FlexTrades Marketing Team, Author at FlexTrades

From commuter sedans to long-haul trucks, tires are essential to everyday life. At FlexTrades, our skilled technicians travel across the country to support U.S. manufacturers — and many of them drive thousands of miles to reach their assignments. So when it comes to the reliability of tires, we don’t take it lightly.

In fact, we support several leading tire manufacturing clients nationwide, providing the talent that helps keep production lines rolling. That’s why, in this edition of How It’s Made, we’re exploring the process behind the rubber that meets the road.

Tire Materials

Tire manufacturing starts with a mix of natural and synthetic materials, blended for strength, flexibility, and durability.

Natural Rubber
Synthetic Rubber / Polymers
Steel Wire: Used in belts, beads, and truck tire plies
Textile Cords: Provide structural support within plies
Fillers: Carbon black and silica, used to reinforce rubber during the Banbury mixing process
Antioxidants & Antiozonants: Protect the rubber from heat, oxygen, and ozone damage
Curing Additives: Sulfur and zinc oxide, key ingredients during vulcanization

Rubber Manufacturing Process

There are three key operations used to prepare rubber for tire building:

Banbury Mixing: Raw and synthetic rubbers are mixed with fillers under heat and pressure to form solid, workable rubber
Extruding: Shapes the rubber into usable forms
Calendering: Layers rubber with fabric or steel to create belts, plies, and edge covers

Once processed, the material is cut, sheared, spliced, or shaped to exact specifications — ready for tire construction.

Tire Components

Every tire is made of multiple layers, each with a specific purpose:

Innerliner: Keeps air sealed inside the tire
Plies: Provide strength and hold air pressure
Bead: Ensures an airtight seal with the wheel
Sidewall: Protects the structure from road and curb damage
Belts: Add strength to the tread and improve performance
Tread: Provides grip, traction, and durability

How Tires Are Made

The tire-building process happens in two stages on highly specialized machinery, such as:

Tire Building Machine (TBM)
Tire Assembly Machine (TAM)
Tire Forming Machine (TFM)
1st and 2nd Stage Machines

These may be manually operated or fully automated depending on the facility.

Stage One: Casing Building

This step forms the base structure of the tire — also called the carcass. It includes:

Wrapping the innerliner onto the drum
Layering body plies over the innerliner
Placing the beads at each side
Inflating the drum bladder to shape the plies over the beads
Adding and pressing sidewalls into place

Stage Two: Tread & Belts Application

The carcass moves to a second machine where steel belts and tread are added. At this point, it’s known as a green tire — shaped but not yet cured or hardened.

Curing the Tire

The green tire is placed into a curing mold, which functions like a large clamshell. A bladder inside the mold inflates with steam, pressing the rubber into the mold to form the tread pattern and sidewall lettering.

Passenger tires cure for 10–15 minutes at 300°F
Heavy-duty or off-road tires may cure for 24 hours

Once cured, the tire is cooled on a Post-Cure Inflator (PCI) to stabilize its shape before inspection.

Inspection & Testing

Every tire undergoes strict quality control to ensure safety and performance.

Tire Uniformity Testing: Measures balance and roundness under simulated road conditions
X-Ray Testing: Detects internal flaws
Destructive Testing: Verifies structural limits under extreme stress

After passing all inspections, the tire is ready for the road.

For a closer look, watch this Tire Manufacturing Video. And if you’re curious about tire care, check out our article on safe driving and tire maintenance.

Safe travels!

The pandemic disrupted the global workforce in ways few could have predicted. Now, as industries rebound and evolve, many workers are rethinking their future — and if you’re one of them, it might be time to consider a career in manufacturing.

At FlexTrades, we believe in the power of skilled trades to provide growth, advancement, and long-term stability. One of the most promising career paths in this space is in CNC machining and programming — a field with strong demand, competitive wages, and clear opportunities for advancement.

Whether you’re just starting out or looking to level up, here’s how you can carve out your path to becoming a CNC Programmer, starting from the ground up.

