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[Featured Video] HeliXwing Conference Table Project

Bruce Rosenbaum of Modvic has never been known to pursue ordinary projects. In August 2018, his latest innovative venture was installed at its final location: The Brush Innovation Center (BIC) of Sanderson MacLeod Inc. Envisioned to be a fusion of Sanderson’s industrial past, innovative present, and groundbreaking future, Rosenbaum created a one-of-a-kind conference table to serve as the centerpiece for the company’s newly renovated BIC. M-Pact TV recently produced a video documenting the story of how this unique collaboration came to be. In it, they explain the origins of the table’s concept, how the table was made, and the final touches which led to the completion of the HeliXwing conference table.

The table is nearly 100% fashioned from long-retired brush making tools, automation equipment, and industrial revolution era antiques found in the company’s warehouse and local flea markets. Its construction would ultimately involve an unusual collaborative team comprised of local students, teachers, artists, tradespeople, and Sanderson MacLeod toolmakers.

[Press Release] Sanderson MacLeod Awaits Completion of Rosie II Stylet Machine

Sanderson MacLeod To Institute Second Revolutionary Guidewire and Stylet Production Line:

  • Sanderson MacLeod set to install production line by December, 2018.
  • Rosie II name inspired by longtime operator who walked seven miles a day at her station.
  • Sanderson MacLeod is the world leader in OEM precision guidewires and stylets for the medical and industrial markets.

Sanderson MacLeod recently announced the planned introduction of a second Automated Stylet Machine work cell, to be installed in late 2018. Currently under construction, the machine was designed to produce fully automated closed-nose medical stylets up to 20 feet long. The machine was proudly engineered and built by Sanderson MacLeod’s internal engineers, partners and toolmakers. The new line will provide expanded capacity and unparalleled production controls for brush consistency such as fiber density, multistage overtwist capabilities and dimensional tolerances of up to a thousandth of an inch. Such automation innovations allow Sanderson MacLeod to remain the world leader in OEM precision guidewires and stylets for the medical and industrial markets.

The machine cell has been named Rosie II, in further recognition of a recently retired veteran operator, Rosie Noble.

When Rosie Noble retired after 50 years at Sanderson MacLeod, it was clear that it would be impossible to find a replacement for her. After all, she covered almost seven miles a day walking back and forth in 14-foot lengths making medical stylets. With her retirement fast approaching, a logistical problem became apparent; how to replicate the work she did everyday for 50 years. The engineering team at Sanderson MacLeod began brainstorming how to apply machine and brush making knowledge in order to assist operators to work faster and more efficiently.

“Automation like the Rosie II is only possible when automation is built by people who clearly understand the end product and the various challenges its process requires,” said Mark Borsari, President of Sanderson MacLeod. “Our latest production expansion is yet another successful effort put forth by our engineering team and one they should be proud of. Not only will their efforts give our clients an edge in highly competitive markets, but it will further reinforce our dedication to patient safety through technically superior and consistent cleaning and sterilization products”.

Automation is always a hot button issue in the world of manufacturing. Many see the word and think of layoffs and replacing current employees. At Sanderson, automation serves a different purpose… Technological advancements are utilized by our engineers to give our employees (some of the most experienced and talented brushmakers in the world), new proprietary tools and technology to do their jobs even better than before. It also allows them to spend their time on more crucial components of the brush making process, rather than spending most of their time walking seven miles a day back and forth on one machine, as Rosie once did.

By giving Sanderson operators such a technological advantage, they are able to achieve higher and more predictable efficiencies. These new high capacity production cells are expected to reduce lead times and enhance product offerings including stylet assembly, protective systems and new product design options.

The Rosie II is also capable of being interlinked to Sanderson’s automated Z-Tip machines to augment the existing product with a protective tipping process exclusive only to Sanderson MacLeod. The Z-Tip brush is an exclusive, proprietary innovation which created a new manufacturing process using high-energy, fusion-welding technologies. The result is an entirely new protective brush tip that melts the brush’s preconstructed core wire into a consistent, smooth and inseparable protective tip, known as the Z-Tip.

The Rosie II is yet another example of Sanderson MacLeod reaching outside of the brush industry for inspiration to create proprietary automation solutions for those customers seeking cost effective, superior twisted wire brush solutions.

Whatever happened to Rosie? Well, we still see her around town…Walking, of course. While the machine bears Rosie’s name, it also symbolizes the dedication and hard work the employees of Sanderson MacLeod, Inc. have put in over the last 50+ years.

Sanderson MacLeod is a contract manufacturer specializing in domestically-produced twisted-in-wire products, including twisted-wire medical brushes, firearm cleaning brushes, cosmetic brushes and general purpose cleaning brushes. Established in 1958, the company employs approximately 120 people and operates a modern 137,000 square foot facility in Palmer, MA.

[Press Release] Sanderson MacLeod Celebrates 60 Years of Innovative Manufacturing

Looking Ambitiously Towards the Future of Brushmaking:

  • The past 60 years have seen Sanderson Macleod develop numerous industry-changing innovations such as the first twisted-wire mascara brush, the revolutionary Z-Tip, and Z-Tip+ technology
  • Continued focus on customer satisfaction and integration has served as a major motivation for company-wide LEAN Six Sigma implementation
  • The company expresses gratitude to its extremely loyal employees to which it owes the continued success

In 60 years, the twisted-wire brush industry has taken massive leaps forward. Consistently at the forefront of these advancements has been Sanderson MacLeod. Initially focused on catering to the cosmetic industry, Sanderson MacLeod has worked tirelessly to diversify its skillset into other markets. The past ten years have seen a dramatic increase in demand for other twisted-wire applications including medical sterilization and diagnosis, firearm cleaning and customer specific OEM cleaning and deburring products. When most companies sought to export operations in an attempt to reduce cost, Sanderson MacLeod remained committed to domestic manufacturing. These efforts included extensive automation investment and process driven LEAN manufacturing integration in their Palmer, Massachusetts facility.

“We really do have an inspiring blend of people, process, and technology. That’s the key to our continued success,” said company president, Mark Borsari. “Together, we’ve worked hard refining every aspect of our business. And, I think it shows when you consider not only our delivery and quality results, but in the way we can rapidly innovate products for the brush industry.”

For the company, innovation continues. In late 2017, Sanderson MacLeod proudly announced the expansion of their Brush Innovation Center. The center, often referred to as the BIC, first opened in 2015 and due to increasing demand was later expanded in July 2018. The center’s collection of dedicated sampling equipment allows for real-time prototyping of a brush or applicator products. Using Sanderson MacLeod’s expert engineering staff, changes and improvements can be made until the product is perfected. The expansion of the BIC allows Sanderson MacLeod to further establish itself as a global leader in twisted-wire brush manufacturing.

In the past decade, growth in new markets has allowed for further innovation in a variety of areas. In 2010, Sanderson patented the Z-Tip twisted-wire brush. The Z-Tip is produced using a manufacturing process that leverages high energy fusion welding technologies to melt a pre-constructed core wire section of a twisted-wire brush into a consistent, smooth and inseparable protective tip.

Sanderson MacLeod is a contract manufacturer specializing in domestically-produced twisted-in-wire products, including twisted-wire medical brushes, firearm cleaning brushes, cosmetic brushes, and general purpose cleaning brushes. Established in 1958, the company employs approximately 120 people and operates a modern 137,000 square foot facility in Palmer, MA.