Ziehl-Abegg is less than a month away from launching production of motors and fans for commercial ventilation systems at its North American plant in southeastern Winston-Salem.
Even as the equipment is being set up in the mammoth 520,000-square-foot plant in Union Grove Industrial Park, company officials already have their sights set years — if not decades — down the road.
The new Ziehl-Abegg plant, a German manufacturer of fans for ventilation and air conditioning applications, is shown on Tuesday at 4971 Millennium Drive in Winston-Salem.
Allison Lee Isley photos, Journal
The $100 million plant represents the German manufacturer’s single-largest, one-site capital investment in its 130-year history.
It also symbolizes a start-from-scratch format where most of the fabricating is done onsite rather than molds and other key components being imported from European facilities.
It is a pivotal advantage since Ziehl-Abegg purposefully carries a limited inventory supply.
The initial production goal is more than 100,000 fans by the end of the year, dramatically up from 1,000 fans when production commenced at the Regional Road facility in Greensboro that Ziehl-Abegg is exiting.
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Full production is projected to approach 800,000 fans annually.
“It will allow us to shorten delivery times, be closer with our research and development, and build stronger relationships with our North American customers,” said Marc Wucherer, the company’s president. “It is the result of increasing demand for quiet, reliable, highly efficient and energy-saving fans that can play a role in helping protect the environment.”
A view of the lounge area at the new Ziehl-Abegg plant in Winston-Salem.
Allison Lee Isley, Journal
“This plant helps us provide better lead times, better costing to our customers,” Jimmy Mitchell, the plant’s vice president of operations, said during a preview tour of the plant at 4971 Millennium Drive.
Rows of production and assembly lines will turn out customized fans for customers ranging from commercial and industrial manufacturers to hospitals, schools and universities, data centers and agricultural markets, such as greenhouse operators.
“This plant will enable us to expand in all those North American markets and look to enter other markets as well,” Mitchell said.
Referring to its own plant as a typical customer, Mitchell said “we believe we have just begun to scratch the surface of our potential in the North American market. This plant will enable us to get more into those areas.”
Why move?
The plant at 4971 Millennium Drive is about four times larger than the Regional Road facility in Greensboro the manufacturer is exiting. The plant sits on a 71-acre tract.
That plant, a former furniture manufacturing facility, was cumbersome in part because key operations were on opposite ends and, in part, because of age.
A major gain is 100,000 square feet of dedicated warehouse space, compared with space located off the Greensboro facility campus.
“Having raw materials, pallets and finished goods under roof, rather than 30 minutes away, is an obvious logistical advancement,’ Mitchell said. “We’ve already made plans for additional expansion of another 80,000 to 100,000 square feet. That flexibility is another reason why we chose this location.”
Mitchell said the manufacturer has been intentional in how its space is being utilized, including dedicating ample front-door room for customers to review and test the fan products.
“We want to give ourselves space where we can collaborate, have large gatherings, while not interrupting our day-to-day operations,” Mitchell said. “We have to be one-on-one with our customers. We need space where we can engage, see what their needs are, show them everything we have to offer, offer a fully digital showroom, and offer them the ability to break down any products that they see.
“We want to help them grow because they, in turn, helps us grow as well.”
Hiring plans
Mitchell said that when the manufacturer began explaining to employees the need for a larger and more modern plant and the decision on the new site, most of the 225 Greensboro workforce supported the decision even though it meant a longer work commute for many.
About 60 Greensboro workforce members already are working in the new plant, with the rest to transition there by the end of the year. They will be joined by a projected 80 to 100 new hires. The average annual salary range is $50,000 to $60,000.
Work shifts will be 7 a.m. to 3 p.m. and 3:30-11:30 p.m.
Under consideration are four-day, 10-hour work shifts Mondays through Thursdays and three-day, 12-hour shifts Fridays through Sundays in which those employees will be paid for 40 hours of work.
As production ramps up between now and 2030, Ziehl-Abegg projects a hiring goal of 100 annually to expand from about 275 now to more than 800. Among the immediate employee needs are for personnel in administrative, marketing and sales departments, engineers, CNC machinists, machine operators and welders.
“As we continue to expand in production, we will add other departments,” Mitchell said.
Among worker-friendly amenities include: a cafeteria serving a fresh meal each shift at a subsidized cost to employees; a canteen, a fitness center with showers for before and after work or on off-days; and company subsidized employee benefits.
