You can’t pick up an electrification industry trade magazine lately without reading about new developments in the field of energy storage. The technology offers numerous benefits… It can smooth demands on the local electrical grid, negate concerns with solar/wind energy fluctuations, lower costs to end-users by avoiding peak-rate surcharges, harness the outputs of multiple sources of renewable energy, provide backup capabilities for critical infrastructure (i.e. hospitals), delay local Governments needing to invest in costly grid improvements, and more.
Often, the acronyms ESS and BESS seem to be used interchangeably. Both refer to Energy Storage Systems, which are used to store and release energy, but there is a difference between the two.
ESS stands for "Energy Storage System." It is a broad term used to describe any system that stores energy for later use. This includes CHEMICAL (i.e. biofuels, hydrogen), ELECTROCHEMICAL (i.e. Batteries, Fuel Cells), ELECTROMAGNETIC (i.e. Inductors, Superconducting Magnets), THERMAL (i.e. latent heat), MECHANICAL (i.e. compressed air, flywheels), HYDRAULIC (i.e. pumped hydro storage, pressurized fluids) and HYBRID (i.e. battery-to-fuel cell) systems.
BESS stands for "Battery Energy Storage System." Because batteries store electric energy as chemical energy (then convert it back to an electrical form when needed), it is a type of ELECTROCHEMICAL ESS. As such, BESS is only one of many sub-categories of the broad "Energy Storage System” (ESS) framework.
Concote Corporation, doing business as InsulFab and Spectape, is pleased to have once again been included on the Dallas Business Journal’s List of Top North Texas Manufacturing Companies, ranked by total local employment. Concote made the list at #10, up from its previous ranking of #18 from 2021. The Dallas Business Journal compiles a variety of business lists that appear in the Business Journal’s weekly edition and annual Book of Lists. Over the course of the prior two years, the North Texas Manufacturing List has included several of Concote’s Customers, such as Lockheed Martin, Envision Dallas, and Raytheon, as well as other large-scale regional manufacturers, including General Motors Arlington Assembly, Trinity Industries, and Bell Helicopter. With an overall North American workforce of approximately 200, Concote continues to grow remain a premier converter and fabricator of engineered materials for a variety of original equipment manufacturers.
Rogers Corporation, makers of silicone under the trade names Poron and Bisco, recently hosted its Preferred Converters Conference in Philadelphia, Pennsylvania during the first week of May. Although many companies fabricate and convert Rogers Engineered Materials, Preferred Converters maintain high standards of quality, technical capability and customer service ensuring the best possible experience for end-users. The three day educational summit focused heavily on electrification of vehicles and equipment. Significant investment is being made by Rogers and its Preferred Converters, like InsulFab, to meet the design challenges presented by Electric Vehicle battery packs, as well as those of the Electric Vehicle chargin and supply equipment.
Does InsulFab fabricate materials that are installed in the new fighter jets featured in the Paramount’s upcoming film, Top Gun: Maverick, schedule for released in May 2022? According to Shelby Ricketts, an aerospace product manager, it’s classified. “We could tell you, but then we’d have to kill you.”
In the movie, Maverick’s new ride is a Boeing F/A-18 Super Hornet and is a successor to the F/A-18 Hornet, with a 20% larger airframe, 33% more fuel capacity and 41% longer range. Top Gun: Maverick will also feature the F-35C, made by Lockheed Martin. The F-35C is the Navy’s aircraft carrier version of the Joint Strike Fighter, but with greater wing area, more robust landing gear and, of course, the requisite aircraft carrier landing hook.
As an AS 9100 aerospace and defense supplier to OEMs Boeing and Lockheed, InsulFab provides engineered insulation products that meet strict specifications for weight, flammability and density. High standards of quality, technical capability and regulatory compliance are not only expected, but demanded. As for whether or not InsulFab supplies materials for the fighter jets featured in Top Gun: Maverick, we prefer not to say.
