Category Archives: St. Louis Facility

What is a Spin Line?

Spin LineThere is a LOT of secretive information that we don’t disclose about our spin lines, but we can hint around the topic a bit to give you an overview. A spin line is our term for the manufacturing equipment required to produce the hollow fibers inside our membrane separators. It’s a little bit similar to carpet fiber manufacturing. Polymer squeezes through a tiny funnel jet, and then cools in a series of water baths.  All of these steps happen in a harmonized sequence managed by our Spin Line Operator experts. These folks also monitor fiber quality throughout the spin line by carefully taking measurements and performance calculations. The exclusive fiber inside our membrane separators is the key to our long lasting, reliable membrane products…and it all begins on the spin line!

 

If We Can’t Answer the Phone on Tuesday Mornings, You Now Know Why

We’re extra busy on Tuesday mornings! This is the time that the Site Director, and practically our whole entire membrane business, gathers together for a weekly manufacturing and quality control review. Our “Stand Up” meetings are casual and usually only last 15 minutes… but we are committed to being there every week to share ideas about improving quality and high productivity on our manufacturing floor. We’re proud that Continuous Improvement is part of our membrane manufacturing culture.

By the way, we’ll gladly call you back if you leave a message.

Seeking Stability

If it is 10am on a Wednesday, you are not going to be able to use our Continuous Improvement Conference Room… you will have to use Conference Room 2. That’s because our stability team will be in there holding the universe together…ok that’s dramatic… but what these operations and engineering folks are doing is seeking stability in our membranes manufacturing process.  They analyze charts of performance and if anything seems to be trending off course, they investigate the issue. One little dot on the chart wiggles off course, and they’re down there measuring the humidity, the temperature, and all of the tricky little things that make manufacturing membranes a challenge. If we don’t continue to monitor these changes, how will we ever expect our customers to trust that we are putting our best product out there?  We do it because we have our priorities straight and safely making a great, reliable, long lasting, highly performing membrane is the most important thing we do here.

We Took a Quick Break from Building Membrane Separators

Just before the Fourth of July holiday, our plant employees enjoyed a quick little event that brought out some friendly competition. After enjoying a tasty meal of summer-time grilled favorites, the employees were challenged with a group bridge building competition. Printer paper and standard glue sticks were the only materials permitted to build a bridge capable of withstanding the weight of a toy truck. We saw creative ideas and big smiles which confirmed that taking a quick break from manufacturing membrane separators to laugh and strengthen teamwork was totally worth it!

It All Began in North Carolina

Take a trip with me as we zoom back to the 1980s – a time when our current Saint Louis PRISM Membranes building was actually an electrical distribution warehouse. In fact, the business unit of “Air Products PRISM Membranes” wasn’t even formed until years later.

It started in Research Triangle Park (North Carolina) as a manufacturing project underneath the parent company ofCross Section Monsanto. Monsanto, who is now a dominant seed & agricultural development company, was an active player in textile manufacturing in the 1970s. They spun tiny textile fibers from plastic which eventually led to spinning hollow fibers for the purpose of gas separation. But nobody in the gas industry had really heard of using these tube-like membrane separators to generate gases, so customers were hard to come by.

Monsanto made some changes to their textile business in 1984. They closed their big building in North Carolina and moved the gas separation employees to Saint Louis…in a vacant building down the street from their corporate office. The building had vacant space, and that’s about it, nothing fancy. So they built a few walls and hallways and moved the fiber spinning equipment over. After years of development, the business grew and more offices and walls went up in our building. The next time you’re in our facility, take a look at the layout, it makes no sense. But it was the product of a growing business, so walls went up where they were needed. And everyone was always too busy to worry about what the building looked like.

1990s EmployeesIn 1991, Air Products acquired the membrane separation business from Monsanto as part of their desire to sell both gas molecules and gas generating equipment. Encouragingly, Air Products kept the existing membrane employees on board. In a merger or acquisition, that’s not always the case. But membrane manufacturing isn’t something you learn overnight, so I assume they valued the years of experience. Like it says in our corporate governance statement:

“Air Products has built a reputation for quality, integrity and goodwill that is the cornerstone of our success.”

So although it all started in North Carolina, we’ve been true Saint Louisans since
1984. And yes, we eat toasted ravioli and flat pizza with weird cheese.

Every Time the Bell Rang, They Smiled

They heard the crackle of the PA system and then a little bell chimed throughout the building. Everyone would stop what they were doing and they’d look up with a big smile. oldbuildingThe membrane separator business just made some MONEY!

Back in the 1980s, our business unit operated more like today’s typical startup. A lot of people worked hard to discover new ideas and to develop successful membrane solutions. It was an exciting time. But big sales were few and far between. So when an order for membrane separators did come in, it was worth celebrating.

That’s why our sales team would ring a bell over the building’s PA system. It sparked a little excitement and congratulated the whole organization. Today, our membrane separators are much more mainstream, but our team still feels the appreciation when we review the order book each Tuesday morning.

We don’t ring a bell for every order anymore…that would get annoying. But a lot of us remember the days when we did. And we’re excited by how much our business has changed and grown since then.

Hello World!

Welcome to the Membrane Insider, a blog written by the Air Products PRISM Membranes group in Saint Louis, Missouri. We’ll post every week or so to give you a little dose of what’s going on in our world.  Click the follow button on this blog so that these weekly updates are delivered to your email…we promise not to be annoying.

group photo PRISM Membranes