Hiring challenges
Ziehl-Abegg acknowledges facing a stiff challenge to stand out in an ever-expanding number of advanced manufacturers in the Triad, foremost from Toyota Battery Manufacturing N.C.’s pledge to create 5,100 jobs at its nearly $14 billion electric-vehicle battery plant in Liberty.
Other advanced manufacturers looking to launch or fill their Triad workforces include Avgol Americas Inc., Dai Nippon Printing Co. Ltd., Deere & Co., Egger Wood Products, Honda and Honda Aircraft Co., Marshall Aerospace USA, Nucor Corp., ProKidney Corp., Renfro Corp., Siemens Mobility North America, Tex-Tech Industries and Vecoplan LLC.
It’s a daunting hiring and training challenge, to be sure, but one that Triad economic and educational officials are embracing in hopes of establishing a durable advance manufacturing network and creating a sustainable pipeline of trained and skilled employees.
Wucherer told local elected and civic leaders that “it won’t be an easy task, but emphasizing that one advantage for Ziehl-Abegg is the variety of jobs we will be creating.”
“We knew of the manufacturing heritage of this region, people who are willing to work hard in production, and that’s why we’re not worried about finding the right people to come on board,” Wucherer said.
As Ziehl-Abegg outgrew the Greensboro facility, Mitchell said North American-based company officials wanted the new operational site to remain centrally located in the Triad, in particular close to the interstate system.
A review of where the current 325-employee workforce lives played a role in choosing the Union Cross Industrial Park site near Herbalife Ltd. and Caterpillar.
Mitchell said there was a sense the company was close to reaching a workforce saturation point from the labor pool in Greensboro and Guilford and Alamance counties.
“We know it’s going to be a very competitive market for employees with Boom Supersonic, Toyota and other advanced manufacturers coming in or expanding in the Triad,” Mitchell said. “Being in Forsyth County was not only going to put us more in play for potential workers, but also make us more of an option for people in Davidson, Davie, Stokes, Surry and Yadkin counties, even southern Virginia and Patrick County, who are accustomed to commuting to work into Forsyth and Winston-Salem.
“We believe we will be attractive to those who favor a manufacturing work environment.”
Another hiring factor are apprenticeship initiatives Ziehl-Abegg is establishing with the Learn and Earn Apprenticeship Program (LEAP) at Forsyth Technical Community College, and Guilford Apprenticeship Partners (GAP).
Apprenticeship programs are staples for many European manufacturers that have been brought to the Triad, such as Egger Wood Products in Linwood and Siemens Mobility North America in Lexington.
“We want to get them young, get them early,” Mitchell said with a chuckle.
Mitchell said Ziehl-Abegg doesn’t rely on sending new employees right into the production line “with a learn as you go” training concept.
“We want to focus on them understanding what it is they’re going to be doing, what’s the purpose of each fan, which fan is going to which customer, so they see the end game need and use, whether in a data center or a hospital,” he said.
Expanding the pathway
The state legislature recently formed a caucus study committee focused on expanding foreign manufacturing investment in North Carolina, particularly from Germany.
The study committee represents a spinoff from the bipartisan Caucus on Economic Development and Foreign Trade that debuted during the 2024 regular session. State Sen. Michael Garrett, D-Guilford, is one of the caucus co-chairs.
Economic development and recruitment have been a rare bipartisan area for state legislators. They have provided hundreds of millions of dollars in performance-based incentive packages to Japanese investors that include Toyota North America, HondaJet, Kyowa Kirin, Dai Nippon Printing Co. Ltd. and Fujifilm Diosynth Biotechnologies U.S.A. Inc.
The goals for the study committee are twofold at this point:
Examine ways the legislature can foster manufacturing growth in the state; andFiling a resolution in the N.C. House encouraging Congress to work more closely on economic and trade issues with Germany, one of the leading sources of capital investment and trade in North Carolina.
The study committee plans to engage with industry leaders, policymakers and stakeholders “to explore best practices and identify challenges and solutions, support workforce development and promote innovation.”
Garrett said in the news release that emphasizing German manufacturing is a logical follow-up to how much success North Carolina has had in recruiting Japanese manufacturers.
“Guilford County has a proud history of manufacturing that has fueled our local economy and provided jobs for our community,” Garrett said. “As a co-chair of the new Manufacturing Study committee, I aim to build on this legacy by addressing the unique challenges and opportunities we face in our region, attracting high-tech manufacturing firms, and ensuring that North Carolina remains a competitive and innovative hub for manufacturing well into the future.”
