The longtime supplier of needles and machine parts has rolled out a line of SttchEX sewing-related machines.
Leveraging its well-established history as a supplier of sewing needles and other machine parts and benefitting from the deep knowledge of one of the sleep products industry’s leading machine designers, New England Needles has entered a new business segment that is proving to be a significant area of growth.
At this year’s ISPA EXPO in March, New England Needles unveiled a half dozen proprietary sewing-related machines it is designing, building and marketing as SttchEX. The line includes the patented NEN-4127 flanger, a variable flange machine that can sew thick and thin materials on the same platform. Operators can change modes on demand with the push of a button, and an accelerated feed motion reduces needle deflection.
“The reception to this new flagship flanger and the other new machines we introduced at ISPA EXPO was fantastic,” says Aaron August, president of the Burlington, Connecticut-based company. “The NEN-4127 is basically two machines in one, so it offers customers a more efficient way to flange bedding panels with a clear cost savings, both upfront — when they buy the machine — as well as down the road, in terms of parts and maintenance.”
New England Needles has been developing the SttchEX line for several years in conjunction with Steve Marcangelo. A longtime R&D manager for Porter International and Leggett & Platt Inc., Marcangelo launched his own sewing machine service firm in 2021.
“I decided to focus on the I-95 corridor between Florida and New England, servicing machines, selling parts and offering training seminars,” Marcangelo says. “My travels led to a conversation with Tom Lees (the late founder and CEO of New England Needles), who asked if I would like to design a new flanging machine for him. That’s how this whole initiative began to come together.”
Building on Success: From Kits to Complete Machines
New England Needles’ initial forays into machine design involved developing add-on kits to enhance the functionality of existing machines.
“We didn’t want to just introduce a completely new machine without first testing all the ideas that we had for improvement,” Marcangelo says. “So, we took a lot of small steps relating to feeding, cutting and sewing and then embedded those new features into kits that could be added to machines already in the plants. With all our R&D, our top priority is finding ways to deliver the best machine possible.”
Taking this approach enabled customers to see the benefits of the new features New England Needles was bringing to the market without having to make a major investment in an entirely new machine. It also gave the company valuable input into how its ideas would work in real-world plant environments.
to an NEN-4127 flanging machine.
“When we could see the results and worked out any kinks, that’s when we made the decision to roll out a program of new machines and kits at ISPA EXPO,” August says.
New England Needles quickly began taking orders for SttchEX machines during the trade show, in part, because a number of customers who had been using the company’s performance kits were ready to replace their old machines. To help customers determine which approach — an add-on kit or a new machine — is best for them, New England Needles will conduct a site visit so that it can review operations and make recommendations.
At ISPA EXPO, New England Needles also introduced its patented NEN-5127 bucket binder. A high/low, walking foot binder, the machine has two modes: an HD mode for closing seams and crossing tape lines, and an LT mode for normal operation, with or without tape. Operators can easily switch between the modes with the push of a button.
“In addition to enhanced performance, our bucket binder features a simplified spring system that makes it easy to maintain,” Marcangelo says. In addition, a special chamber seal prevents debris from entering the lubrication system, so oil needs to be changed only once per year.
With all its industrial sewing machines, New England Needles’ goal is to deliver maximum durability and efficiency at an affordable price. “Our research-based approach results in fewer component failures, smoother operations and increased productivity,” August says.
Building on its reputation for “lightning-fast delivery” of parts and supplies, the company strives to become the “preferred supplier for all the sewing machines, parts and equipment that bedding producers might need, exactly when they need them,” August says.
Comprehensive Sewing Solutions: Parts, Machines, and More
Thomas Lees started New England Needles in 1977 after working for 20 years at the Torrington Co., a manufacturer of sewing, knitting, weaving and scalping needles for a variety of industries, including footwear and textiles. When Torrington went out of business, Lees became a distributor for other leading needle brands.
As shoe manufacturing began to move offshore in the 1980s, Lees identified the sleep industry as an area of opportunity. Over time, his bedding business grew and evolved to become a full-service provider of machines, performance kits, needles, and other parts and supplies for the sleep products industry. Today, bedding accounts for the bulk of New England Needles’ business, although the company still provides sewing needles, parts and machines to a range of other industries, including alterations, drapery, laundry, boating and upholstery.
