Just before Christmas, the first new brick factory to open in Wisconsin in more than 50 years fired up its production line for the first time.

CalStar Products is now producing residential and commercial facing bricks, as well as paving bricks, in its 63,000-square-foot facility in Caledonia. The company began moving into the new facility last August, and is now preparing for full-scale production.

CalStar’s bricks are the only bricks in the world produced from fly ash, a by-product of the coal power generation process. The company sources its fly ash from the nearby Wisconsin Energy Corp. coal plant in Oak Creek.

Traditional bricks are made from clay and require as much as four days of baking time at 2,000 degrees Fahrenheit. CalStar’s bricks are “cooked” at less than 200 degrees for 24 hours, said Thomas Pounds, chief operating officer.

While CalStar’s bricks are “green” they function the same as other conventional bricks.

“These can be used in any project that would take masonry,” Pounds said. “Our initial target is the commercial architectural segment – all varieties of commercial construction including multi-family, residential, office, retail and others.”

The company’s bricks will be sold at the same prices as traditional bricks, Pounds said, which should help make their introduction to the market easier.

“We’re going to market at price parity,” he said. “There are lots of indicators that people are interested and excited about green products but they’re less excited about paying a premium for it.”

CalStar Products is headquartered in Newark, Calif., in Silicon Valley.

“We have a collection of entrepreneurs who are visionary and see big challenges and big problems in different ways and are willing to take risks,” Pounds said. “We have investors who are like-minded and a terrific pool of technical resources from universities and the tech scene.”

CalStar Products has been funded by the venture capital firms Foundation Capital and Enertech Capital.

On Friday, CalStar received $2.4 million in Wisconsin tax credits in recognition of its energy-reducing production techniques.

The company decided to build its first production facility in Caledonia because of a strong pitch from We Energies, which is selling its fly ash to CalStar.

“Wispark (LLC, the real estate arm of Wisconsin Energy Corp.) owns this building and we’re leasing from them,” Pounds said. “In August when we moved in, it was bare bones. In about 20 weeks, we got the whole plant up and in place with all the equipment moved in.”

CalStar currently has about 15 employees in Caledonia. It will have about 35 employees by the time it reaches full capacity in the next two or three years.

The Caledonia plant will be one of about six production facilities CalStar plans throughout the Midwest, Pounds said.

“We expect to build additional plants down the Mississippi Valley and East Coast over the next couple years,” he said. “We will get this plant launched and running toward capacity first.”

Click here or on the image below for a video interview with Pounds.

Obama awards $35 million in stimulus tax breaks for Wisconsin manufacturers

President Barack Obama announced that his administration is awarding $2.3 billion in tax credits to the private sector for clean energy manufacturing projects across the country, including eight companies in Wisconsin that will receive $35 million in tax breaks.

A total of 183 projects across the nation will receive the tax breaks, which are part of the federal economic stimulus package passed last year.

The White House said the projects will create 17,000 jobs and will boost U.S. manufacturing of advanced clean energy technologies including solar, wind and efficiency and energy management technologies.

“Building a robust clean energy sector is how we will create the jobs of the future,” Obama said. “The (tax credit) awards that I am announcing today will help close the clean energy gap that has grown between America and other nations while creating good jobs, reducing our carbon emissions and increasing our energy security.”

The Wisconsin recipients of the tax credits are:

• Milwaukee-based ZBB Energy Systems is receiving a $14.8 million tax credit. The manufacturer of energy storage systems for utilities has significantly expanded its facility and capacity over the past year.

• Waukesha Electric Systems Inc. is receiving a $12.45 million tax credit to expand its plant in Waukesha to product large, high-voltage power transformers. The company anticipates that more than 80 percent of them will be used to help bring renewable energy to distant load centers or to replace aging, less efficient transformers.

• Caledonia-based CalStar Products is receiving a $2,443,547 tax credit to manufacture bricks and pavers from coal power plant fly ash. The process uses 88 percent less energy than traditional fired clay products, while avoiding the carbon dioxide emission associated with concrete, and makes beneficial use of fly ash.

