Fuller Industries Inc. employee Maribel Balderrama Monday prepares the new monopod machine to run a batch of cleaner pods. While efficient and can produce 300 pods per minute, the device requires careful attention and calibration.

A cleaning product is injected into what will become monopods using Fuller Industries Inc.’s new, high-tech machine designed to produce up to 300 pods per minute.

Shown are newly minted Fuller Industries Inc. monopods.

A growing demand

Fuller boosts monopod production with a new state-of-the-art machine

In a small chamber at the back of Fuller Industries Inc.’s plant west of Great Bend, the longtime manufacturer’s new, gleaming stainless steel and glass monopod machine chugs along, as brightly colored cleaner pods roll into awaiting buckets.

The state-of-the-art device allows the company to significantly increase the production of its award-winning monopods and further solidify Fuller’s position as a leading provider of these innovative cleaning tool solutions.

“This is a game-changing moment,” said Joe Mann, Fuller’s general manager. “Our monopods are a big part of our future and a massive step in our ongoing commitment to sustainability. We see ample opportunity for growth here.”

The new machine, recently installed, dramatically surpasses the output of the company’s previous equipment. It enables Fuller to produce 300 pods per minute, a substantial increase from the prior rate of 1,400 per hour, and fill 600 cases in an afternoon. This enhanced capacity will enable Fuller to better serve its commercial, industrial and institutional clients.

Fuller’s 100% water-soluble monopods simplify cleaning by providing precise dilution, cost-effective concentrate usage, and the convenience of ready-to-use solutions. The pods dissolve completely, the plastic containers are recyclable, and the smaller, concentrated packets are lighter, occupy less space and are easier to ship, reinforcing Fuller’s commitment to environmentally sustainable products.

“For decades, custodial personnel have struggled with jugs of cleaning product concentrates, often leading to inaccurate mixtures and potentially hazardous contact with chemicals,” Mann explained. Fuller’s monopod dosing system eliminates these issues.

“Fuller is an innovator in the pod world,” Mann said. “Our research team continues to develop new products that keep Fuller at the forefront of the cleaning industry.”

The new equipment represents Fuller’s ongoing investment in automation and modernization. Incorporating advanced technology improves efficiency, reduces costs and ensures consistent product quality.

“We are committed to staying at the forefront of the commercial cleaning industry,” Mann said. “This new equipment is just one example of how we are continually innovating to meet the evolving needs of our customers.”

How does it work?

Fuller received the machine last November. But Mann said some preparation work had to take place before it could be put into service.

A climate-controlled room was created to house it. Then, new electrical connections and plumbing had to be installed.

These are all important because it’s not just a matter of flipping a switch.

“There is a lot that goes into this,” Production Manager Chris Cowles said. “There are a lot of variables and adjustments that need to be made.”

The machine, about the size of a small SUV, stands as the centerpiece in the room. It is surrounded by ancillary equipment and pipes and hoses.

In a nutshell, two rolls of water-soluble film are fed into the machine. One rolls across a large drum and is sucked into rows of small molds and the various products are injected into them, creating small pockets that become pods.

Next, this is merged with the top layer and heat-sealed. The sheet is then cut into individual pods which roll out into buckets.

“This is not as simple as it sounds,” Cowles said. “There is a lot of fine-tuning.”

The two incoming films must be perfectly aligned, and the jets must inject at the right pressure. The liquid must have the correct viscosity (thickness) and temperature.

Consistency is crucial, he said. The pods must be of uniform weight and fill.

Fuller’s chemists worked together with the production team as they made adjustments to formulas to ensure the quality.

“This is truly a team effort,” Mann said. “We have dedicated employees who operate the machine. They value what we do and strive to make us better.”

What’s on the menu?

Fuller Industries monopod offerings include:

• Washroom cleaner
• Glass cleaner
• Industrial surface degreaser
• Defoamer
• Industrial floor cleaner
• Neutral floor cleaner
• Carpet extraction cleaner
• Winter neutralizer (an all-purpose cleaner that can tackle ice melt residue, lime deposits and hard stains)

About Fuller Industries Inc.

Based in Great Bend, Kan., with a rich heritage dating back over a century to the Fuller Brush Man, Fuller Industries is a leading American manufacturer of industrial products, including cleaning chemicals and supplies, as well as brooms, mops, brushes and more. Fuller serves manufacturing, commercial, institutional and agricultural clients across the Western Hemisphere. Call 620-792-1711 or visit Fullerindustriesinc.com.