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Customer Highlight: How NPF Improved Yield

Since 1927, New Process Fibre has been committed to producing high performance, cost-effective products. By performing every step of our manufacturing process in-house rather than outsourcing, we maintain oversight of the entire project to eliminate discrepancies, ensure timely delivery, and provide customers with high quality finished products.

One of our customers, recently utilized our in-house non-metallic stamping services to improve the efficiency of their manufacturing process.

Customer Highlight

Woman jogging down an outdoor trail at sunsetBased in MI, our customer manufactures medical foot orthotics for global distribution by healthcare professionals; the inserts are vital for people with medical problems related to the foot, ankle, knee, and back. One of our customer’s most popular products is specifically designed for athletes who need balance support when participating in physical activities.

To expedite and improve production of these athletic inserts, our customer needed a manufacturer who had experience working with sheets of acetal copolymer, the key material in their product. The New Process Fibre team was ready to assist.

Improving the Process

The athletic inserts required 24” sheets of acetal copolymer, but our extruders were designed to produce 38” sheets. To achieve the necessary size, we started the job by trimming the material twice: first from 38” to 36” sheets, and again from 36” to 24” pieces.

White orthopedic insole gel isolated on black backgroundWhite orthopedic insole gel isolated on black backgroundAfter producing a set of 24” acetal copolymer sheets using this method, our team discovered a more efficient technique beneficial to both companies; by updating the product design to use larger sheet dimensions, we could extrude the original 38” sheets and make just one cut to reduce them down to 36”. Because only one cut was required, this solution improved efficiency, yield, and cost-effectiveness for both companies. Even better, our customer now saves money on production costs and passes those savings directly to their customer through lower product pricing.

By constantly seeking opportunities to improve manufacturing processes for our customers, we were able to identify a cost-effective solution for our customer, while also avoiding excess material waste.

New Process Fibre: Ready to Help with Your Next Project

We are continuously updating and enhancing our in-house manufacturing capabilities to make it possible to save our customers time and money. Just as we did with this particular customer, we aim to help all of our customers become more efficient, increase yield, and eliminate unnecessary costs.

npf-brochureWith an extensive inventory of equipment for use on virtually any job, our facility is  well equipped to meet any company standard. Our quality management system is extensively documented with ISO registration.

To learn more about NPF, our capabilities, and our drive to go above and beyond on every project to better serve our customers, download our Company Overview.

DID YOU KNOW...

THERMOPLASTIC FORMULAS, SUCH AS NYLON AND TEFLONTM PTFE, PROVIDE A HIGH-PERFORMANCE, LOW-COST ALTERNATIVE TO THE TRADITIONAL METAL WASHERS, GASKETS,AND SPACERS?

Download Material Selection Guide:Nylon and TeflonTM PTFE

Download Guide
Download Material Selection Guide

Additional Resources

Your Guide to Non-Metallics Download
Acetal Components Explained Download>