Marshalltown Hammer, previously Vaughan, in Bushnell, has invested more than $5 million recently to modernize and improve its manufacturing plant, according to President and CEO Joe Carter.
The upgrades include a $300,000 automatic powder coating booth, extensive equipment repairs and purchases, and major facility improvements aimed at boosting productivity and employee comfort. Carter said the company has reduced its footprint from 14 buildings down to five, streamlining operations and improving organization.
One major project was a $500,000 roof replacement on the main 60,000-squarefoot plant, ending persistent leaks that had plagued the facility for years.
“On rainy days or during bad snowstorms, we’re no longer getting water inside,” Carter said. “That might not sound exciting, but after years of putting out five wastebaskets in the front office every time it rained, it’s a huge improvement.”
The company also remodeled all bathrooms in the main plant, including adding a women’s restroom for the first time. Previously, female employees had to cross the street to use facilities. Restrooms in the shipping and packing buildings were also upgraded, eliminating unsafe concrete stairs and installing new fixtures.
“Again, these may seem like small things, but when basic standards aren’t met, they make a big difference in employees’ daily lives,” Carter said.
Marshalltown employs just over 100 people in Bushnell. Since Carter took over, the company has caught up with customer demand and is poised for growth. He said the company aims to regain business lost during previous shipping struggles, including accounts with major retailers like Lowe’s.
In July of last year, Gov. JB Pritzker visited the Marshalltown Hammer plant to announce $5 million in state funding to preserve manufacturing jobs in Bushnell.
“Marshalltown Hammer sincerely thanks Governor Pritzker and the State of Illinois
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for their courage to step forward and keep the legacy of Vaughan alive,” Carter said at the time. “Without that help, Marshalltown Hammer could not and would not have taken on this major challenge to save these jobs and breathe life back into this 155-year-old company. This is not only good for the people of Illinois, but the people in the USA.”
If not for the persistence of Kim Pierce, CEO and President of the Macomb Area Economic Development Corp. (MAEDCO), the state’s $5 million grant award might never have materialized. Pierce facilitated the funding through her relationships with the Department of Commerce and Economic Opportunities (DCEO) and the Governor’s office. She also worked closely with the City of Bushnell’s Mayor and Utility Board to secure utility incentives for Marshalltown.
In addition to the Bushnell improvements, Marshalltown Company recently acquired RACATAC, a Louisiana-based company with a patented tiling product the company has sold for 20 years. The acquisition adds a new product line and strengthens the company’s market position.
Carter said the upgrades and acquisitions position Marshalltown for continued growth in the coming years.
“We’re pretty excited about what we’ve done and hopeful to see more business come in,” he said.
History of Vaughan and Marshalltown In 1890, Jesse and Lester Williams opened a modest machine shop on East Church Street in Bushnell, initially repairing bicycles and automobiles and fulfilling occasional tool orders for local contractors. Their breakthrough came when a local plasterer asked them to customize tools for his work. Pleased with the improved design, the plasterer’s requests multiplied, prompt- ing the brothers to produce and market more trowels. Word spread quickly beyond state lines, transforming their small shop into a thriving manufacturing and mail-order business.
Meanwhile, a separate but equally storied legacy began in 1869 when 18-year-old blacksmith Alexander Vaughan founded a plumbing business in Chicago. Vaughan soon established a blacksmith shop behind a hardware store owned by Sidney Bushnell. That same year, Vaughan patented an improved post auger and began crafting custom tools. In 1922, the Vaughan family bought out the Bushnell family's stake, and by 1940, they opened a factory in Bushnell, Illinois. The company moved its headquarters to Hebron, Illinois, in 1963 and became the first striking tool manufacturer to earn ISO 9002 certification in 1993.
Over the next century, both businesses expanded significantly. Vaughan & Bushnell became renowned worldwide for its American-made hand tools, including hammers and pry bars. In 2018, Vaughan acquired DASCO PRO, a leader in chisels and punches.
Facing financial challenges, Vaughan & Bushnell announced plans to close in 2024. However, in May of that year, Marshalltown Hammer, a division of the Marshalltown Company, purchased all of Vaughan’s assets, preserving the legacy of these iconic American toolmakers.
