Company Profile

Facilities and Equipment

Falcon conducts business from two facilities, one of which is located in Medina, Ohio and the other in Cosmos, Minnesota. The Ohio facility is a brand new facility designed and built for Falcon in 2008. It contains over 30,000 square feet of manufacturing and 3,450 square feet of office space. The facility contains two 5-ton capacity overhead cranes running the length of the building to facilitate the handling of larger conveyor screws. The Cosmos facility was built in 1997 specifically for Falcon. It was expanded in 2006 to its current size of 26,000 square feet, situated on five acres.

Falcon understands the concerns of our customers regarding shipping costs and lead-times. With operations in both Ohio and Minnesota, Falcon’s shipping costs can be managed better than many competitors. We target a lead-time of three weeks or less for all orders.

Falcon currently has 53 full-time employees. This includes 19 shop employees and 5 office personnel in Minnesota as well as 23 shop and 7 office personnel in Ohio. Employees in both plants are cross-trained on various machines and the various aspects of our operations. This has increased our flexibility as orders can be filled by an increasing number of skilled employees. Cross-training has also enabled Falcon to shift orders between the two plants and improve capacity utilization, take advantage of better raw material pricing, and meet customer delivery dates. Our production facilities in both Ohio and Minnesota have Plant Managers overseeing manufacturing operations, marketing managers and customer service representatives to coordinate orders, production, and customer expectations.

Falcon operates 1-1/2” capacity plasma burning machines, as well as a variety of metalworking equipment in each location. We have various sizes of flight forming presses and flight winders in both locations. Falcon has constructed several new flight winders during the past few years. All of the flight producing equipment is designed and manufactured by ourselves. Recent equipment additions and upgrades have resulted in increased size capability and flexibility at both facilities.