• Ann Arbor, Mich.-based Kaydon Corp. is receiving a $1,774,800 tax credit to re-equip and expand its manufacturing facility in Milwaukee to produce pitch and yaw bearings used in the production and assembly of wind energy turbines.

• Milwaukee-based Ingeteam Inc. is receiving a $1,665,299 tax credit to manufacture wind turbine generators in various technologies. The company will also manufacture power converter and control systems for the wind and solar industries.

• Wausaukee Composites Inc. is receiving a $930,810 tax credit to manufacture fiberglass wind turbine components.

• Kaukauna-based Bassett Inc. is receiving an $868,500 tax credit to manufacture wind turbine towers and foundation components for all sizes of turbines and a $75,000 tax credit to manufacture carbon capture and sequestration systems to extract and trap carbon from waste systems from coal fired power plants.

• Waukesha-based Cooper Power Systems LLC is receiving an $846,180 tax credit for its new facility that will be producing high efficiency transformers.

C&D awarded $19 million Army contract

C&D Technologies, Inc., a battery manufacturer with an expanding Milwaukee facility, has won a four year, $19 million contract by the U.S. Army for the development of large-format lithium-ion battery systems. 

The new advanced lithium-ion battery systems will be developed and produced in C&D's Milwaukee operations, which has been a focus for renewed investment for the company over the last two years.

C&D began a $26 million upgrade to its Milwaukee facility last August. The upgrade could add up to 150 new jobs, the company said previously.

The technologies developed under the Army contract will also be utilized in meeting the needs of C&D's commercial customers, with potential application to large-scale grid-energy storage, renewable energy applications and distributed power for telecommunications systems, in addition to broader application in other branches of the military. The result will be a sustainable, domestic U.S. source for high performance, large-format lithium-ion batteries, with the potential for achieving economies of scale to ensure affordability in a range of military and commercial applications.

"This contract will allow C&D Technologies to establish a world class research and development facility in Milwaukee, Wisconsin, including pilot production capability dedicated to large-format lithium-ion batteries, and will establish a domestic manufacturing base for C&D designed lithium battery systems," said Dr. Jeffrey Graves, president and CEO of C&D Technologies.

Oshkosh Corp. lands another military contract

Oshkosh Corp. announced that its Defense division has received another order valued at more than $290 million from the U.S. Army Tank-automotive and Armaments Command Life Cycle Management Command (TACOM LCMC) to deliver more than 725 next-generation Palletized Load Systems (PLS) A1.

The order was issued under the U.S. Army's existing Family of Heavy Tactical Vehicles (FHTV) contract. Production will begin in April 2010 and be completed in September 2011.

"The modernized PLS A1 delivers superior performance and protection capabilities to help deliver supplies and equipment in some of the U.S. Army's most demanding operations," said Andy Hove, Oshkosh Corp. executive vice president and president of the company’s Defense division. "The PLS truck and trailer combination can load and unload a variety of heavy-payload cargo, which helps eliminate the need for material-handling equipment and results in leaner, more efficient logistics units."

The PLS A1 is the next generation of the PLS, which Oshkosh has manufactured for the U.S. Army's distribution and resupply needs for its most challenging military missions.

Mukwonago-based Empire Level Mfg. Co. has played an integral role in the construction of most of the structures that are standing in metro Milwaukee – and many more around the nation.
Empire is the market leader in designing and manufacturing levels and layout tools used in the construction and contracting industries. It is also a market leader in high-end leveling tools for the home handyman.
The company’s focus on accuracy has built its reputation for quality in the marketplace, said Jenni Becker, president of Empire Level and the fifth generation of her family to work in the company. Her great-great-grandfather, Henry Zieman, started the company in 1919 in Milwaukee.
“Our entry price point (levels) are more accurate than our competitors’ high end models,” she said. “Accuracy is a big focus for us. Even our opening price point models are good enough to do a lot of contractor-grade work.”
Empire’s can be found in big box stores such as Home Depot and Menards, as well as specialty contractor supply stores.
The company has been able to further its position as a market leader by developing its True Blue line of vials, which are used in its high-end levels and deliver readings that are accurate up to 0.0005 of an inch. The True Blue level vials were introduced in 2005 in the company’s E70 line of levels, and are made using proprietary molding technology, Becker said.
“We took the equipment that is used to mold medical equipment and modified it to make a (level) vial,” she said. “Each one is made one at a time on our precision equipment.

