INTRODUCTION 1

About Us

2 ORDER PROCESS

Replacing the Garbage Can

3 REMANUFACTURING

Our Unique Solution for Damaged Mats

4 FREIGHT OPTIMIZATION

Strategies and Best Practices

5 COST BENEFIT

Leveraging Waste Reduction for Profit

ABOUT US

Our roots in the textile service industry go all the way back to the early days of mat manufacturing and industrial laundry rental service. The beginning of NuMat Systems was similar to other specialty manufacturing startups with broad product catalogs and an array of styles, competitive prices with top quality. We had a lot of fun and some success but the core of our current business is actually the chance result of a customer request and challenge to repair their damaged mats. The series of events that followed put us on the path towards sustainability and is why we are still serving the laundry industry today.

While we continued to manufacture new mats for our regular customers the rest of the team was busy experimenting with combinations of raw and finished feed stock, adjusting, adapting, and testing the limits of our equipment and collective imagination. We modified processes, engineered production tooling, and invented a unique solution for damaged mats called Remanufacturing.

Over a decade later we are happy to share that 99% of our work now is focused on damaged mats and we are dedicated to reducing the industry’s impact on the environment.

2008
NuMat Systems is founded in Roanoke, Alabama as a manufacturer of rubber-backed walk-off mats.

2010
Capital investments double capacity and major pivot of production focus to remanufacturing for damaged mats.

2012
Introduction of custom built shipping cage available to any active mat repair customer for transport.

2014
NuMat Systems remanufacturing process is certified by The National Floor Safety Institute (NFSI).

2015
Introduction of proprietary process that permanently repairs rippled walk-off mats.

2018
NuMat Systems celebrates 10th anniversary in business.

2019
Capital expenditures and process innovation further increase capacity at the Roanoke facility.

2020
Strategic partnership with Landon Haney Company in Riverside, California enhancing service level to West Coast customer base.

Acquisition of machinery assets of Dacorp Inc. Mat Repair Division in Morganton, Georgia.

ORDER PROCESS

REPLACING THE GARBAGE CAN

WHAT
CAN YOU
DO WITH DAMAGED MATS

In business it is rare that the most cost effective option is also the most ethical.

The laundry industry is founded on the principle of RE-USE and we share that same focus.

By choosing to remanufacture your damaged mats not only are you saving money but you are also making a green industry even greener.

HOW TO IDENTIFY GOOD REPAIR CANDIDATES

RIPPLED

MISSING BORDER / SMALL TEAR

SHARK BITES

CUSTOM SHAPES

SEVERE DAMAGE IN LARGE MATS

These mats should have years of useful rental ahead but they are discarded as waste.

Most damaged mats are removed from service for minor damage like torn borders, small tears, or rippling.

All of the most common types of damage can be repaired with our service. Your team is already filtering for non-conforming inventory in every batch so the next step is to replace the garbage can with a pallet or shipping cage for collection.

Prioritize newer, high value inventory in large sizes. Logo mats are also great candidates for our service because of their cost premium and lead time for replacement.

Damage is totally unpredictable and this is only a short list of the most common variables that can affect our work.
We have seen many interesting mat problems but we know we haven’t seen it all.
If you are unsure about any particular mat just give us a call!

PLEASE DO NOT SEND

3X5 WITH SEVERE DAMAGE

MISSING PILE, STAINS, WET, MOLDY

MOLDED RUBBER, SCRAPERS, FOAM

We have a simple process for mat remanufacturing that insures you get the best return on your inventory investment. Our goal is to repair the damaged mat in its current size if possible. If not, then we will adjust the mat to the next largest trade size.

Unfortunately we can’t save them all. Every mat is a snowflake and if there is missing pile throughout the textile top or large tears on small trade sizes we will not be able to salvage any rentable product.

We work primarily with the rubber elements of the mats and if a mat is dirty, stained, wet, or moldy it will not be processed.

The examples above are not suitable for remanufacturing but if your team sends anything that is rejected from the order you will not be charged for repair. With this in mind we still recommend filtering out mats that have irreparable damage because it will help to reduce the freight cost per finished mat.

Remanufacturing gives your inventory another chance at a profitable life — instead of being amortized in the landfill.

REMANUFACTURING

OUR UNIQUE SOLUTION FOR DAMAGED MATS

THIS IS NOT A PATCH JOB

We replace the entire border whenever there is damage.

1. Damaged borders removed

2. Mat is trimmed to size

3. Borders are replaced with our uncured custom compound profile of nitrile rubber.

4. Assembly is prepared for vulcanization.

5. The combined product then passes through the manufacturing line
and a vulcanized bond is formed.

The quality and condition of your inventory can be subjective but safety is not debatable. The National Floor Safety Institute develops standards and audits flooring products for compliance in order to prevent slips, trips and falls. Damaged mats are ugly but the real risk is the loss of safety certification and resulting liability for you and your customers.

Every mat that you purchase has been evaluated and certified to the same safety standard and a repair should be no different. Thermal patches, glue, tape, or other in house remedies will not reduce your safety risk or improve the appearance of your mats. Our remanufactured mats will protect your profit margin and your reputation.

FREIGHT OPTIMIZATION

STRATEGIES AND BEST PRACTICES

STANDARD

Every repair program needs a plan for shipment. We accept mats in any containter and packing style that you prefer but you might consider these strategies to reduce the freight cost per mat.

Pallets should hold between 50-100 mats.

Mats do not need to be sorted by size or style.
Fold larger mats to fill the area of the pallet.
Secure stack to the pallet with straps or wrap.
Contact us with weight and dimensions.

We can make logistics arrangements and provide consolidated billing for freight and repair when you’re ready to ship just let us know!

COST BENEFIT

LEVERAGING WASTE REDUCTION FOR PROFIT

ANNUAL COST

OF DAMAGED MATS PER DAY

Every day your team will remove damaged product from inventory in order to maintain quality standards. The useful lifespan of a mat should be measured in years but too often there are many that get trashed after the first or second rental. In this chart you will find that when you have as few as two damaged mats per day you could save up to $10k over the cost of replacement.

There is an old saying in the laundry business that the “profit is in the pennies” and you can see the net reduction in inventory cost is significantly more than pennies or a few percentage points. Our customers enjoy between 40% and 70% lower cost than replacing damaged product. Cost reductions on that magnitude are possible even with just one order per year.

PRICING FUNDAMENTALS

UNDERSTANDING REMANUFACTURING COST

Damage is unpredictable but our price structure allows you to keep your expenses under control.

Our goal is to provide a product that is like new at a fraction of the cost.

Our prices are consistent across all of your inventory styles, colors, border thickness and manufacturer. We only charge for the finished size so if a 3x10 is resized to 3x5 then it is evaluated as a 3x5 and not the original size.

We offer three tiers of repair service for each of the following mat sizes: 3x5, 4x6, and 3x10. Our pricing tiers are based on the number of repairs needed: 1-2, 3-4, or 5-6 repairs. The average cost of repair is less than half the cost of replacement.

PROGRAM SUMMARY

METRICS OF SUCCESS

Our goal is to deliver the most cost effective solution to damaged mats and the most ethical answer to rubber waste.

The benefit of remanufacturing is more than just cost reduction on inventory replacement. Our customers also enjoy lower waste disposal fees and better looking mats. The net effect of remanufacturing can be quantified as a dollar amount in the budget surplus but the real value is found in customer retention through increased safety and quality.

We are proud to serve the laundry industry and we are here to help your business make the next step towards a sustainable future.

INTRODUCTION TO REMANUFACTURING