Step One: CNC Operator

Getting started doesn’t require decades of experience. Here are three common ways to launch your CNC career:

Go Back to School: Enroll in a technical or trade school with an accredited Machine Tool or CNC Manufacturing Technology program. You’ll build a strong foundation in both theory and hands-on skills — including safety, print reading, machining techniques, and quality control.

Become an Apprentice: An apprenticeship with a local manufacturer gives you real-world experience. Whether it’s short-term or leads to full-time work, make the most of it by learning everything you can and building relationships.

Start Entry-Level: Find a nearby manufacturer using CNC equipment. Even if they’re not hiring operators, apply anyway. Be willing to start in another role and work your way up. Express your long-term interest in CNC from the start.

Once you’re in, show up, speak up, and keep learning. The manufacturing floor rewards initiative and consistency.

Step Two: CNC Machinist

As a CNC Operator, your job is to load materials, run the machine, monitor operations, and inspect finished parts. But when you’re ready to step up, your goal is to become a CNC Machinist — someone who sets up and configures machines for each new job.

To make that move:

Ask questions and learn from your team — coworkers, leads, supervisors, anyone who’s done the job before
Observe setups, take notes, and look for opportunities to shadow
Do your research. Understand the steps involved in setups and study tooling and processes
Request hands-on training and be proactive when a gap appears
Pursue certifications from organizations like NIMS to solidify your credentials

When a skilled machinist retires or advances, be ready to step in. Let your leaders know you’re prepared and committed.

Step Three: CNC Programmer

Programming is where art meets precision. To reach this level, build on everything you’ve already done — and take it further.

To become a CNC Programmer:

Master G & M Code — it’s the core language of CNC operations
Study CNC tooling to understand what tools to use, when, and why
Consider buying your own seat in CAM software like Mastercam or Fusion 360 to practice at home
Enroll in a CNC Programming course at a local technical school
Take advantage of online training options — many software vendors offer detailed, video-based instruction (like Mastercam University)

The more you learn, the more valuable you become — not just as a programmer, but as a problem-solver and leader on the floor.

Keep Growing with FlexTrades

Once you’re a skilled CNC Programmer, your path doesn’t end. The world of advanced manufacturing is constantly evolving, and so are the machines, materials, and software behind it.

That’s where FlexTrades comes in.

As a CNC Operator, Machinist, or Programmer working with FlexTrades, you’ll get to travel the country, work on cutting-edge equipment, and gain exposure to new technologies across industries. You’ll sharpen your skills and expand your experience while helping American manufacturers grow.

Just starting out but recently graduated from a technical school? Join the FlexTrades ReTool Team. We help new grads get hands-on experience that complements classroom learning and sets you up for long-term success.

In Minnesota, we like to say we have 11 seasons — not four. They are:

Winter
Fool’s Spring
Second Winter
Spring of Deception
Third Winter
Mud Season
Actual Spring
Summer
False Fall
Second Summer
Actual Fall

Right now, we’re somewhere between Actual Spring and Summer, which means shelves are stocked with bug spray, sunglasses, and (of course) sunscreen. That got us thinking… how is sunscreen made?

Let’s break it down in this month’s How It’s Made feature.

What Does Sunscreen Do?

The sun emits three types of light: infrared, visible, and ultraviolet (UV). UV light is the most harmful to humans. There are two types of UV rays:

UVA: Can penetrate deep into the skin, damaging cells and the immune system
UVB: Can burn the outer skin and contribute to skin cancer

Sunscreen helps by either blocking UV rays or absorbing them before they penetrate the skin. To do this, sunscreen includes active ingredients such as:

Titanium Dioxide
Zinc Oxide
Avobenzone
Octisalate
Oxybenzone
Homosalate

These are mixed with liquids (like purified water), functional agents (emulsifiers, stabilizers), and skin-nourishing ingredients like Vitamin E.

Here’s a graph showing the ingredient percentages typically found in sunscreen.

Four Steps to Making Sunscreen

Step 1: Purify the Water

Sunscreen starts with reverse osmosis purification to ensure clean, contaminant-free water.