To read more, click here.

It has taken only 30 years for China to rise from the bottom to the top of the world’s economic rankings. How has it been possible? Ask 20 people and the answers you will get include “no idea,” “cheap labor,” “globalization,” “China Inc.” (the theory that China acts like a corporate conglomerate, using its sovereign wealth to dominate areas of the world trade economy) or the “Beijing Consensus” (the idea that China’s economic practices are part of a long-march political strategy to counter the  “Washington Consensus” by offering a competing ideological agenda).

Apfelbach is new CEO of ZBB Energy Corp.

Milwaukee-based ZBB Energy Corp. has appointed Eric Apfelbach as its president and chief executive officer and a member of its board of directors.

ZBB Energy Corp. provides clean energy storage solutions based on proprietary zinc rechargeable energy storage technology that addresses requirements in multiple markets such as alternative energy applications, large electrical utilities and green residential and commercial architecture.

Apfelbach said, "I am very excited to have the opportunity to lead ZBB and to help the company achieve its plans for growth. The distributed renewable energy industry cannot scale without cost effective energy storage and power management solutions. I believe ZBB's products will address these needs."

Paul Koeppe, interim CEO of ZBB and chairman of the search committee of the company’s board of directors, said, "I believe that Eric's background is a perfect fit for ZBB. His past leadership of high tech companies has been a great proving ground for stepping into the CEO role at ZBB. I am delighted with his decision to join us."

Most recently, Apfelbach founded Virent Energy Systems Inc., a catalytic biofuels company. Before Virent, Apfelbach co-founded Alfalight Inc.

Struthers is new president of Kohler Power Systems

Kohler Co.’s Global Power Group, a manufacturer of engines and power generation systems, has named Jason Struthers as the new president of its Kohler Power Systems business.

Struthers has assumed leadership and management responsibilities for Kohler Power Systems, which includes operations in North America and Asia. KPS Sales & Service, which does business in Europe, Middle East and Africa, also falls under the administration of Struthers. With an emphasis on growing sales, profitability and market share, Struthers will focus on enterprise-wide strategic business and process improvement initiatives, the company said.

Prior to joining Kohler, Struthers served as the president of Viking Pump for three years and in early 2009 added IDEX AODD to his responsibility. Both entities are business units of IDEX Corp., a global company known for highly engineered fluidics systems and components.

In a related announcement, Kohler has appointed outgoing Kohler Power Systems president Otto Kopietzki as president emeritus of the business. A 40-year veteran of the power generation industry, Kopietzki will remain in his new position throughout 2010 in support of the leadership transition.

“Jason brings to Kohler Power Systems a proven track record of driving efficiencies, growth and profitability from the global businesses that were under his supervision,” said Dick Fotsch, Kohler Global Power Group president. “By combining Jason’s progressive approach to management with Otto Kopietzki’s extraordinary power systems experience and deep relationships with Kohler’s customers and suppliers, this transition should be seamless for Kohler Power Systems and the many markets it serves.”

Business groups line up against Doyle’s energy bill

The Clean Energy Jobs Bill proposed by Gov. Jim Doyle would result in 43,000 lost jobs in Wisconsin, according to a recent economic study.

Doyle has proposed the bill to make the state more efficient and energy-independent.

However, several business groups signed on to a letter to legislators recently, expressing concerns that the legislation (AB 649 will raise energy prices and kill even more manufacturing jobs.

“Many families in this state are hurting,” said Scott Manley, director of environmental policy for Wisconsin Manufacturers & Commerce (WMC). “We cannot afford to lose any more jobs, but that is exactly what this legislation will do.”

Wisconsin has lost 160,000 high-wage manufacturing jobs since 2000, and the proposed legislation will continue the high-wage job loss, the WMC said.

