In the heart of Addison, Illinois, sits The Countertop Factory Midwest (TCF), one of the region’s largest fabricators with a reputation for high-quality craftsmanship and efficient operations. TCF recently made a significant change to its workflow, introducing SlurrySep CF and S-Complex by Xcelerate products into its manufacturing process. 

We had the privilege of interviewing Troy Ellsoos, TCF’s Director of Operations, to gain insights into this transformative experience. Here are some of the key takeaways from the interview.

A Solution to Expensive Cartridge Filters

Before implementing SlurrySep CF and S-Complex, TCF faced unexpected challenges and rising costs. Their existing water filtration system required the use of expensive cartridge filters, which were not only costly but also added labor expenses due to frequent cleaning. Ellsoos explains, “Those filters are about $200 apiece, and when you have multiple pieces of equipment, you’re cleaning them daily, which adds labor and material costs.”

The introduction of SlurrySep CF and S-Complex addressed these issues head-on by drastically improving TCF’s shop water quality. This quality improvement allowed TCF to eliminate these cartridge filters from their process, saving costs and reducing labor burdens. Ellsoos states, “Once we introduced the products, it removed all that time and cost. That was an immediate result.”

Increased Cutting Speed and Quality

The benefits for TCF continued with a significant increase in production speed after incorporating S-Complex. “We were running about 180 inches per minute on our saws, and now we’re at 220 with S-Complex,” Ellsoos shares. “We’re not getting any warpage or chipping, and we’re able to maintain that speed without any dips in quality.”

This boost in speed not only increased productivity but also translated to additional cost savings. By producing more countertops in less time, TCF maximized its efficiency and reduced overall production costs.

Increased Employee Safety & Longer Equipment Lifespans

Employee well-being is paramount at TCF, and introducing S-Complex has led to better air quality for employees on the shop floor. Ellsoos notes, “My employees are comfortable. My employees haven’t had any side effects, and the equipment is running great. If anything, we’ve had better results with the equipment.”

In fact, S-Complex even extended the lifespan of their saw blades, increasing their durability from 5-6 days to 8-10 days. This added benefit further contributed to TCF’s cost savings and operational efficiency.

Conclusion: A Bright Future for TCF Midwest

Looking ahead, Ellsoos is enthusiastic about the future of Xcelerate Products at TCF. He envisions even greater capabilities as they upgrade to newer CNC machines and explores the full potential of S-Complex. 

He encourages other fabricators to consider these products, highlighting their potential to reduce labor costs and save on tooling expenses. “If you’re interested in trying any of these products or have any questions or concerns, feel free to reach out to me or John,” Ellsoos offers.

TCF’s experience with SlurrySep CF and S-Complex is a testament to the power of innovation and the willingness to embrace new solutions. By adopting these cutting-edge products, TCF has not only streamlined its operations but also enhanced its overall efficiency, ultimately benefiting both its business and its employees.

Read on for the full transcript here:

“My name is Troy Ellsoos, Director of Operations of the Countertop Factory Midwest in Addison, Illinois. We’re one of the largest fabricators in the Midwest. We also have shops in Phoenix, Arizona, and in Tucson, Arizona. With the HydroClear™, it was, it’s been in our water enough. We had to introduce the Big Bubba filters to all of our equipment. 

Thus, that was an added cost that we were unexpected. Those filters are about $200 apiece. And when you have seven pieces of equipment, eight pieces of equipment, and you’re cleaning those daily, you know that adds a labor cost and a cost of goods cost. So once we introduce the products, right, by adding that removed all that time and that cost, that was an immediate result, right? 

Once we introduced the S-Complex, we were able to also, you know, increase our speeds from the saws. You know, we were running about 180 inches per minute on the boxes and the, and the fusion we currently run our saws, is now at 220 with S-Complex in our system. With the speeds, we’re not getting any warpage, we’re not getting any chipping, we’re able to maintain that speed with good quality products. I feel that my employees are comfortable. There has not been any side effects with the equipment, or with the, the skin from the employees. If anything, we’ve had just better results with the equipment. We used to get 5 to 6 days on our blades with our production. I’m seeing anywhere from 8 to 10 days, I think to try any product, you have to give it what it’s worth, and you have to make it work for your facility. 

I would love to say that I see a good future with those products. Some of our equipment’s a little outdated in the future when we purchase new CNC’s. I haven’t seen the full capabilities that S-Complex can do. I’ve heard and talked to some other shops that are running at much faster speeds than what we can run. So I’m excited for the future for TCF and John’s product. It helps saves your life on your tooling, your saw blades, helps in your CNC tooling. So if you’re not looking to gain and your labor cost, then at least try it to reduce on your cost of goods. If you’re interested in trying any of these products or you have any questions or concerns, feel free to reach out to me or John. We can help assist with your questions in any way.”