Step 2: Mix the Ingredients

Solids, powders, and flakes are added to large kettles or vats with purified water. Recipes outline exact measurements, time, temperature, and mixing speed.

Curious how similar this process is to other manufacturing operations? Check out our past articles:

Step 3: Transfer to Stainless Steel Tanks

Once mixed, the formula is pumped through sanitary piping into 1,000-gallon tanks inside sterile rooms.

Step 4: Fill & Package

From these tanks, sunscreen flows into pressurized filling machines via more stainless piping.

Bottles are fed in by conveyor
Nozzles fill, cap, and seal each bottle automatically
Products are then boxed, palletized, wrapped, and shipped

Choosing the Right Sunscreen

Manufacturing it may be straightforward. Buying it? Not always.

If you’re standing in the sunscreen aisle unsure what to choose, you’re not alone.
Here are two great resources:

American Academy of Dermatology: Sunscreen FAQs
Understanding SPF: Sun Protection Factor

And remember — no matter how many “seasons” your state has, wear sunscreen year-round.

Happy (and SAFE) Sunning!

We hear about “going paperless” all the time — a byproduct of technological advancement. And while digital workflows are growing, paper remains an essential part of modern life. From packaging and printing to hygiene and education, its uses are vast and vital.

But paper isn’t new. In fact, many historians agree it was invented in China around 105 BC — making it a true innovation of the ancient world. In this edition of How It’s Made, we’re diving into the modern papermaking process.

Step 1: Logging & Cutting

It all begins with trees — mostly fast-growing evergreen species. That said, more and more manufacturers now use renewable fibers like cotton, bamboo, hemp, and jute to reduce environmental impact.

At the logging site, harvested trees are debarked and processed into wood chips using heavy-duty machinery. Check out the debarking and chipping process here!

Those wood chips are then transported to a paper mill for processing.

Step 2: Pulping

Pulping breaks down wood fibers and separates out the components needed to form paper. There are two primary methods:

Chemical Pulping: Used for high-strength products like containers, paper bags, and writing paper, this method cooks the chips in a solution of sodium hydroxide and sodium sulfide under high pressure (sulfate/kraft process). This removes lignin, sugars, and other impurities to form a fiber-rich slurry, which is then washed, bleached, and screened.
Mechanical Pulping: Commonly used for newspapers, paper towels, and tissues, this method grinds wood chips using rotating discs — no pressure or heat required. The resulting mixture is also diluted into a slurry and further cleaned for processing.

Step 3: Beating

The pulp slurry is then sent to a beating vat, where it’s pounded and refined. Here, filler materials like chalk, clay, or specialty chemicals are added to control texture, weight, and opacity — all tailored to the intended final use of the paper.

Step 4: Drying

The slurry still contains lots of water — and that moisture needs to go. First, it’s sprayed onto mesh screens to form a wet mat. Then, it’s pressed through industrial rollers to remove about 50% of the water. After pressing, the mats are heated and dried further, bringing total water removal to 90-95%.

Step 5: Rolling

At this stage, the paper is nearly finished. Depending on its end use, additional treatments may be applied. Finally, the dried sheets are fed through industrial rolling machines, creating large paper rolls for use in manufacturing and converting.

Want to see the scale of this operation? Check out this full paper mill tour!

And if you’re interested in sustainability, don’t miss our How It’s Made article on recycling — also on the FlexTrades blog.

With warmer weather finally arriving, chances are you’ve been opening windows to let in that long-awaited fresh air. But spring isn’t just about renewal — it’s also a great time to talk about window safety.

Window Safety Week, observed during the first full week of April, is a reminder of the simple, proactive steps families can take to prevent accidental falls and keep loved ones safe.

Why It Matters

Falls from windows are more common than you think. According to a report by SafeKids Worldwide:

An average of eight children under five die each year from window falls
More than 3,300 children are injured annually

These incidents are tragic — and preventable. That’s why we’re joining the Window Safety Taskforce and the National Safety Council in encouraging families to take action.

