Kolberg-Pioneer, Inc. stands out in the competitive aggregate-processing equipment industry through its commitment to manufacturing excellence. Unlike many peers who primarily assemble machinery, Kolberg Pioneer Inc prides itself on a comprehensive, in-house manufacturing process.
“Unlike a lot of our competitors, who just assemble machines, we manufacture from the ground up,” states Jeff May, president of Kolberg Pioneer Inc, based in Yankton, S.D. “This allows us to control the process and control the quality; we’re atypical in that respect.” This dedication to end-to-end production distinguishes Kolberg Pioneer Inc and ensures superior quality control throughout their product lines.
A Legacy of Manufacturing Excellence within Astec Industries
Kolberg Pioneer Inc is a key manufacturing division within KPI-JCI and Astec Mobile Screens, a prominent global manufacturer of heavy-duty equipment. These entities, in turn, are part of Astec Industries’ aggregate and mining group. Astec Industries is a leading name in the United States, renowned for producing asphalt road building equipment, aggregate processing solutions, pipeline and utility trenching machinery, and wood-processing equipment. The integration within this larger, reputable group reinforces Kolberg Pioneer Inc’s position and resources within the industry.
From Pioneer Roots to Industry Leader
The history of Kolberg Pioneer Inc traces back to 1928 with the establishment of Pioneer Gravel Equipment Manufacturing Company in Minnesota. Kolberg Manufacturing followed in 1965 in South Dakota. The two entities merged in Yankton, S.D., during the 1980s. In 1997, Astec Industries acquired the combined company, renaming it Kolberg Pioneer Inc, a tribute to its foundational names. This rich history underpins the company’s deep industry expertise and long-standing commitment to quality.
In-House Manufacturing: A Pillar of Quality Control
Kolberg Pioneer Inc utilizes a wide array of advanced manufacturing processes and equipment. Central to their operations is a CNC machining center, facilitating precise milling, turning, and cutting of raw materials. This capability allows for meticulous creation of components from the ground up.
Beyond machining, Kolberg Pioneer Inc manages the entire production cycle in-house. This includes raw steel processing, welding parts into subassemblies, and the final assembly and painting of finished machines. The Yankton facility also houses dedicated bays for manufacturing replacement parts, ensuring continuous support and minimizing downtime for customers. This comprehensive approach to manufacturing is a cornerstone of Kolberg Pioneer Inc’s operational philosophy.
Diverse Product Lines Cater to Varied Industry Needs
Products at Kolberg Pioneer Inc move through four main assembly lines, each specialized for a primary equipment category. The South Dakota facility manufactures four core equipment types:
- Material-handling equipment: Solutions for efficient movement of materials in various operations.
- Crushing and screening machines: Robust machinery for reducing and sorting aggregate materials.
- Washing and classifying equipment: Systems for cleaning and separating aggregates to meet specific quality standards.
- Track-mounted equipment: Mobile and versatile equipment solutions for flexible deployment.
This diverse product portfolio allows Kolberg Pioneer Inc to serve a broad spectrum of customer needs within the aggregate, recycling, and construction sectors.
Lean Manufacturing and Continuous Improvement
Kolberg Pioneer Inc integrates lean manufacturing principles throughout its operations. Practices like 5S, kaizen, and rigorous safety initiatives are integral to their processes, driving efficiency and continuous improvement.
A dedicated quality assurance department ensures adherence to stringent standards. Furthermore, cross-functional teams are assigned to each project, fostering collaboration and innovation. “We work to achieve cost-reduction targets, improve our products and make them more functional and easier to use,” May explains. This commitment to lean principles and quality assurance translates to superior products and customer satisfaction for Kolberg Pioneer Inc.
Investing in People: Workforce Development and Expertise
Kolberg Pioneer Inc prioritizes finding the right fit for its manufacturing team. Prospective employees gain firsthand experience on the production floor and in operations before hiring decisions are made.
“They see where they would be working and see what they will be doing, and our supervisors and employees have a chance to determine if we are a good fit for each other,” May notes. This careful selection process ensures a motivated and skilled workforce at Kolberg Pioneer Inc.
