June 11, 2024
Hamburg, NY — Contract manufacturer Staub Precision Machine announces the expansion of its operations with the addition of a 60,000 square foot manufacturing facility on its existing manufacturing campus at 3 Staub Drive. This announcement represents the company’s commitment to innovation and growth as a US manufacturer.
Staub – new 60,000 SF facility construction.
Strategically located just south of Buffalo, NY, Staub has broken ground on the 10 acre parcel of land adjacent to two of their other buildings on their manufacturing campus. After years of planning, construction of the new facility started in Q1 2024 with completion targeted for Q1 2025. This facility is just the first of two strategic phases that will bring Staub to the forefront of American contract manufacturers.
History of Growth
This isn’t the first time the company has expanded to meet demand. As they approach the 50 year anniversary of the company next year, the historical timeline of change and growth has been impressive. Founded in 1975 in a garage, Staub operated there until 1995 when it was moved into an old grocery store building in Hamburg. In 2010, the growth continued by adding 2 more buildings, and was followed up with an ownership change. Today’s planned expansion will be a continuation of the growth, progress and innovation Staub has amassed over the years and will be a cornerstone on their continued journey.
Staub – the walls go up on the new building project.
Production will continue in Staub’s other manufacturing facilities nearby. The addition of this advanced manufacturing space will help bring some fabrication activities under one roof by consolidating key production lines and streamlining manufacturing processes. The new facility boasts dedicated areas for improved quality and inspection, climate controlled storage and warehouse, dedicated areas for inventory, a unique floor layout and separate loading dock that will allow raw materials to come in while maintaining strict quality control measures. There will also be employee training and meeting space and more.
“We are excited to see new efforts to modernize all three entities and the investment in Staub’s future should lead to a growth in new contract manufacturing projects, new customers and allow us to gain access into new markets and industries,” said Jonathan Halas, Project Manager and champion of Staub’s new facility.
The new facility will house an array of 3, 4 and 5-axis mills, lathes, finishing equipment as well as other in-house capabilities used to complete contract jobs for customers in a number of different industries such as aerospace, medical, tech and communication.
Quality & Inspection
The new facility is being built specifically with adherence to ISO and AS9100 quality standards in mind – including a larger and more capable quality department. It will encompass a state-of-the-art, temperature controlled quality area that will surpass the strict ISO & AS9100 quality standards to deliver products that exceed customers’ requirements in these challenging industries.
Unique to the new facility is a dedicated logistics area that is laid out in such a manner that it promotes the FIFO (first in, first out) inventory management, minimizes FOD (foreign object debris) risks, and isolates the primary manufacturing area to maintain strict temperature and humidity environment required to hold micron tolerances. All facility layout design requirements for the world-class components manufactured by Staub.
Capacity & Capabilities
Years of manufacturing experience were put to use in the planning of the new building. Not only was the focus on larger space for more capacity, it was designed to optimize every facet of the production process focusing on Lean manufacturing principles. This will maximize Staub’s capacity and encourage growth with contract manufacturing projects looking to harness the wide variety of in-house capabilities they have.
“Our new plant will play a pivotal role in acquiring new contract manufacturing business and providing precision machined solutions for customers looking to maximize every efficiency possible. Combine our range of in-house machining options, finishing options, and assembly with our engineering team and we feel we can do more for customers who are looking to optimize their business with a one-stop option,” said Kevin Ernst, Sales Manager, Staub Precision Machine.
Innovative Infrastructure
The first planned stage of the new expansion will be a consolidation of all area operations under one room to optimize efficiencies in operations and quality procedures,” said Halas, “But there are also other innovative things we focused on regarding the infrastructure that will help us be as efficient as possible.”
A couple of behind-the-scenes features in the new building include a centralized coolant system to support the high level of advanced equipment that will be housed in that building. Temperature control is key in maintaining rigid quality requirements for customer projects.
Additionally, there is a planned installation of modern uninterrupted power source (UPS) which will improve the quality of power feeding equipment. This will reduce unnecessary equipment downtimes due to power outages and interruptions, therefore further reducing scrap and waste associated with power interruptions and losses.
Workforce Development
As an ongoing advocate for workforce development, this new building will allow Staub to develop skilled employees, train people, and provide ongoing professional development. While the expansion will provide a 5% increase in workforce, the true goal is to utilize modern technology to improve skilled machinists and technicians within a STEM (Science, Tech, Engineering & Math) environment. Growing and improving staff skills will result in a broadened offering of capabilities and a further expansion into aerospace and medical industries.
This new manufacturing space should help Staub broaden their capabilities beyond their current facilities and help them concentrate on bringing in new contract manufacturing opportunities that will take their business into the next 50 years.
By partnering with local companies, Scheid Artichectural and Lehigh Construction, Staub is expecting the exterior of the building to be done by the end of the year with completion of the facility sometime mid-late 2025.
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Staub Precision Machine, is a leading innovator in precision machining and contract manufacturing. Located in Hamburg, NY, Staub is certified to AS9100 and adhering to rigorous ISO 9001 quality standards, and operates as a production shop, specializing in recurrent, high-volume production of component parts for manufacturers across the country. State-of-the-art, automated equipment allows Staub to provide CNC Milling & Turning, 4 & 5 Axis machining, finishing and value-added services. Between an in-house engineering staff and an extensive range of production equipment and capabilities, Staub’s facility custom manufactures components and subassemblies that not only meet, but exceed expectations. Contact Staub today.