Window Safety Tips

Follow these simple tips to help protect the ones you love:

Close and lock windows when small children are present
Open windows above child reach height when ventilating
Supervise children and keep play away from windows, balconies, and patio doors
Avoid placing furniture near windows — kids love to climb
Don’t allow jumping on beds or couches, especially near windows
Don’t rely on insect screens — they keep bugs out, not kids in

Windows rank among the top five hidden hazards in the home. With a few mindful changes, you can greatly reduce the risk of injury — not just during the spring, but year-round.

Please share these tips with friends, neighbors, and family. One conversation could save a life.

Happy Spring!

Want more tips to protect your home and workplace?

Check out our post on National Drug and Alcohol Facts Week.

The first day of spring arrived on Sunday, March 20, and with it comes sunshine, fresh air… and spring break! It’s the perfect season to get out, explore, and maybe try something a little different.

This year, we invite you to think outside the box and take your travels in a new direction — one shaped by American manufacturing and industry.

It might sound niche, but industrial tourism is more common than you think. And with a wide mix of in-person experiences and virtual options, there’s something for everyone whether you’re traveling or staying in.

Regional Manufacturing Travel Ideas

The Rust Belt: This Great Lakes region (PA, MI, IN, WV, OH) shaped the American industrial backbone. Rich in coal, iron, and transport networks, it’s known for automotive, metal fabrication, food, and chemical manufacturing.

California: A hub for electronics, computers, chemicals, and petroleum products. California has long been a leader in both tech and heavy industry.

Texas: Similar to California, Texas is strong in petroleum and chemical production. It also leads in food and building materials like brick and cement.

New England: With deep roots in America’s earliest industrial revolutions, New England (MA, CT, NH) is now a powerhouse in aerospace, electronics, and appliance manufacturing.

Must-See Museums and Exhibits

American Precision Museum – Windsor, VT
Henry Ford Museum of American Innovation – Dearborn, MI
Louisville Slugger Museum & Factory – Louisville, KY
Kregel Windmill Factory Museum – Nebraska City, NE
Baltimore Museum of Industry – Baltimore, MD
Museum of History & Industry – Seattle, WA
The Kazoo Factory – Beaufort, SC
Minnesota Transportation Museum – St. Paul, MN
Heritage Center of Dayton Manufacturing & Entrepreneurship – Dayton, OH
Lowell National Historical Park – Lowell, MA
Goodenough Silver Mine Underground Tour – Tombstone, AZ

Statues and Historical Memorials

The Hat Maker Statue – Danbury, CT
Mechanics Monument – San Francisco, CA
Rosie the Riveter Memorial – Richmond, CA
Thomas Talbot Statue – Atlanta, GA
Brown Building Plaque – Manhattan, NY

Virtual Tours & Online Exhibitions

If you’re interested in more manufacturing history, don’t miss our post:

Inventors & Leaders – Black History Month

Mr. Yuk might not be on every household bottle anymore, but his message still matters.

Created by Dr. Richard Moriarty, founder of the Pittsburgh Poison Center and the National Poison Center Network, the green-faced Mr. Yuk stickers were developed in the 1970s and 80s to help parents warn children away from dangerous household substances. Moriarty believed the traditional skull and crossbones was outdated — even appealing — to kids. Mr. Yuk, on the other hand, was meant to scare. And if it did? It worked.

Today, we might not see Mr. Yuk’s face as often, but the risk is still very real. So is the need to teach, not just warn, when it comes to preventing poison-related accidents.

Child Poisoning Facts

800,000 children are rushed to emergency rooms each year due to accidental poisoning.
Around 30 children die annually from those incidents, according to the Consumer Product Safety Commission.
Nearly 70% of non-fatal poisonings involve toddlers ages 1 to 2.
24 million people call poison control centers each year. While most cases aren’t serious, that number highlights how common these accidents are.