Insul-Fab is pleased to have been presented with a Performance Excellence Award by one of the world’s largest aerospace OEM, the Boeing Company.
Insul-Fab utilized the AS 9100 Quality System, Epicor ERP Manufacturing software and the dedication of over 150 employees to reach superior supplier performance. Receiving a Performance Excellence Award involves supplying Boeing with defect-free products, utilizing the tools found in Boeing’s quality system, ordering platforms, while also successfully navigating the stringent contract and supply process. Insul-Fab’s performance is monitored and measured by Boeing monthly, and its facility and systems are independently audited by representatives from The Boeing organization on a yearly basis.
Insul-Fab hopes to continue on this path of success.
Insul-Fab, based in Coppell, Texas, is typically manufacturing parts for Original Equipment Manufacturers of HVAC equipment, commercial aircraft and computer companies. But during the Covid-19 pandemic, a line of personal protective equipment (PPE) was released to help protect U.S. healthcare workers and citizens. After starting with medical face shields, dental face shields, and non-surgical isolation gowns, the FDA registered company engineered and began producing Desk Shields and Table Shields for classroom and lunchroom use as the country returns to school.
CEO, Shelby Ricketts, worked with his engineering and production teams to deploy a free-standing desktop isolation device, called the IF DESK SHIELD for students. Each trifold desk shield is made from durable white corrugated plastic with three transparent polycarbonate windows for visibility. They are portable and safely free-stand on a table or desk to isolate an individual student. "Once we showed our concept to local educators and administrators, we were overwhelmed by the response. There is clearly a unmet need to implement measures keep our students safe, and we're glad to support that need", Ricketts said.
The IF DESK SHIELD product is currently in mass production and being shipped to fulfill direct orders from Texas school districts and private schools. They are also available in limited quantities through the company's Amazon storefront.
The next product being released is a similar device for tabletops in an "X" configuration to isolate four students at a classroom or lunchroom table. The IF TABLE SHIELD is made from the same materials and maintains the feature of being free-standing, which dramatically simplifies installation and use. These can also be purchased through the company's or may be, ordered directly from Insul-Fab.
SpecTape is constantly looking for ways to increase specialty and customized items to better provide our customers with solutions that fulfill their packaging, fabricating, and production needs.
Recently SpecTape had the opportunity to offer a packaging solution to a customer that could reduce the estimated 1 million dollars lost due to damages occurring during transport and delivery of their products.
The customer needed a solution designed to hold their large molded parts together during transit. The solution needed to be robust enough to protect the product during loading, unloading, and any additional handling during the delivery process. After reviewing the issues presented by the customer and working one-on-one with their packaging team, SpecTape identified the best solution was to design a custom stretch film machine to handle the customer’s bulky products. SpecTape then partnered with Western Plastics to produce a customized piece of equipment designed to hold the customer’s product on the machine during packaging. This machine could take the very bulky, stacked parts and wrap them securely enough to the point where there was little to no movement occurring during transit. The film selected has exceptional memory and keeps constant tension on the pack, making the finished pallet of goods more secure.
With the custom equipment and specialty film in place, the damages have declined significantly. This customer has since added a second machine to their main location and many others have begun purchasing the solution designed by SpecTape. We were able to design a custom process with a personal touch to provide the customer the perfect solution to their issues. SpecTape shines in custom applications where the challenges go beyond providing another “me to” product by leveraging our knowledge, expertise, and solutions on the best materials to guarantee success in your application.
Insul-Fab, based in Coppell, Texas, is typically manufacturing parts for Original Equipment Manufacturers of HVAC equipment, commercial aircraft and computer companies. But after a conversation with a key supplier, 3M COMPANY, they were challenged to use materials that they had already sourced in order to fill the growing demand in Personal Protective Equipment for front line health care workers.
