While the manufacturing of professional cleaning products can seem like magic, the true power lies in the precision of chemical compounding. Fuller Industries Inc. is pulling back the curtain on its complex manufacturing process, highlighting how high-tech engineering and chemistry transform raw elements into industry-leading solutions.
At the heart of the Great Bend facility are cavernous compounding rooms, where a sophisticated network of pipes directs myriad chemicals into massive vats. According to Production Manager Cory Gros, the process is an intricate dance of timing and chemistry.
“Following the formulas is like following a recipe,” he said. But the stakes can be high.
“Attention to detail is important,” Gros said. “There is a lot of pressure. One small mistake can ruin an entire batch,” a costly error.
The Fuller compounding team juggles hundreds of formulas through the three inside and two outside compounding chambers. They blend the raw materials that come in totes, barrels, bags and drums, and there are most often four different products mixed at any given time.
“The scheduling is crucial,” Gros said. “Our tanks must be meticulously flushed and cleaned between products. To make the most effective use of our time, we have to be strategic about what we are making and when.”
The science of compounding
Unlike simple chemical blending - which merely mixes ingredients together - chemical compounding involves a fundamental transformation, Gros said. It is the process of chemically bonding two or more different elements to create an entirely new substance with unique properties. Every formula relies on exact ratios to ensure consistency and safety across every batch.
Through the intense mixing, the molecular structures of raw materials are altered to form inseparable new compounds. This precision ensures that Fuller’s products consistently achieve specific quality control benchmarks, such as enhanced durability and performance properties, Gros said.
“Fuller is leader in the commercial cleaner industry,” said General Manager Joe Mann. “By mastering the transition from raw elements to finished compounds, Fuller Industries continues to set the standard for efficiency and chemical integrity in the industrial cleaning sector.”
