Every fabrication shop owner knows that choosing the right industrial sewing machine can make or break your success in the exacting, often fast-paced world of marine fabrication. In addition to boosting your bottom line, it also might protect your sanity.

“Buying the right machines increased the confidence I had in the projects I accepted,” says Annie Mahle, owner of Georges River Canvas in Rockland, Maine. “Before, it felt like every week there was something else going on with my machines. There was this constant adjusting and waiting for a mechanic to come. Once I had two new machines, I felt more confident about new projects and the timelines I was able to commit to.”

To shed light on what kinds of machines have worked well for fabricators—and how best to use them—we talked shop with Mahle; machine vendor Frank Henderson, CEO of Henderson Sewing Machine Co. Inc., in Andalusia, Ala.; machine vendor Pedro Cecena of JUKI America Inc., headquartered in Hialeah, Fla; and fabricator James Foster, owner of Heber Springs Marine Upholstery Inc., in Heber Springs, Ark.

What should fabricators consider when choosinga machine?

Henderson: It’s very much based on what product you’re going to sew. [Marine fabricators] are most likely going to sew vinyl-coated goods, Sunbrella^®, canvas products or other heavier-weight goods, and those usually utilize a one-needle walking foot lockstitch industrial machine. If they want a flat bed, it’s generally a one-needle or two-needle. Depending on how heavy the goods are, they’ll want a vertical hook that’s standard, extra or XXL, and those decisions are driven by the thread size and the amount of thread that’s going to wind in the bobbin. Other factors are foot lift height and needle height, especially if they’ll be folding a lot of thick fabrics. Budget also drives decisions; you may want more expensive features if you’re tech savvy or you’re a high-output manufacturer.

Cecena:Determining the weight of your product will help you determine if you need a drop-feed machine, a needle-feed machine or unison-feed machine. Then each category has its own subdivision. Reliability is also key, which goes in-hand with learning how to do proper maintenance. Working space is also an important factor, as some items are oversized [and] limited space can be a burden.

What are common mistakes people make when buying a machine?

Henderson: Often, people put too much faith in just buying the most inexpensive product, even if it may not be the best fit. And a machine should last 20 to 30 years, so you’re going to buy a lot of needles, bobbins, bobbin cases, etc., and you need to consider where you’ll get those parts and what they’ll cost. The value of those parts will pay for the machine four to five times over the life of the machine if you buy certain brands.

Foster: Failing to do regular maintenance and choosing the wrong type of machine for the job, with one-size-fits-all thinking.

Cecena: It’s not uncommon to see companies base their purchasing decision entirely on price, just to later find out they’re unable to ramp-up production because their machines are unable to meet their productivity expectations. Another mistake would be purchasing online, then [receiving an unassembled machine] or one not able to do the job.

Which brands do you use or recommend, and why?

Henderson: We sell 60 different brands. JUKI is the largest in the world and it’s a very good one, but so are Dürkopp, Highlead, Consew and Jack.

Foster: We use Consew machines. Growing up in the industry, I have seen their reliability. My favorite features would be their reliability, ease of maintenance and ease of obtaining parts. We have one set up for seating and one for canvas, plus an NC carpet binding machine for putting edging on carpet mats.

Mahle: I have two JUKI 1508s, one JUKI DU-141H-7, an older Pfaff and another Pfaff. I like their precision from a mechanical perspective. It’s possible for them to do just one stitch at a time, and when coming to a corner, you can adjust stitch length as you’re going around. Overall, I just need workhorse machines that are dependable and are going to show up every single day. I’m not into anything that requires much of a computer chip; to me, that just sounds like something that’s going to go wrong.

How should fabricators think about ROI (return on investment)?

Cecena: You don’t want your machine to be idle for extended periods in-between production. Examine the sewing process closely. What does it require? Does the operation require the dexterity of an operator for maneuvering, turning and accommodating the material as it’s sewn? Then you might consider a machine with automatic features like thread trimmers, foot lifter and automatic backtack. Or is the process repetitive and time-consuming, such as an “X-box tack”? Then a CNC machine might be a better option, as it can sew independently, freeing the operator to prepare the next piece. The less time your machine is idle while you lift the foot, cut the thread or turn the fabric, the quicker the machine will pay for itself.

What are some of the best machines for beginners?

Henderson: Standard, basic walking foot machines. An upgrade would be buying something more expensive with greater speed, larger hooks, higher quality and additional features.

Cecena: “Plain” sewing machines. Plain doesn’t carry a negative connotation, but they keep it simple, making them an excellent starting point. Generally, as long as you keep them lubricated, balance your thread tension, use the correct needle and thread sizes, and thread them properly, they’ll perform consistently well.

When should a fabricator consider upgrading a machine?

Cecena: As you gain more experience, you’re likely to demand more from your machine. That’s when many start considering additional features such as higher speed, safety clutch to prevent damages from thread jams, and automatic functions to enhance productivity.

Mahle: As the scope of our projects required more precision, we started replacing our least-useful machines first. One just kind of died; after 17 or 18 years, the pieces were just worn out and we couldn’t get parts any longer.

Any tips for learning to use a new machine?

Henderson: We offer training if you want to come to our place and set up your machine, and we do seminars three to four times a year on the basics of industrial sewing machines. Obviously, online there are tons of tutorials.

Cecena: We cannot emphasize this enough: Read the manual! It contains essential information that’s often overlooked. Beyond that, seek advice from your distributor and manufacturer. We’re always happy to provide guidance. Our no-cost app ShuHaRi offers a simple checklist of steps to take before and after sewing, and we offer a training program for basic knowledge of sewing.

How much do industrial sewing machines cost?

Henderson: A Chinese brand might be a few hundred dollars, while a high-speed, higher-quality machine with good features might be $1,000 to $2,000.

Cecena: An entry-level top-and-bottom or unison-feed machine typically ranges from $1,000 to $2,500. In contrast, a fully equipped unison-feed machine with all the advanced options might range between $4,500 and $7,000.

What are the major machine improvements over the last decade?

Henderson:  Machines are probably more reliable, with more modern manufacturing techniques, better lubrication systems, servo motors and more features. The majority of late-model equipment is far more flexible when changing and adjusting for different thread types, needle sizes etc. Some later-model machines have more distance or working space underneath the arm and are higher off the bed of the machine so you can put higher plies of different goods underneath. Some enhanced machines today actually learn as time goes along. Some have electronic servo motors and are energy-saving.

Cecena: Digitalization allows for difficult adjustments to be done simply by touching a panel; it saves key settings to be recalled later and to copy to other machines. It also de-skills the operation by automatically applying setting changes when the thickness of the material changes. Those machines also represent savings, as you don’t need compressed air to make them work. 

Michelle Miron is a freelance writer based in Hugo, Minn.

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SIDEBAR: Fixing machine malfunctions

It’s up to us as business owners to understand and learn as much as we can about the intricacies of each machine, then we can teach our teams. You may not learn overnight, but you could start by watching YouTube videos and reading everything the manufacturer sends connected to your machines.

“When a team member hits a snag with a machine, I sit down and use a problem-solving ‘investigative tree’ to check that everything’s on, everything’s in the place it needs to be, it’s threaded properly, the correct needle and thread are used, nothing’s snagging or fouling up the wheel and the tension is right. If those are all fine, I ask what was happening right before the machine didn’t work. Ninety-five percent of the time, I can fix it myself.”

Annie Mahle, Georges River Canvas