President and CEO, Shelby Ricketts, is working with his engineering and production teams to deploy a light-duty face shield ideal for first responders, temporary COVID-19 testing stations, hospital personnel and others workforces that may be exposed to fluids while coming into close contact with people who may be ill. The product covers the nose, mouth, eyes and ears. It is lightweight and lays flat, making it easy to ship in bulk and distribute to personnel on the front lines. It is made from a 10-mil polycarbonate film, with a foam spacer made for skin contact and an adjustable elastic Velcro strap. It is ideal for local governments, large hospitals and other entities that need a high volume of easy-to-deploy face shields.
“As a 3M SELECT CONVERTER, we are ready to bring low cost protective shields to thousands of health care workers during this critical time. We are prepared to shift our high-volume production resources to provide the protection they so desperately need. Our ability to manufacture and distribute on a large scale makes us uniquely qualified to fill a void in PPE for healthcare workers” said Ricketts.
Insul-Fab is a Division of Concote Corporation, headquartered in Coppell, Texas, a suburb of Dallas-Fort Worth. It employs over 200 people between its three locations in Coppell, Tyler, Texas and Monterrey, Mexico. It has over 200,000 square feet of manufacturing space dedicated to manufacturing a variety of insulating materials for the HVAC, Aerospace, Defense, Medical and Original Equipment Manufacturing industries.
To learn more about the design and manufacturing or for media inquiries, contact:
Shelby Ricketts President and CEO Concote Corporation 600 Freeport Parkway, Suite 150 Coppell, Texas 75019 Phone (214) 693-2208 www.insulfab.net firstname.lastname@example.org
To address the numerous inquiries that Insul-Fab, Division of Concote Corporation is receiving regarding the status of our capability to supply products to our customers, we have established this informational news page. Please check back as needed for updates until the effects of the Coronavirus (COVID-19) Outbreak are no longer a concern.
3/23/20 - On Sunday, 3/22, Dallas County issued a “Stay Home Stay Safe” order restricting the activity of citizens in an effort to further contain the spread of the COVID-19 virus. Concote Corporation’s headquarters are in Coppell, which is within the Dallas County limits. Many of our employees at that facility also reside in Dallas County. We take this order very seriously and will follow its guidance regarding essential business activity and DCHHS distancing and hygiene recommendations. Concote Corporation has been contacted and identified by many of its customers as an essential business making products to support the Defense Industrial Base, Healthcare, Transportation, Energy, and First Responders infrastructure of our country. We will remain open and endeavor to supply our customers to support this request. Employees that are healthy, willing, and able to participate in normal work activities are asked to do so, where work-from-home practices aren’t feasible. Likewise, companies that supply us with materials and services to make and deliver these products are also deemed essential by the guidelines provided by the Department of Homeland Security and the Department of Defense. We are maintaining contact with all major suppliers and providing them with justification of our essential business status, to further the importance of maintaining the supply chain under proper conditions. Many of them are responding that they already identify under this status as well, and plan to maintain uninterrupted supply to the best of their ability. We are not currently aware of any significant supply interruptions. As always, any delay to our customers’ orders will be conveyed to them on a case-by-case basis. We thank them for working patiently with us during this dynamic situation. Concote Corporation also operates Insul-Fab production locations in Tyler, TX and Monterey, Mexico that are not impacted by the new order in Dallas County.
3/20/20 -As impacts of the coronavirus COVID-19 continue to develop, we remain committed to our customers, employees, suppliers, and representatives to provide you with the latest news of our supply chain status. To date, our operations in Texas and Mexico have still had minimal business impact and we are a meeting a high level of product demand. Supply of materials from our suppliers remains steady and few are reporting any anticipated delays in conjunction with their assurances that detailed measures are being taken within their own organization to avoid contamination of their workforce and facilities. Overnight, news of California, Pennsylvania, and New York directing the immediate closure of all “non-essential” businesses changed the domestic supply situation. Others could potentially follow this measure. We are contacting vendors in those states for specific updates on their operations and any outstanding orders we may have. Where these have implications affecting our customer orders, this will be communicated on a case-by-case basis as soon as possible. Within our own operations, we continue preventive hygiene practices, regular disinfection of common touch-surfaces, distancing of employees through physical and shift adjustments, and providing work-from-home and virtual meeting services where applicable. Non-essential visitors are prohibited, and essential non-employee visitors are required to execute proper hygiene practices upon arrival. The safety and health of our employees and their families is paramount, and we remain thankful that thus far, none have been infected by the virus.