Once onboard, employees receive weekly job training progress reports. Kolberg Pioneer Inc partners with a local technical education center to provide certification programs in welding and other critical disciplines, continuously enhancing employee skills. Training extends beyond internal teams, with programs offered to salespeople, clients, and dealers on equipment features, benefits, and applications. This investment in training and development underscores Kolberg Pioneer Inc’s commitment to expertise at every level.
Providing Total Solutions Across Industries
Kolberg Pioneer Inc serves a diverse clientele across mining, recycling, and aggregate production. “You can find our equipment in a rock quarry, gold mine, as well as on the interstate recycling existing asphalt and concrete from an old road to be used again,” May illustrates.
The company’s broad industry reach offers a significant advantage. “A lot of folks come to us because we can offer them a total solution and have both standard product offerings as well as engineered solutions,” May adds. Kolberg Pioneer Inc boasts a substantial design engineering group of 42 professionals, complemented by sales application engineers who collaborate closely with dealers and customers. This dedicated engineering expertise allows Kolberg Pioneer Inc to tailor solutions to specific customer needs, considering factors like desired aggregate products, existing machinery, and production targets.
“We think of ourselves as solution providers,” May emphasizes. “Our main focus is helping our customers become more profitable.” This customer-centric approach defines Kolberg Pioneer Inc’s market strategy.
Reliability, Durability, and Customer Support: Key Differentiators
Kolberg Pioneer Inc emphasizes product reliability, durability, productivity, ease of maintenance, and safety. The ready availability of replacement parts is another major selling point, particularly crucial for heavy-duty equipment. “Because of the violent nature of equipment like jaw crushers, the need for repair and parts is absolutely critical,” May points out.
The company’s commitment to support and adaptability is evident in its aftermarket services. Kolberg Pioneer Inc provides quality replacement parts not only for its own equipment but also for competitor machines. A notable example is Butler Brothers Supplies, a Canadian ready-mix and aggregate producer who chose Kolberg Pioneer Inc wear parts to retrofit an older log washer. This retrofit is projected to save the customer over $40,000 while improving product cleanliness compared to competitor units. This proactive customer support and parts availability further solidify Kolberg Pioneer Inc’s reputation.
Proven Performance in Demanding Projects
Kolberg Pioneer Inc equipment operates in diverse and challenging environments. For instance, a robust FT2640 track-mounted jaw crusher, weighing 83,000 pounds and manufactured by Kolberg Pioneer Inc, was deployed at the Niagara Gorge for a $32 million construction project. Contractor Mark Cerrone Inc. utilized this equipment to process materials for a power station revamp near the edge of the 200-foot gorge, demonstrating the equipment’s reliability in demanding applications.
Employee Pride and Core Values Drive Success
May attributes Kolberg Pioneer Inc’s success to its dedicated employees and Astec Industries’ five core values.
“I think our associates have a great deal of pride in what they do, and that gives me a lot of satisfaction,” he says. “Our number one core value is continuous devotion to meeting the needs of our customers. We take a lot of people through our manufacturing facility, and I think they marvel at the dedication of our associates and what they’re doing. Our associates, in turn, are gratified that the work they’re doing is noticed.” This employee pride and customer-focused value system are central to Kolberg Pioneer Inc’s operational culture.
“I’m proud of the way our employees go about the jobs, and proud of the work ethic they have to continue to make their jobs better.”
Expanding Global Reach with Innovative Products
Kolberg Pioneer Inc continues to innovate and expand its market presence. One of its newest products is a horizontal shaft impactor crusher, specifically designed for global markets. This crusher’s design facilitates cost-effective overseas shipping, reflecting Kolberg Pioneer Inc’s strategic focus on international growth.
“Our strategy is to find a way to grow the business and find new markets while continuing to support our current customers as best as we can,” May explains. “We want to grow 10 percent each year, which is a pretty lofty goal when the market itself isn’t growing.” This ambitious growth target underscores Kolberg Pioneer Inc’s commitment to innovation, customer satisfaction, and expanding its global footprint in the aggregate processing equipment industry.