Tips to Prevent Poisonings

Whether you’re a parent, caregiver, or just someone with little ones around occasionally, these steps can help reduce risk:

Choose products with child-resistant packaging — but don’t rely on them completely. Children can and do learn to open them.
Keep all medicines, cleaning products, and chemicals out of sight and locked away. If a cabinet isn’t locked, assume it’s not safe.
Don’t leave dangerous items unattended, even for a second. Take them with you if you need to step away.
Always store products in their original containers. Don’t pour cleaners or medications into other bottles or cups.
Install carbon monoxide (CO) alarms in your home.
Never take medicine in the dark, when label-reading is impossible.
When taking multiple medications, read labels closely to prevent dangerous interactions or overdoses.

And most importantly — talk to your kids. Teach them what’s off-limits and why. Explain what poison is and how it harms. Prevention starts with information.

Poison Help Hotline: 1-800-222-1222

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March is a big month for meat lovers. In the UK, it’s SPAM® Appreciation Week. In the U.S., we celebrate National Deli Meat Month — and what better way to join the fun than by demystifying one of the most iconic canned meats ever made?

In this edition of How It’s Made, we’re taking a closer look at SPAM® — what it is, how it’s made, and why it’s still flying off shelves after more than 85 years.

SPAM® Facts You Might Not Know

SPAM® is produced by Hormel Foods, which has sold over 8 billion cans since 1937 — in 44 countries.
The name came from a naming contest. The winner received $100. No one truly knows if it stands for “spiced ham,” “shoulder of pork and ham,” or something else.
Originally popular with U.S. troops during WWII, SPAM® was used to lubricate guns and grease boots, not just for meals.
Today, three cans are sold every second worldwide.
SPAM® is found in one out of three American households.
Guam and Hawaii are among the biggest consumers per capita — in Guam, the average person eats 16 cans per year.
In South Korea, SPAM® is often considered a luxury gift.
McDonald’s in Guam serves it on the menu.

And for us Minnesotans? SPAM® is a point of pride — Hormel was founded right here in 1891.

How SPAM® Is Made

SPAM® was born when Jay Hormel saw a butcher slicing canned meat at a deli and thought: “What if consumers could skip the butcher and slice it themselves at home?” The result was a shelf-stable, high-protein product that didn’t require refrigeration — a game-changer for American kitchens.

The Ingredients (Yes, Only Six)

Ground pork mixed with ground ham
Salt
Water
Sugar
Sodium nitrite
Potato starch (added in 2009)

Most of the pork used is pork shoulder — a cut that was once hard to process for other purposes. Sodium nitrite acts as a preservative, preventing bacterial growth and creating SPAM’s signature pink hue. Potato starch, added decades later, helps bind the meat and retain moisture while cooking.

Manufacturing Process

Creating SPAM® might be simple on paper — but the process is a high-volume, precision operation:

Hand carve and grind the meat in 8,000-pound batches at controlled temperatures (approx. 20 minutes).
Use a vacuum mixing machine to super cool the meat.
Add remaining ingredients and blend.
Funnel the mixture into cans, vacuum seal, and apply labels.
Cook the cans using hydrostatic cookers (steam + pressure) — up to 33,000 cans per hour!
Package and palletize for global shipment.

Six ingredients. Six steps. No mystery.

Give It a Try

Never tried SPAM®? As a proud Minnesotan, I think you should.

Grab a can at your local store and give it a go. Fry it, bake it, or turn it into SPAM sushi (yes, it’s a thing). Pair it with cheese (and check out this article on how cheese is made) for the full experience.

Happy Eating — and Happy National Deli Meat Month!

FAQs for PMG

PMG provides labor solutions to American manufacturers. That’s what we do in a nutshell and we take the “solution” part of that equation seriously. As a result, all of us here end up asking a lot of questions to make sure we find the right way to solve the real problem. During that process, we end up getting asked a fair amount of questions ourselves. This blog is our effort to provide answers to the questions PMG employees get asked the most.

What is Industry 4.0?

Great question! Here at PMG, we’re big proponents of the continuous improvement mindset necessary to adapt and adjust to the consistent changes Industry 4.0 requires of manufacturers and fabricators. But what is it, actually? Industry 4.0 refers to the fourth industrial revolution and the rise of digitization and automation in pursuit of “Lights Out Manufacturing”.

