Production Summit: Ashes to Automation Plant Tour

Early on the morning of June 15, 2016, a devastating fire raged through Clemens Uniform in Lansdale, PA. The smoke was visible for miles. Fortunately, no one was hurt, but the entire building, along with everything inside, was gutted.

Clemens is a family-run business founded in 1963 by Paul and Kathryn Clemens. Two of their children currently operate the company, which employs 55 people. Randy is the general manager of the uniform, linen and other related businesses. His sister, Janet, oversees accounting and office support.

While the building was still smoldering, Janet and Randy gathered to discuss their options. At first glance, the task of rebuilding seemed too daunting. “Oh yeah, initially we thought, ‘It’s just too much,’” Randy said. “But our family has a strong work ethic. We are completely dedicated to our customers, employees and their families. We knew we had to rebuild.”

Despite this devastating setback, Randy looked for a silver lining. “Before the fire, I was working on a long-term plan to upgrade and automate the plant with the newest sorting (Dispat-U-Veyor conveyors) and identification technologies (RFID). I already knew what companies had the best solutions,” Randy said. “So Janet and I decided we would go forward and rebuild immediately.”

Within days, the company began operating out of smaller storage buildings located on the property. “We made do with what we had. Our entire staff worked hard to provide full service to our customers throughout the rebuild process,” Randy said.

Soon, a new building was under construction and equipment, machinery and systems were ordered. By September 2017, the new high-tech, automated plant was fully operational. Attendees at TRSA’s Production Summit & Plant Tours program this Sept. 25-26 in Philadelphia will get a firsthand look at the new facility.

Highlights of the rebuilt Clemens Uniform plant include:

• A Speed Check monorail storage and delivery system, coupled with their fully automated Rail Management System (RMS) software, that moves soiled garments to Pellerin Milnor’s high-capacity commercial auto-loaded washer/extractors (supplied by PAC Industries Inc.).
• Clean-side sorting conveyors and garment storage conveyors were provided by White Conveyors Inc.
• A Positek RFID identification system was installed to sort, count and track individual items, while further automating and improving garment sorting. Tight tracking of each individual item allows the processing of more than 20,000 lbs. of clothing per day. To ensure order accuracy, bundled garments are scanned in final preparation for delivery.

Janet and Randy acknowledge that the rebuilding process was exhausting – but well worth the effort. “The company is thriving. It all came together perfectly,” Randy said. “We are so grateful to be able to provide our family of employees the automation that reduces fatigue and risk of injuries. Our customers enjoy the high quality, accuracy and reliability. And we are thrilled with the efficiency and productivity that our new production process delivers.”