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Marotta Controls Expands Montville, New Jersey, Design and Testing Complex

Marotta Controls, an aerospace and defense supplier, is expanding and upgrading its state-of-the-art design and test engineering facility in Montville, New Jersey.

According to company officials, the project includes upgrading existing equipment as well as adding new, state-of-the-art equipment to support greater volume and more complex testing procedures. Once completed, the company said it will house one of the U.S.’ most sophisticated testing facilities for a wide range of aerospace, defense, and marine systems across 125,000 square feet.

“Several internal and external factors drove the expansion. For example, we choose to keep up with increasingly more sophisticated customer designs,” said Larry Rayhon, Senior Director, Production Engineering, Marotta. “Interestingly, we’re also experiencing rapid growth in complementary application areas. Our business was anchored in flow control products: solenoid valves, pressure regulators, manifolds, etc. In recent years, we introduced control actuation systems and power electronics, which require more precise, complex and often automated testing processes. This facility upgrade enables us to support that growth, too.”

Marotta officials noted the 77-year-old-company primarily operates in the defense market, a sector that prioritizes more stringent performance qualification standards than those found in commercial or industrial markets. Many of the company’s custom control solutions include unique technological designs that exceed most standard testing houses’ capabilities. Related, third-party testing can become costly and impact program schedules due to shipping lead times, storage fees, advanced engineering support, and remote troubleshooting. For these reasons, Marotta prioritizes in-house testing services investment.

As part of the expansion, its assembly bench capacity will increase by one-third, totaling 40 benches. Eleven benches will simulate 15,000 psi of pressure with the remaining 33 simulating 6,000 psi. All will offer a flow rate of 150 scfm. Grouped testing can be conducted to achieve gas throughput up to 25,000 psi.

Poised to be the most advanced on the East Coast, company officials noted a 1,600 ft2 acoustic testing facility was constructed for airborne and structure-borne noise testing.

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