Earlier industrial revolutions happened with steam and water power, electricity and assembly lines. Finally, computerization transformed then-standard models for production. This latest revolution is all about the confluence of those previous breakthroughs through use of integration technologies to create interconnected networks of systems that can communicate with each other. Basically, Industry 4.0 is the point where our cyber and digital worlds are meeting in real time and it will impact all disciplines, economies, and industries.

What does it benefit?

Many of you have heard of Industry 4.0 before, but you’ve probably just heard it referred to in terms of robots coming to take your jobs. However, this couldn’t be further from the truth.

According to a comprehensive study conducted by the Hays Global Skills Index, we’re expecting technology to eliminate close to 75 million jobs in the next decade. That’s a lot, but the same study estimates close to twice as many new jobs (133 million) will be created. Put simply, the robots won’t take your jobs. In fact, they will make them better, easier, and safer.

Read this Bernard Marr article if you’d like to learn more about the benefits, to all industries, of early Industry 4.0 adoption.

What’s next?

In one word, change. That’s why we believe so firmly in the importance of a continuous improvement mindset. Industry 4.0 is not going to eliminate jobs, but it will cause them to change continuously and consistently for the rest of your career. You need to prepare yourself to be able to change your skills and focus right along with them.

Most commonly, technology changes jobs by moving the human element (you) further and further from where material and machine meet. That’s where inefficiencies, injuries, and human errors occur. This means that, as important as your technical skills are and always will be, the five technological skills below are just as important for you (according to a Deloitte study) to master in the future. These abilities will be necessary for you to be able to continue to apply your technical skills to your job as your trade or facility is disrupted throughout Industry 4.0.

Technology & Computer Skills
Programming Skills for Robotics & Automation
Critical Thinking
Working with Tools & Techniques
Digital Skills

Additional Resources

If you’d like to learn more about Industry 4.0, or how to prepare your career for it, watch our free webinar Manufacturing in the Future: The Changes Yet to Come.

Did you find this informative? Send your questions to our Writing Team and keep an eye out for future FAQ’s for answers!

Want more FAQ? Check out our post on Supply Chain.

Today is National Cheese Lover’s Day, so naturally, we’re turning our attention to one of the most beloved foods on the planet — cheese.

In this edition of How It’s Made, we break down the process behind your favorite wedge, block, or slice.

What’s in Cheese?

Cheese is made from just four basic ingredients:

Milk
Salt
Starter Culture
Rennet

Together — and through the magic of food science — these ingredients can become hundreds of different varieties, each with their own unique flavor, texture, and personality.

How Cheese Is Made

It all starts with fresh, high-quality milk. Milk is stored in refrigerated tanks at the farm, then transported to a processing facility where it’s tested, weighed, heat-treated, and pasteurized.

Sometimes, additional fat, cream, or protein is added to the milk depending on the desired cheese type.

Next, starter cultures — also known as good bacteria — are added. These cultures begin the fermentation process by converting lactose into lactic acid. This step eliminates harmful bacteria and starts to define the texture and flavor of the cheese. (Different cultures = different cheeses.)

At this point, natural colorings may be added. (Think: the orange hue of Cheddar.)

After that comes rennet, a milk-clotting enzyme that coagulates the mixture into a custard- or gel-like consistency. From here, processors carefully manage temperature, timing, and humidity, which transforms the mixture into curds (solids) and whey (liquids).

A cutting step determines curd size — smaller curds lead to drier cheese. When stirred and heated, curds release whey until the desired consistency is reached.

Then, one of two things happens:

The curd is salted and pressed into a form (like Cheddar or Colby).
The curd is pressed into a hoop and brined (like Mozzarella or Swiss).

The final step in some cases is affinage — the aging process. Cheese is stored in special rooms under precise conditions, sometimes for 10 years or more, to develop its final flavor and texture.

Sounds Simple, Right?

Not quite. While the ingredients are minimal, the equipment, process, and scientific precision required to make cheese correctly are anything but basic. It’s an impressive mix of art, chemistry, and control.

And of course, don’t forget to celebrate National Cheese Lover’s Day with your favorite variety — soft, hard, aged, fresh, or somewhere in between.