Outsourcing Engineering Expertise to Break into New Markets

Founded in 1975, Rotobec has become a globally trusted manufacturer in the material handling equipment industry. The company develops superior-quality and robust loaders and attachments for a wide range of industries, including the forestry, scrap, waste, rail, industrial and port sectors. With headquarters in Sainte-Justine, Quebec, and production facilities in New Hampshire, Rotobec products are distributed in over 50 countries to discerning customers that require unbeatable quality and durability for applications in harsh environments.

The challenge: Unprecedented growth leads to pressing engineering needs

Thanks to its market success, Rotobec has experienced unprecedented growth over the years. However, hiring skilled engineering professionals locally became increasingly difficult in a tight labour market. Finding suitable outsourced engineering services became crucial with fixed resources and variable, high-volume demands.

Rotobec began its search for an engineering partner who could not only match its high standards but also adapt to its product development workflows. The goal was to increase the capacity of their engineering department while maintaining the highest product quality. Rotobec wanted to rely on a company that could deliver the same level of equipment consistency as though developed in-house.

Creaform Engineering’s expertise, particularly in mechanical design and finite element analysis (FEA), presented a promising opportunity. Given the desire to accelerate project timelines and the challenges of recruiting skilled personnel in their region, Rotobec opted to collaborate with Creaform Engineering experts.

Engineers during a design review of a new grapple.

This partnership provided access to a pool of qualified professionals, offering the flexibility needed to capitalize on new business opportunities without delay.

Initially, Rotobec aimed to enhance their department’s capacity for ad-hoc engineering projects, but the team soon realized that Creaform Engineering could offer much more.

The solution: Creaform Engineering shares its expertise and eases the pressure

Mechanical designer working on the Evolution 960/965 diesel loader.

Creaform Engineering’s specialists seamlessly integrated into Rotobec’s existing team and were quickly onboarded on operational processes and internal tools used for product development. Over time, Creaform Engineering built strong relationships within Rotobec’s plant, allowing for direct and efficient communication with design and production teams as well as third-party vendors.

Rotobec uses a wide range of Creaform Engineering services. Mechanical designers improve upon existing products and create new equipment, including very large loaders and grapples. Project engineers oversee development and ensure quality and performance. Finite element engineers ensure a robust design and optimize product performance, leveraging FEA to enhance the strength and durability of the product.

Mechanical engineer reviewing a new part with a machinist.

“Since Creaform Engineering is now fully embedded into our teams, there's no longer any additional burden associated with using an outside firm,” explained Matthew Mercier, Engineering Director at Rotobec. In the context of scarce manpower, this has enabled us to sustain our growth even if we're not in a position to hire.”

“Creaform Engineering's experience in various fields brings a fresh perspective to Rotobec’s product development approach,” Michel Roy, Project Manager Engineer at Rotobec, added. “The use of finite element analysis (FEA) early on in the design process allows us to minimize the number of prototypes, improve product performance, reduce risks regarding structural strength and avoid costly rollbacks.”

Finite elements analyses (FEA) on a diesel loader.

Harnessing the potential of a major business opportunity in the port market

The port market, especially in northern Europe, is notorious for being very harsh on equipment that transports bulk materials. The grapples used for this type of port handling are clamshell buckets. Conventional equipment that many businesses use has major weaknesses, causing very expensive downtimes and maintenance. Rotobec saw this as an opportunity to break into the market by offering a grapple specifically designed for this application.

A design team made up of the best resources available at Rotobec and Creaform Engineering’s team designed a brand-new product that offered better performance and durability for material handling in ports. What’s more, this innovation drastically reduced the level of necessary maintenance, making it a hit with customers.

Mechanical engineer and production manager inspecting a grapple before shipping to a customer.

“Rotobec has a proven track record in product development for the heavy machinery market. We have a winning combination with Creaform Engineering's know-how in product development and FEA. The strengths of two leaders generate the perfect fusion of experience, performance, and agility,” Matthew Mercier, Engineering Director at Rotobec, said.

The 15-year partnership between Rotobec and Creaform Engineering has been a remarkable journey of growth and innovation. By enhancing Rotobec’s engineering capabilities, Creaform Engineering has enabled the company to maintain its high standards and market leadership. This collaboration solved immediate staffing challenges and paved the way for product development that set new industry benchmarks.