Our team at Malco Electric is proud to announce the successful completion of our major electrical contracting project for Align Precision in Horsham, PA. This massive undertaking involved the total transformation of an existing 80,000 square foot building shell into a high-tech manufacturing hub, clean room facility, and corporate office suite. Our team was responsible for the complete fit-out which was critical for a company that manufactures specialized parts for various departments of the United States Government. The scope of our work was vast and included the installation of all new power distribution systems, state of the art lighting with smart controls, and complex connections to over 200 individual pieces of equipment. throughout the entire process Malco Electric worked closely with the client to finalize equipment locations and accommodate various changes to the design as the project evolved.
Industrial Power Infrastructure at Align Precision in Horsham, PA
The heart of this new facility is the expansive machine shop floor. To support the heavy electrical load we installed nearly 1,000 feet of overhead bus duct. This system is a significant upgrade over traditional pipe and wire methods because it offers the client incredible flexibility. In a dynamic manufacturing environment production lines often need to be reconfigured. The bus duct allows the client to plug in machinery at any point along the rail without the need for extensive rewiring. This infrastructure powers the impressive array of equipment we connected, including the massive Makino DA300 and several Matsuura MX-520 5-axis CNC machining centers seen on the floor.
These machines require clean and stable power to maintain the micron-level tolerances needed for aerospace and defense components. We also managed the electrical integration for the automated cells, such as the Erowa Robot Easy 250, ensuring that the robotics and the machine tools operate in perfect synchronization. Our installation also supports the yellow Kundel overhead crane systems which are essential for moving heavy raw materials and finished parts across the pristine gray epoxy floors. The success of the industrial setup at Align Precision in Horsham, PA relies heavily on this robust and adaptable electrical backbone.
Precision Lighting and Specialized Environments
Beyond the raw power distribution we focused on creating an environment conducive to precision work. We installed a modern LED lighting package throughout the entire facility. In the machining and quality control areas we utilized high bay fixtures that provide bright and even illumination. This is critical for the technicians who must visually inspect intricate parts for defects. The lighting system is integrated with advanced controls that utilize occupancy sensors and daylight harvesting to reduce energy consumption when areas are not in use.
We also tackled the unique challenges of the clean room installation. This area required specialized power solutions for the Fan Filter Units (FFUs) that maintain air purity. We ensured that all electrical penetrations were sealed air-tight to prevent contamination. The quality control lab also required dedicated circuits for sensitive metrology equipment, ensuring that their measurements are never compromised by electrical noise or power fluctuations.
Delivering Excellence for Align Precision in Horsham, PA
The scope of our work extended beyond the factory floor into the office and employee welfare spaces. The new breakroom and kitchenette area highlights our ability to deliver high-end commercial finishes. As seen in the project photos we wired the facility for an “Avenue C” micro-market which features self-serve kiosks, commercial refrigeration, and coffee stations. The lighting in these areas shifts to a more architectural style with recessed linear fixtures and warm pendant lights over the seating islands. This creates a welcoming atmosphere for the 150 employees who work at the site.
We are honored to have been the electrical partner of choice for Align Precision in Horsham, PA. This facility is now fully energized and ready to support the critical needs of the aerospace and defense industries. By delivering a reliable and future-proof electrical system we have helped lay the foundation for their continued growth and success in the region. For inquiries about our industrial electrical services or to discuss your next project, please contact our team today or give us a call (856) 202-5503.
Photos of Our Work At Align Precision in Horsham, PA
