Alpha Building Center welcomed community in the ribbon cutting of their new truss production facility!
Community members from The Chamber of Commerce of LaGrange County, Farmers State Bank, Ligtel, LaGwana, Crossroads United Way, the LaGrange County Economic Development Corporation, Alpha Building Center, and DJ Construction came together to celebrate the opening of Alpha Building Center’s new truss manufacturing facility. This brand-new facility is located on the west side of State Road 5, just south of Yoder’s Popcorn, at the corner of the US 20 and SR 5 intersection.
Alpha Building Center is a local business that provides materials such as metal roofing, windows, decking materials, lumber, garage doors, and much more to local builders, homeowners, and businesses for any project. The new truss manufacturing facility broke ground in December of 2023 and produced its first order of trusses at the end of September 2024, shortly after a tornado went through LaGrange County, damaging a few homes and barns.
The new facility employs six team members: three in the front office handling mechanics and engineering work, and three assisting in the assembly and production of trusses. The production line is highly automated, covering tasks that would otherwise require 12 positions. Although this might seem like a loss of potential jobs, Kyle Ulrich, CEO of Alpha Building Center, noted that finding dependable labor is currently a challenge. Automation helps Alpha Building Center produce trusses in a timely, cost-effective manner for customers.
The process begins with an engineer designing the truss to the project’s specific dimensions. This design is entered into a computer system that acts as the operation’s “brain.” The computer program directs the machine on which lumber to select based on size and quality. The machine then feeds this lumber into an automated saw that cuts each piece to the required size and angles, ensuring the pieces fit together as designed. Following the saw, the automation system prints a code on each piece to help team members sort and assemble the trusses accordingly. From there, the pieces travel down the line and are sorted by the machine at one of two assembly stations.
Team members assemble the trusses on an elevated workstation, which then flips the trusses onto a rolling line, moving them to a planer where they are smoothed. From there, the trusses are loaded and delivered to the building site. Any scrap generated is used to produce floor trusses, minimizing waste.
Before constructing this facility, Alpha Building Center sourced trusses from Kosciusko County, Indiana, and Michigan. Now, by producing their own trusses, Alpha Building Center can provide customers with locally manufactured products, helping to keep resources available and costs down for those looking to build.
Alpha Building Center worked closely with DJ Construction to ensure the facility was built with future growth in mind. Currently, the facility has one automated truss line; however, there is space to mirror the automation line on the opposite side of the building. Alpha Building Center and DJ Construction paid close attention to details, like the placement of support beams, to ensure open, safe walkways within the facility in case a second automation line is installed.
With the completion of this facility, Alpha Building Center can produce a maximum of a 60-ft truss in just 90 seconds in their 35,000-square-foot facility. These trusses are available at their locations in Shipshewana, IN; Nappanee, IN; and Nottawa, MI, with free delivery within a 50-mile radius. Alpha has been innovative in utilizing automation to address labor shortages and enhance sustainability.
