, with a total valueof $712,962, according to the latest report from the U.S. Departmentof Commerce. The cost per ton of this broom corn was $2,103, with acost per pound of $1.05. All but 9 short tons of these imports camefrom Mexico. For July, 13 short tons of broom corn were imported,with a total value of $32,581 and a cost per ton of $2,506 ($1.25 perpound).
Caddy said he is surprised by July’s light import figure of 13 short tons,but feel the price per pound is fairly accurate, especially if it contained amixture of hurl, insides and/or raw broom corn.
“The Mexican processors I work with still have broom corn available.I don’t think they are as busy as in the past right now,” Caddy said. “Weare still able to get what broom corn we need. The quality of the recentlyharvested Torreon broom corn from Mexico looks pretty nice, and pricinghas been steady. Whatever supply is available for export to the UnitedStates right now is enough to take care of current demand.”
He added that the price for yucca fiber remains stable and quality is“decent.”
“It’s probably not the best yucca fiber that we have seen over the pastyear, but it’s good enough. There are no real problems. You can get a loadin two to three weeks.”
R.E. Caddy also supplies mop, broom and brush producers with vari-ous types of wire. He reported that wire rod remains in good supply.
“I haven’t had any negative issues either with the quality of the rod,”he said. “Rod supplies do get scarce from time to time, which can increasepricing. This has not happened lately.”PelRay International CFO Bart Pelton, of San Antonio, TX, also
reported on the current availability of broom corn and yucca fiber. Heexpects broom corn imports for August and September to be higher thanJuly’s 13 short-ton mark.
“I feel a lot of people were waiting for the new Torreon crop to becomeavailable in July and then see what was going to happen with prices,which did increase some,” Pelton said. “The second Torreon crop usuallystarts harvesting in late September and into October, but we haven’t heardanything about it yet. People are not traveling to where the broom corn isbeing grown very much right now due to the violence in northern Mexico.It’s hard to get information.
“Yucca fiber prices, meanwhile, are a little higher. This may be due toslightly higher costs involved in doing business in Mexico. The Mexicanpeso has decreased in value during the past few weeks. At the moment,this hasn’t impacted prices. The peso has to stay down a little longerbefore we start seeing some price discounting taking place. This is truewith everything coming from Mexico.”
always be an interested market,” Williams said. Contact: Boucherie USA Inc., 8748 Gleason Rd., Knoxville, TN 37923. Phone: 865-247-6091.
Since the company’s establishment in 1957, Italy’s BizzottoGiovanni Automation has worked to affirm itself as a key providerof innovative machinery for the brush manufacturing industry,
along with profitable technical solutions, according to Bizzotto GeneralManager Marco Bizzotto.
“Following the path marked out by our founder, Giovanni Bizzotto, aperson with a passion for mechanical equipment, and putting to good usethe experience achieved after many years of hard work, BizzottoGiovanni Automation has evolved in the mechanical and industrial sec-tors,” Marco Bizzotto said.
He added that due to constant technological research and development ofsophisticated automation systems, the company has widened its horizons, pre-senting itself as a supplier of totally customized machinery for different indus-trial sectors. The company has also focused on offering a complete partnership
with customers that expresses itself in thecapacity to understand the needs of each cus-tomer and provide them with “made-to-meas-ure” solutions.
Bizzotto specializes in providingmachinery for three main areas. They are: • Handle Machinery Sector— Sanders,
chucking machinery (i.e. doming, tapering,tenoning, threading, end boring. cross bor-ing, etc.), painting machinery (lacquering),labeling systems and packing machinery
for the production of wooden handles;Complete machinery lines are also available for the production of
metal handles, starting from flat steel or aluminum band coil and includ-ing painting lines; machines for assembling various plastic inserts (hang-er tips, thread inserts, mop inserts, tapered inserts, etc.); boring, deform-ing and cutting equipment; as well as labeling systems and machines forpackaging with the use of different systems including robotized; • Woodworking Machinery Sector — Profiling and shaping
machines; boring and tapping machines; and sanders for the production ofbroom and brush blocks, paintbrush handles and similar items; and,• Industrial Automation Sector — Customized machinery for the
preparation, positioning and assembly of particular products and acces-sories for the cleaning industry (mops, floor scrubbers, detergent dis-pensers, velvet lint brushes for clothes cleaning, adhesive lint brushes forclothes cleaning, toothbrush/accessories etc.), automotive industry andthe kitchen appliance industry.
“Our commitment is to continue to provide new and profitable techni-cal solutions for customers. To reach this aim, the company recentlyincreased its engineering department as well as added to its team ofdesigners and electronic experts in order to provide the most suitable andup-to-date technical solutions possible. This focus is being applied to themachinery we produce,” Marco Bizzotto said.
He added that the current state of the world economy has not affected thecompany too much. He feels this is due to Bizzotto’s ongoing commitmentto understand customers’ needs and provide state-of-the-art solutions.
“We are aware that the success of our customers keeps us successful aswell,” Marco Bizzotto said.
Many of these customers will be attending InterBrush in 2012, a veryimportant event for Bizzotto Giovanni Automation as well. The compa-ny’s goal at InterBrush will be to meet with current and new customers,“Who can appreciate the technological solutions that we offer, specifical-ly designed for their own needs,” Marco Bizzotto said.
“Most of our customers, as broom, brush and/or mop manufacturers,
choose to periodically develop new products and models, increasing thevalue added to their products,” he explained. “They invest in innovationas it’s the only way not to get involved in the war of falling prices amongcompetitors. Those companies that produce innovative products oftenreceive more profits from these products.”
