At EMCO, the customer comes first. Which is why we offer quick turnaround time, the ability to run small lots and custom extrusion through our Custom Order Program (COP). Read on to see what EMCO can do for you:

COP Solution: Brush Bristle
A client wanted to design a disposable brush that would be used to apply medication. The bristles had to be round and would need to maintain critical tolerances in production. No stock product met these requirements—and thus custom extrusion was necessary. To further complicate the issue, the client only required a small run and was having difficulty finding a vendor that would manufacture such a product under these conditions.

We looked at the available options and realized that we could easily adapt processes originally developed by EMCO employees. With this process, we were able to successfully produce a hybrid fiber from two incompatible-—and inherently oval-—materials to create a round single strand that could be flagged to a feathered tip, from which the brush could be made. This precisely-sized strand maintained a diameter consistency within .5%—well within our client's needs. Even with the extensive R&D involved, we were able to deliver the product on time and on budget.

COP Solution: Synthetic Whisker
A toy molding manufacturer came to us with an experimental molding process which required 14 strands of nylon whiskers to pay off a single spool, feeding into 14 holes of a mold. Nylon was chosen as it needed to be able to withstand high temperatures (due to the molding process) and needed to maintain size consistency so that the mold wouldn't leak around the inserted strands. We worked closely with the customer to develop a new process that would satisfy his requirements. The solution was a unique spooling technique that allowed for a precisely aligned and evenly tensioned multi-strand tow.

COP Solution: Thread
A commercial thread distributor wanted to create a spool with a unique shape that would pay out easily. Our solution was to create a spool with a wide base and smaller end. The base design allowed for an increased volume of the spool, which improved sewing efficiency and productivity. The smaller end decreased drag and improved the payout of the thread. This unique spool with a compound contour not only gave our customer an improved product but a great marketing advantage as well.

COP Solution: Cable Filler
A client needed a strong, lightweight, non-hygroscopic wire cable filler with a high electrical insulation value. We considered the available options and soon realized that custom extrusion would not be necessary-—the solution was already an EMCO product. Although it had never been used in this capacity, oriented polypropylene foam (PPFO) matched the customer's needs perfectly. It has a high yield per pound, is non-hygroscopic (unlike the traditional twisted paper/jute materials,) and adds overall strength to cable. It is also available on large spools, which allows for longer, continuous runs. Now one of our top sellers, PPFO is quickly becoming known in the cable and wire industries for its excellent insulation properties, strength, and value. While other companies make foamed polypropylene, ours is the most versatile on the market.