Calstone is a family-owned Canadian OEM manufacturer that offers customized metal products with unmatched precision and speed. As a one-stop shop, it undertakes design, prototyping, fabrication and production, painting, assembly, packaging, and logistic services for a range of products, including modular workstations, fitness equipment, and carts.
Quality is ingrained into Calstone’s services. To achieve this, it follows a step-by-step process, starting with connecting with clients to the final delivery of products. Its expert team interacts with engineers to ascertain their requirements, including product specifications, customizations, end users, and delivery timeframe.
“Once we receive the drawings, we ‘Calstonize’ the designs, applying our capabilities and offering them a quote,” says Matt Ecclestone, vice president of operations at Calstone. Based on the design, Calstone creates a product prototype free of cost. After the prototype is approved, the team meets with customers to discuss improvement opportunities and incorporate revisions until the client is satisfied. In one instance, it made 30 revisions to the prototype, which is rare in the industry. Unlike companies that take months to create a prototype, Calstone completes the job in two weeks. All necessary modifications are made at its facility, and production begins.
Working extensively with sheet steel, tubing, and bending fabrication, Calstone adapts its machinery to complete vast, demanding projects. It houses best-in-class machinery and constantly upgrades its capabilities to accommodate everchanging requirements. Calstone’s top-of-the-line lasers can cut through any steel, whether an inch thick or 20-gauge steel or lower. It leverages brake presses for bending materials and deploys robotic welders to carry out specific processes for high-volume activities. The team applies a combination of manual and automated processes to continue providing customized services to clients.
Calstone’s ability to take a project from start to finish was best displayed when a multipatented inventor of isometric strength training devices approached its team to expand his production capabilities. Its engineers, shop managers, and machine operators worked closely with the client to precisely manufacture the machine to their specifications. After numerous revisions, based on feedback from high-level fitness trainers and testers, the final design was developed, and the Isophit M.S.K. was born. Engineered for maximum versatility and portability, the product is now used by celebrities, sports teams, and gyms
worldwide.
“Our extensive manufacturing capabilities ensure that we are never at capacity, allowing us to seamlessly fulfill our client orders and promptly meet lead times,” says Ecclestone.
Calstone works hand-in-hand with its logistics partner to deliver the manufactured products on time. The team takes great pride in having zero cases of late deliveries in the last 35 years. Despite the supply chain disruptions caused by the pandemic, it maintained steady lead times by expanding its production facilities and acquiring new machinery. Going from strength to strength, Calstone has grown from a 47,000 square feet facility to 250,000 square feet spread over five buildings.