Sen. Jim Burgin, R-Lee, cautioned that “if we don’t act soon to support manufacturing, including related to agriculture and particularly in rural counties, we’re going to miss out on a golden opportunity.”
Germany is one of the largest originators of foreign direct investment for North Carolina.
German companies contributing $2.2 billion over the past 10 years in new capital investment and employing more than 40,000 North Carolina residents.
“Germany is one of America’s closest allies in Europe and a cornerstone for democracy worldwide,” said Rep. Robert Reives, D-Chatham. “The partnership that exists economically between North Carolina and Germany goes back to the very early days of our state, and it has driven a lot of innovation and job creation through to the present day.
“Our resolution highlights this unique relationship and brings attention in a way that we hope will encourage both sides to continue to work together in building toward a stronger relationship and a more prosperous future for both countries.”
PHOTOS: Ziehl-Abegg’s new plant in Winston-Salem
The operations management office area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area with an office pod at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area with an office pod at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area with an office pod at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
An executive board room that seats 34 people at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
A view of the lounge area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The lounge area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
A training center at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The canteen at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
A vending area in the canteen at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The women’s locker room is provided as well as an employee fitness area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Apprentices Shykeim Austin (clockwise from foreground), Tyler Woodard and Luke Wright put together a work bench for the first step in the final assembly line in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Completed fans ready for shipment are currently being stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Completed fans ready for shipment are currently being stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Completed fans ready for shipment are currently being stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Bill Bentley drives a forklift to move fan housing in the shipping and receiving area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Eddy Rodriguez walks with a pallet jack to retrieve parts in the shipping and receiving area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Eddy Rodriguez walks with a pallet jack to retrieve parts in the shipping and receiving area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Jimmy Mitchell, vice president of operations, stands for a portrait in the shipping and receiving area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
An axial fan is stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Axial fans (foreground) and centrifugal fans are stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
A centrifugal fan is stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
A centrifugal fan is stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
A centrifugal fan is stored in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
Employees Joseph Justice (from left), Logan Camden and Christian Miller work together to install part of the final assembly line in the electronic commutated production area at the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The exterior of the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The exterior of the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The exterior of the new Ziehl-Abegg, a German manufacturer of fans for ventilation and air conditioning applications, plant on Tuesday, Aug. 6, 2024, at 4971 Millennium Dr. in Winston-Salem, N.C.
Allison Lee Isley Journal
The new Ziehl-Abegg plant, a German manufacturer of fans for ventilation and air conditioning applications, is shown on Tuesday at 4971 Millennium Drive in Winston-Salem.
Allison Lee Isley photos, Journal
Employees Joseph Justice (from left), Logan Camden and Christian Miller work together to install part of the final assembly line in the electronic commutated production area at the new Ziehl-Abegg plant.
Allison Lee Isley, Journal
Jimmy Mitchell, vice president of operations, stands for a portrait in the shipping and receiving area Tuesday at the new Ziehl-Abegg plant at 4971 Millennium Dr. in Winston-Salem.
Allison Lee Isley, Journal
A centrifugal fan is stored in the electronic commutated production area at the new Ziehl-Abegg plant. The German company manufactures fans for various uses.
Allison Lee Isley Journal
A view of the lounge area at the new Ziehl-Abegg plant in Winston-Salem.
Allison Lee Isley, Journal
Apprentices Shykeim Austin (clockwise from foreground), Tyler Woodard and Luke Wright put together a work bench for the first step in the final assembly line in the electronic commutated production area at the new Ziehl-Abegg plant in Winston-Salem.
Allison Lee Isley, Journal
Eddy Rodriguez walks with a pallet jack to retrieve parts in the shipping and receiving area at the new Ziehl-Abegg plant.
Allison Lee Isley, Journal
The new Ziehl-Abegg plant features a canteen and other features for employees. Among other worker-friendly amenities are: a cafeteria serving a fresh meal each shift at a subsidized cost to employees; a fitness center with showers for before and after work or on off-days; and company subsidized employee benefits.
Allison Lee Isley, Journal
A training center is shown at the new Ziehl-Abegg plant. Jimmy Mitchell, vice president of operations, said Ziehl-Abegg doesn’t rely on sending new employees right into the production line “with a learn as you go” training concept.
Allison Lee Isley Journal
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