In 2015, Federal Foam Technologies took a strategic leap forward by acquiring ACT, a transformative move that added a plant footprint in Northwood, IA. The acquisition of ACT was more than a business transaction—it was a vision for growth. ACT brought a strong business reputation along with a skilled workforce and established customer relationships. Federal Foam saw the potential to enhance its product offerings and capacity to better service the power sports, construction and agricultural industries with thermal, acoustical, insulative and vibration / sound dampening solutions in foam and plastic.
What began as a strategic acquisition has evolved into a story of synergy, innovation and cultural revitalization. The Northwood plant, once facing challenges in leadership connection and operational efficiency, now stands as a model of transformation and forward momentum.
Northwood, IA: A Plant Reimagined
Since joining FFT 10 years ago, the Northwood plant has undergone several transformations, including material processing capabilities, a significant cultural change, equipment investments and the implementation of LEAN manufacturing processes.
Investments in these key areas have evolved FFT’s Northwood plant into a model of operational efficiency and product quality.
Expanding Horizons: New Customers & PET Plastic Material Processing Capabilities
With the acquisition, FFT introduced Northwood to industries ACT hadn’t previously served and additional customers within its existing industries. While the Northwood plant mirrored the capabilities of FFT’s New Richmond, WI, a stark difference was processing PET plastic. PET plastic is the main material FFT uses to manufacture form and trim cab components for power sports, construction and agricultural vehicles.
“Moldable PET was a product that was converted and fabricated in New Richmond that we brought to Northwood, which significantly expanded our service and capacity for our larger OEM customers,” says Chad Wihlm, Senior Account Manager who worked at ACT until 2010 before joining FFT that year. “This was a major material advancement that helped Northwood grow its impact at FFT and bring in more business from key accounts.”
A Seamless Cultural Fit with ACT & Federal Foam Technologies
ACT was previously owned by a steel company, which created a disconnect given ACT’s focus on plastics and acoustics. Sometimes, there wasn’t much communication with or visibility to company leadership.
“When FFT purchased ACT, you could see the cultural synergies immediately,” says Chris Hulsing, Northwood’s HR Generalist who came to FFT with the acquisition. “Not only did the business side fit better, but the leadership team was hands-on and invested in the plant’s success. This made a huge difference in employee morale and our ability to recruit new talent to the organization.”
Chad echoes this sentiment. “It felt like we were a supplier to Worthington,” he says, referencing ACT’s former parent company. “With FFT, we became partners. That shift in mindset opened doors for growth.”
Company leaders, such as President Wyman Smith, visited consistently and were always on the plant floor engaging with employees, observing the operations and having discussions with the team on what could be improved.
“It’s a servant leadership approach,” Chris says. “Employees appreciate that our leaders are on the floor with them, it isn’t a me vs. them mentality.”
LEAN Manufacturing Processes for Foam & Plastics Fabrication
Since the acquisition, Northwood has seen substantial investment in infrastructure and technology. A new waterjet was installed, expanding capacity and capabilities. More recently, a CNC 5-axis robot was added to support growing demand.
But the most transformative shift has been in manufacturing philosophy. Northwood has embraced single-piece flow, a LEAN manufacturing approach that replaces traditional batch processing.
“Instead of completing all parts in one process before moving to the next, single-piece flow allows parts to move seamlessly from forming to trimming, assembly and packaging,” says Bill Zimmerle, Plant Manager, who worked for ACT prior to the acquisition and joined FFT two and a half years ago. “It’s led to better quality, improved efficiency and created cross-training opportunities. We’re doing more with less.”
Looking ahead, the plant is preparing to implement Single-Minute Exchange of Die (SMED)—a LEAN initiative aimed at reducing changeover times. This will allow Northwood to respond faster to customer needs with greater flexibility and no added cost.
The Future of Foam & Plastic Fabrication at Northwood
As FFT continues to grow, the Northwood plant remains a vital part of its future. With a strong foundation and a forward-thinking team, the facility is well-positioned to support new product development, expand into emerging markets and drive operational excellence across the organization.
“It’s refreshing to hear leadership talk about growth, not just in words but with actions such as equipment investments and allocation of time, energy and resources,” Chad says.
Bill expresses a similar sentiment: “FFT is committed to investing capital that will get our facility to the next level, which is exciting and motivating as we move forward into the next 10 years and beyond.”
From a human capital standpoint, Chris says FFT Northwood has all the tools to continue attracting top talent. “With new machines and new business, there’s room for advancement and movement across roles. Employees from New Richmond have even visited Northwood to observe operations, reinforcing the collaborative spirit between sister plants.”
The journey from acquisition to advancement has been one of transformation, and Northwood stands as a shining example of how FFT turns potential into performance.