“We need to reverse the current trend, and find a way to bring family-supporting manufacturing jobs back to our state,” Manley said. “But hitting Wisconsin’s economy with the expensive new energy regulations proposed (last week) will significantly increase our cost of electricity, and kill jobs while doing nothing to address global warming. Lawmakers must understand that increasing the cost of energy for Wisconsin families and employers is a recipe for further job loss.”

But Doyle said his bill would:

• Promote an affordable, renewable and diverse energy supply.
• Target investments in job creation and new business opportunities.
• Improve the environment.

QuadTech unveils new technology for packaging industry

QuadTech Inc. has added a Web Viewing System to its expanding product line for printers and converters in the packaging industry.

With direct, real-time digital viewing of the moving web, the QuadTech Web Viewing System enables operators to detect defects and register errors before they become visible to the human eye. Operators can detect print quality problems such as print and die-cut registration, perforations, streaks, voids, fills, damaged plates and more.

“Printers are facing ever-escalating quality control challenges,” said Randy Freeman, vice president and general manager of packaging at Sussex-based QuadTech. “Our Web Viewing System gives them an additional tool that will enhance quality and reduce waste without sacrificing press speed.”

The addition of the Web Viewing System represents another major move into the packaging market for QuadTech. In 2008, QuadTech acquired print inspection technology innovator Vigitek, a leading manufacturer of state-of-the-art print defect detection technology.

QuadTech is a subsidiary of Sussex-based Quad/Graphics Inc.

Menomonee Falls Chamber to honor Harley-Davidson and Wacker Neuson

The Menomonee Falls Community Chamber will present the the Captain of Industry Award at its Annual Awards Banquet to Wacker Neuson Corp. and Harley-Davidson Powertrain Operations on Jan. 12th. Wisconsin’s Secretary of the Department of Commerce, Dick Leinenkugel, is scheduled to present the awards.

The awards highlight the contributions made by manufacturers who have given their time and talent to create a better community. 

“Both Wacker Neuson Corporation and Harley-Davidson Powertrain Operations are a vital resource to our community,” said Sue Jeskewitz, Executive Director of the Community Chamber. “They have contributed to making Menomonee Falls a better place to live and work and are more than deserving of the Captain of Industry Award.”

BizTimes Milwaukee invites readers to get a jumpstart on 2010 by attending the annual Northern Trust Economic Trends Breakfast.
The breakfast, which will be presented by BizTimes Milwaukee on Friday, Jan. 22, at the Italian Community Center, 631 E. Chicago St., Milwaukee, will provide forecasts and insights about the year ahead in business.
The featured panelists for 2010 will be:

• Michael Knetter, Ph.D., the dean of the University of Wisconsin School of Business in Madison and a former U.S. presidential economist. Knetter will provide a macro-economic overview.
• Bob Arzbaecher, CEO of Actuant Corp., which is expanding and moving its global headquarters from Butler to a facility in Menomonee Falls. Actuant is a $1.2 billion diversified manufacturing company with facilities in 30 countries. Arzbaecher will discuss the outlook for global competition and manufacturing.
• Aaron Jagdfeld, CEO of Generac Power Systems Inc., which is growing in Waukesha and recently filed to become a publicly traded company. Generac manufactures portable residential power generators. Jagdfeld will provide the outlooks for manufacturing, innovation and energy.
• Andy Nunemaker, president of EMSystems LLC, a Milwaukee-based company that develops software systems for emergency rooms throughout the United States. EMSystems has acquired three other companies in the past 18 months and continues to grow. Nunemaker will discuss the outlooks for technology and health care.

For additional information or to register to attend, visit www.biztimes.com/trends.

The Milwaukee Society of Plastics Engineers will present "What Designers and Engineers Need to Know When Considering Tool Steel Selection & Coating and Finishes for Ultimate Productivity" on Tuesday, Jan. 19 from 6 to 9:30 p.m. at the Sheraton Brookfield Hotel, 375 S. Moorland Rd., Brookfield. Cost is $30 for members, $35 for non-members. For information or to register, click here.