3/16/2020 - As of this date, we are not currently experiencing any delays of inbound materials that would prevent the manufacture of existing customer orders as a result of COVID-19. Concote Corporation is currently operating with full capacity, with all employees reporting to work and all equipment operating. Our supply chain has not been significantly impacted, but we are continually checking with our largest suppliers routinely and asking for them to provide us with forewarning of such delays, if possible. Order status and delays for any reason will be communicated on a per customer or per order basis, the same as during normal operations. It is, however, incumbent upon all of our valued customers to honor standard lead times that have been agreed to, as expedited and unplanned requirements for product may not be able to be met, as they have often been in the past.
Internally, the management team at Concote Corporation is providing our employees with supplies to keep personal work and common areas clean to mitigate the transmission of viruses for their safety. Employee travel is restricted and onsite visitors have been reduced. Employee presence is encouraged at our facilities unless they present symptoms of illness or have been in contact with anyone known to carry the coronavirus. Thankfully, no Concote employees or their immeidate family members have been diagnosed with COVID-19. As needed, employees with children needing attention at home during school closures will be allowed flexibility of work-remote status or PTO to accomodate the current circumstances. We currently have a staff adequate to support all orders in time to meet the delivery dates confirmed to our customers.
Concote continues to expand its work in flexible insulation blankets for the diesel engine industry.
Diesel engines burn fuel differently than their gasoline-powered counterparts, and often produce less desirable emissions. As global emission standards increase, diesel engine manufacturers have implemented new engine designs which improve emissions but cause significant, additional heat generation.
Concote’s diesel exhaust wraps reduce and control potential radiant heat damage. Concote is continually its diesel exhaust wrap line into industries such as motor home, bus, commercial power generation and a number of industries, all of which grapple with a common problem: how to reduce radiant heat associated with diesel exhaust. Concote’s diesel wrap insulation blankets provide protection at the most demanding temperatures - up to 1300°F. Additionally, Concote’s exhaust wraps are custom-fitted with fastening systems designed for easy installation, removal and servicing.
In addition to celebrating its 50th year anniversary last February, Concote has recently awarded its 50th employee reaching 20 years of service to the company!
Although there are many employees at Concote with well over 20 years of service, the 20-year milestone is celebrated by providing employees with an engraved award, placement on our 20 year employee wall of fame and also a monetary award. Concote takes great pride in having long tenured employees who devote a significant part of their working life to the company and we are proud to have so many employees that have reached the milestone.
Founded in 1968, Concote typically employs 150 dedicated employees in Production, Purchasing and Logistics, Quality, Sales, Customer Service, Accounting and a variety of other departments. We are proud to have handed out our 50th 20-year service award, and we look forward to handing out many more in the years to come!
Insul-Fab has recently made major investments and upgrades to its Radio-Frequency (“RF”) Sealing capabilities in order to produce a leading-edge thermal wrap for patient rehabilitation. The wraps provide compression and thermal management for rehabilitation of common soft-tissue injuries such as sprains by inflating and circulating chilled water through the wrap, without the need for ice.
The wraps themselves are made from a combination of nylons and ether films, which must be sealed around polyurethane tubing to provide an airtight and watertight seal. RF sealing provides a high strength bond, which is flexible, but highly durable and leak resistant. It requires the maintenance of special RF sealing machinery, the ability to manufacture and calibrate precision, hard-tooling, as well as the capability to test each part for tensile strength and leak-resistance.
