Displaying spotless, shiny floors that a hospital would envy, Injectronics Corp. recently unveiled the $1.5 million transformation of its two facilities. It increased one facility's space by 50 percent and boosted its overall clean room space by 40 percent.
“Both facilities have been expanded and renovated. We added both clean room and white room space,” said President and CEO Paul Nazzaro, during a June 14 tour of the Clinton plants.
“When we sold the automotive business [in 2006], our medical business was about $10 million and we've more than doubled that in the last six years,” he said.
He noted that sales were “‘north of $20 million,” with double-digit growth in the previous year.
Nazzaro and his management team pointed to the drive for perfection and zero defects, as well as a culture of effective cost management, as key ingredients that medical companies strive for. Injectronics has been growing organically with its customers and recently added at least one more customer as it plans ahead. It makes components for defibrillators, patient-monitoring devices and diagnostic disposables.
Injectronics' Clinton headquarters is 80,000 square feet, with 4,500 square feet of ISO Class 8 clean room space. It contains injection molding machines as well as a thermoforming machine, making it possible to produce components and packaging in the same Class 8 area. It also converted 10,000 square feet to accommodate white room work.
The Westborough, Mass., plant is about 15 miles away and was expanded by 50 percent to 30,000 square feet by acquiring additional space within the building. It now has a 5,000-square-foot clean room and is designed for high-volume, automated work such as diagnostic disposables. Work cells can be set up for fully automated lights-out operations.
Westborough now has two conference rooms and a new reception area. It is nearly complete.
Injectronics also upgraded the ancillary services such as water, electrical and material handling for the facilities.
Overall, it has 21 injection molding presses ranging from 20-618 tons and it is planning for a sizable investment for more machinery in Westborough in the next year or so. It has 85 employees overall and expects to add to that total as well.
“We buy equipment for the application,” noted Michael Simmons, vice president of operations and engineering.
Company officials stressed that Injectronics' success has been earned by entering the product-development process early and then helping the client to manage the project through the various stages.
Simmons said the combination of low-, medium- and high-volume setups allows the firm's clients to work with one supplier. Thus, Injectronics can adjust as the need arises.
One company that Nazzaro could not reveal has worked with Injectronics for eight years and has cut costs by 22 percent in that time period, he said.
Jeremiah O'Connor, director of sales and marketing, admitted that performance helps keep the company's customers happy, but he said that adding new customers is more about providing problem-solving.
That's where experience counts. Nazzaro, who has been with the company 22 years, said turnover is low and Injectronics has worked on incentive and communication efforts to keep everyone focused on service.
There are bonus programs and outings such as summer barbeques to keep employees interested and informed. New flat-screen televisions in various areas of the Clinton building give information about projects and company news. A similar setup will be added soon at Westborough.