To service its customers, New England Needles offers a comprehensive line of Atlanta Attachment, Galkin, Gribetz, Juki, Pegasus, Pfaff, Porter, Singer, Union Special and Yamato parts. In addition, it stocks sewing machines from leading manufacturers, including Juki, Pegasus, Reliable, Singer and Yamato.
“We offer the best-quality parts, machinery and dedicated service possible,” August says. “We have most parts in stock, so back orders occur infrequently. Each call from our customers is answered immediately and every effort is made to guarantee that orders are delivered in a timely fashion.”
The Next Chapter: A New Era of Innovation
August, who is Lees’ grandson, joined New England Needles full time after graduating from Central Connecticut State University in 2016. But he has been working regularly at the company since high school, delivering orders to nearby customers and helping in the warehouse.
Lees died in June at the age of 88, and August is now sole owner of the company.
“I grew up around the business, so I have a good understanding of my grandfather’s values and sense of mission,” August says. “He was a special, one-of-a-kind guy. He was always positive and upbeat and open to new ideas. He wanted everyone he worked with to be successful, from the members of our team to all our customers.”
Lees stayed active in the management of the company until 2022, when his health began to deteriorate. “He would be very proud to see the launch of these new SttchEX machines,” August says. “He always was working on better ways to serve customers, and this program is a good example of that.”
In the early years, New England Needles bought lunch for its employees every day. Today, although the company is a bit larger, with a total staff of 15, it continues that tradition, buying lunch for the entire staff on Tuesdays and Thursdays.
“We’re a very close-knit group,” August says. “Our employees are the most valuable asset we have.”
Like his grandfather, August encourages his team to take ownership of their work, says Tony Giordano, vice president. “We always have lots of projects, as well as different ways to get involved. Information sharing is key, and everyone here does a great job of transferring knowledge so that we understand exactly what needs to be done and then do it correctly.”
Building for the Future: Our Commitment to Growth
To support its new machinery line, New England Needles has broken ground on an expansion of its 30,000-square-foot facility at its Connecticut headquarters. When finished in 2025, the building will have 50,000 square feet of space for offices, warehousing and machine assembly. As capacity grows, so will the size of the company’s team, August says. The company hopes to attract fresh, young talent into the sleep industry to support its long-term commitment to growth.
“We’ve added some talented technicians here recently to support the launch of SttchEX,” Marcangelo says. “And we expect to do more hiring going forward.”
The response to the new line has been a “home run,” August says. “We’re focusing all our energies on making sure we can supply the machines quickly and that we can provide the level of service our customers expect from us.”
of the company’s new SttchEX machine line.
Providing top-notch service has always been a cornerstone of New England Needles’ business, and service is even more important in today’s just-in-time production environment, August says.
“It used to be that manufacturers would shop around with all their suppliers to see who had the best price before placing an order,” he says. “Things don’t really work that way anymore. Now, whoever has the part in stock and can get it there the next day is the one who gets the order.”
August says that when his grandfather started New England Needles, it wasn’t unusual for him to load up his car with boxes of needles and drive to his customers if a factory had an emergency and needed to replenish its supplies. “He’d drive there that same day if a factory was down,” August says.
That same philosophy continues today. “We don’t literally hop in our cars anymore but we make sure to get orders out the next day so our customers can keep operations running,” he says.
New England Needles also maintains a close relationship with its machine customers, supporting their service needs with training and on-site repairs, as needed. “You can’t just sell something and walk away from it,” Marcangelo says. The opportunity to deliver quality machines and service was a key driver in New England Needles’ decision to develop its own line, he adds.
A Future-Focused Approach: Staying Ahead of the Competition
To manage its inventory of roughly 100,000 different items, the company relies heavily on an enterprise resource system and other tech tools. The combination of software and highly knowledgeable staff enables the company to keep a close eye on ordering patterns so that needles, loopers, knives and other key parts remain in stock.
As 2024 winds down, August feels confident that the company will close the year with a 30% increase in revenues compared with 2023, thanks to the successful launch of its
SttchEX machine line. As for 2025, he is optimistic that New England Needles will stay on its strong growth trajectory.
“It’s too early to make predictions,” he says. “But we’re very excited about the prospects for SttchEX. We’re already working on new machines that can bring additional benefits to our customers.”