Insul-Fab’s RF line can seal a variety of vinyls and nylons for use in a wide variety of applications, from flexible noise enclosures to flexible wraps for industrial bladders or medical wraps.
Insul-Fab has recently added a new dual-head, fixed bridge 5-Axis Router to its CNC Machining center. The speed, efficiency, and precision gained from automated manufacturing can now be matched by few in the industry. This is due to enhanced speed and dual-head capability, allowing Insul-Fab to produce dual cuts for each pass.
The new heavy duty, cast iron 5-Axis router, manufactured by C.R. Onsrud, also adds redundancy to Insul-Fab’s current 5-Axis and 3-Axis routing lines.
Insul-Fab is a leading fabricator in its ability to CNC cut a wide variety of materials including plastics routing, composite machining, panel processing, aluminum and alloy milling, carbon fiber routing and graphite machining. Many of the parts are trimmed as panels or from vacuum molded or thermo-formed parts, which are used in HVAC, defense, aerosspace, transportation and general industrial markets.
Insul-Fab embraced the ISO 9001 Quality Standard in 2008. Since that time, it has made major commitments to continually improving its Quality System, including investing in an Advanced Quality Software system from IQS, Inc.
Most recently, Insul-Fab updated its Quality System to AS 9100D, the latest revision of the Aerospace and Defense Quality Standard. The AS 9100D revision incorporates the concepts contained in the ISO 9001 standard, but enhances the level of compliance to meet the exacting requirements of the aerospace and defense industries, which ultimately benefits all customers.
Insul-Fab is pleased to have been selected by a major aerospace OEM to assist with material selection and design implementation for a moisture control application.
As condensation in an aircraft freezes at altitude and then melts upon the aircraft’s decent into warmer temperatures, overhead moisture migrates into passenger cabin areas, a phenomenon often referred to as “rain on the plane.”
Insul-Fab assisted a major customer in analyzing several needle-punched, nonwoven felt materials that wick moisture away from entry points in the cabin. The end result was a bevel-edged, die cut gasket with pressure sensitive adhesive to assist in installation. The gasket diffuses moisture across its surface, allowing evaporation without pooling or dripping in passenger areas.
Condensation is a continuing problem in appliance, HVAC, refrigeration and a number of general industrial applications. Contact Insul-Fab to discuss not only thermal management solutions, but also moisture management solutions for equipment.
Each year, Concote makes significant capital investments in its production capabilities.
In 2016, one of Concote’s major initiatives was to enhance its thermoforming capabilities. As a result, it purchased a large-bed, Gulden Single Station Thermoformer. The machine can hold a 48” x 96” mold and has upper and lower independent platens with pneumatic clamping frames for quick cycle production. Additionally, it has an enclosed, quartz hearting-controlled oven, making it ideal for materials that require precision temperature control, such as heavy gauge plastics and high-density foams.
The new thermoformer, coupled with Concote’s in-house mold production and post-production precision trimming and measuring equipment, make Concote a clear choice for thermoforming and pressure forming three dimensional parts and profiles. This is just one reason that Boeing has approved Concote to perform thermoforming and thermobonding of parts for its newer-model aircraft.
In order to request more information on Concote’s thermoforming capabilities, please view our video page or visit the Contact page.
With more than 180 years of materials science and process engineering knowledge, Rogers provides product designers with solutions to their most demanding challenges. Roger's innovative materials technologies help power, protect and connect the world.
Headquartered in Connecticut (USA), Rogers operates manufacturing facilities in the United States, Belgium, China, Germany and South Korea, with joint ventures and sales offices worldwide.
Zotefoams plc is the world’s leading manufacturer of cross linked block foams. Its products are used in a wide range of markets including sports and leisure, packaging, transport, healthcare, toys, building, marine and the military.
Through a unique production process, the company produces foams that have controlled properties and are of strength, consistency, quality and purity superior to foams produced by other methods.
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