Douglas Rulmeca has successfully completed Project Vulcan, the first phase of a multi-year initiative to modernize idler production. By moving from manual processes to fully automated lines, the company has boosted efficiency, preserved and expanded its workforce, and delivered repeatable, high-quality results from day one. This milestone not only strengthens idler production but also positions the entire product line—pulleys, take-ups, magnets, and impact beds—for long-term growth.
Key Takeaways:
Project Vulcan automated idler production in just 12 months.
Automation increased speed, capacity, and product consistency.
Jobs were preserved, with the team expanding by 25 employees.
Quality control delivers repeatable, high-performance results.
Next steps include pulley modernization and ConExpo 2026.
“We took the elbow grease out of it. Now people are using their brains instead of their brawn—and that’s the best thing about it.”
– Paul Ross, President
Project Vulcan: A Game-Changer for Idlers
In just 12 months, Douglas Rulmeca transformed idler production with the completion of Project Vulcan, a fully automated manufacturing line. Previously, idlers were produced through a largely manual process that required significant time and labor. Today, machines handle the heavy lifting, while employees focus on operating advanced equipment and ensuring quality output.
This shift has dramatically increased production capacity, allowing the company to ship idlers faster and build inventory to support sales. What once took time and elbow grease now flows with repeatable precision.
Investing in People and Growth
Despite the automation, Douglas Rulmeca emphasized its commitment to its workforce. Not only were all jobs preserved during the transition, but the company also grew its team by 25 people over the past year. Employees now focus on running high-tech equipment, improving efficiencies, and fine-tuning operations, all while maintaining a culture centered on quality.
Quality at the Core
Automation hasn’t just increased output—it has strengthened Douglas Rulmeca’s long-standing reputation for quality. Rigorous testing protocols were built into the process from the start, ensuring that every idler meets the highest standards of repeatability and reliability. As Paul explained, “Quality is a mentality… it’s something our team carries through to all products, because we know it’s the customer that matters”
Global Collaboration, Local Impact
Project Vulcan was not achieved in isolation. The company worked closely with other Rulmeca group companies, especially colleagues in Italy, who provided engineering, operational, and financial support. The result is a global effort that strengthens local production in Pell City, Alabama, while enhancing the company’s ability to serve customers worldwide.
Looking Ahead: Pulleys and ConExpo
With phase one complete, Douglas Rulmeca is already setting its sights on the next frontier: pulleys. Lessons learned from automating idler production will soon be applied to further modernize and expand pulley capabilities.
At the same time, preparations are underway for ConExpo 2026, where Douglas Rulmeca will showcase its products as part of a unified Rulmeca group booth in North America. This event will mark an important milestone in sharing the company’s innovations and message with a global audience.
Contact Us
Douglas Rulmeca is dedicated to delivering conveyor components that combine durability, precision, and innovation. To learn more about our idlers, pulleys, and other solutions, contact our team today.