Continuous evolution of products pushes companies to search for flex-ible technologies and, at the same time, for the lowest in investment andmanagement costs.
“All this requires the use of technologically advanced production and,therefore, machinery with high flexibility in order to continually adapt tonew requirements,” Marco Bizzotto said. “We believe the most importantthing we offer is a complete partnership with customers. This expressesitself in the capacity to understand their specific needs, and provide cus-tomers with ‘made-to-measure’ solutions.”
According to Marco Bizzotto, his company does not simply buildmachinery. Instead, its complete staff, with competencies that range fromdesign to engineering, supports each customer in the evaluation of possi-ble ergonomic and technical improvements for which a specific machineand automation must be created.
“Once the final specifications of an item are identified, our team ofdesigners and electronic experts set the most suitable technical solutionsin place to apply to the machinery. A sophisticated computer net allowsfor strict cooperation between different departments. This guarantees aconstant updating capability for any phase of the project, and the applica-tion of the most innovative and reliable technologies,” Marco Bizzottosaid. “Only then will each component be produced with great care whilethe final assembly of the parts and testing also takes place. Lastly, a teamof qualified technicians attend to the installation and start-up of ourmachinery. We can provide this service anywhere in the world.”
Bizzotto officials believe in the slogan, “The solution is … automa-tion.” The company feels automation should be applied as much as pos-sible in all production processes.
“We are currently developing some fully automatic production lines;however, most of our machines are custom-made, and most of our proj-ects must be kept confidential,” Marco Bizzotto said. “This is an aspectof how we do business and it’s appreciated by our customers.”
He added that a continual push toward automation is important as ithelps decrease production costs. It not only reduces manual labor butoptimizes productivity — assuring a high and consistent standard of qual-ity that cannot be attained through a manual process.
Overall, Marco Bizzotto said the company has carved out a niche with-in the machinery marketplace by providing customized and flexibleequipment, while also supporting customers during every step of the pro-duction process.
“Each solution that we propose is dedicated to a specific item or itemsthat our customers need to produce. It’s with the passion of an ‘artisan’that our state-of-the-art solutions are produced and highly appreciated inmany parts of the world,” he added.
Looking ahead, Bizzotto will continue to work on providing a moreaccurate design and application of advanced automation machinery tooptimize the production process, according to Marco Bizzotto. It’s alsoimportant to the company that officials keep a watchful eye on costs andother business-related challenges.
“Achievement of this requires a serious commitment that we are ableto put together as a company due to our experience and dedication to serv-ice for the benefit of all customers,” he added. “Bizzotto’s future centersaround building greater custom automation systems for all areas ofassembly and packaging as the future of the broom, brush and mop indus-tries is contingent on developing new products and models.”
Contact: Bizzotto Giovanni Automation Srl., Via M.Buonarroti, 67 Paviola di S. Giorgio in Bosco (PD).
The 2011 National Broom & Mop Meetingis scheduled for Thursday and Friday,November 17-18. Industry manufacturers andsuppliers will meet at the Renaissance St.Louis Airport Hotel in St. Louis, MO,(www.marriott.com/hotels/travel/stlsa-renais-sance-st-louis-airport-hotel/) located at 9801Natural Bridge Road, St. Louis, MO 63134.This is a new St. Louis location for the meetingthan in the recent past.
The meeting will allow attendees to discusscurrent market trends in the rapidly changingfloorcare and related business segments.
On Thursday evening (Nov. 17) attendees areinvited to a welcome reception hour followedby a round table dinner.
Friday morning’s meeting (Nov. 18) willinclude supplier presentations on the impact ofglobal supply issues. New for this year’s meet-ing, a panel discussion comprised of industryleaders will replace a keynote speaker. In addi-tion to specific attention directed toward theindustry’s challenges for both the short and longterm, the panel of manufacturer and supplierrepresentatives will offer insight to questionssubmitted by attendees.
The meeting is targeted for conclusionaround noon Friday.
For those attendees traveling by air, the hoteloffers a complimentary shuttle service. Hotelreservations must be made by Thursday, Oct.27, 2011 to secure the rate of $99. Reservationscan be made by phone at 1-800-468-3571.Make sure to reference the National Broom &Mop Meeting for special rates and rooms.
For more information, contact Co-ChairJoel Hastings, Nexstep Commercial Products(exclusive licensee of O-Cedar Commercial)at 800-252-7666, email [email protected]; or Co-Chair Andrew Dailey, JonesCompanies, at 877-849-2767, email [email protected].
2011 National Broom & Mop MeetingScheduled For November 17-18
Tanis, Inc., AcquiresRegal Manufacturing
Company
Tanis, Incorporated has acquired Regal Man -ufacturing Company, of Fond du Lac, WI. The twobrush manufacturers have had more than twodecades of collaboration, and Regal’s formerowner, Greg Fuhrman, will continue to beinvolved in the company going forward.
Tanis, Inc., is a manufacturer of standard andspecialty brushes for industrial purposes, withmore than 30 years’ experience. The company hasa customer base in an array of industries — fromagriculture and food processing through materialhandling, industrial distribution, printing and mul-tiple others.
Regal Manufacturing Company, established in1934, specializes in twisted-in-wire and staple-setbrushes.
Tanis, Inc. is a privately held, ISO 9001-2008-certified manufacturer with a wide offering of twist-ed-in-wire, staple-set, strip and rotary brush prod-ucts. Its abrasive brush selection features traditionalabrasive nylon filament materials plus CeramiX™— a new filament technology developed in con-junction with 3M™. Visit www.tanisinc.com or call800-234-7002 for more information.