How a Tow Truck is Born

Miller Industries, Inc. is the nation’s largest manufacturer of tow trucks and towing equipment. This month, some of us from Airport Towing had the opportunity to tour the factory 2,600 miles away from our Seattle area office in Ooltewah, Tennessee. The Miller facility is just outside the city of Chattanooga, where the first tow truck was invented in 1916 by Ernest Holmes. Today, Holmes is a division of Miller Industries. Miller also produces Century, Vulcan, Chevron, Challenger, Champion, Eagle, SP Series, Boniface, and Jige towing and recovery units.

Inside the Tennessee plant, tow trucks emerge from pieces of raw metal right before our eyes. Millers’ 100,000 square foot warehouse is their primary manufacturing facility where thousands of tow trucks are manufactured each year. Our personal factory tour led us through the plant to follow the production of units from initial parts order to final completion. Employees we encountered during the tour were informative and helpful, teaching us the true meaning of “southern hospitality”.

We began at the first step in the process of building a tow truck, where the appropriate sizes and amounts of raw steel are acquired and stocked. When a tow unit is ordered, Miller employees round up all the necessary materials from their stock within the warehouse to build the sub-frame and transfer the parts to a welding station within the facility. Nearly all of the steel acquired by Miller is American made and forged locally. After the necessary materials are assembled, a skilled welder begins joining the metal to create the structural support of the tow unit. Miller boasts that their low turnover of skilled workers has been a key ingredient in yielding a high quality man-made product for several years.

Once unit is structurally sound, the functional parts are attached. Following the final welding process, the conjoined pieces are bead blasted. Bead blasting is necessary because the welding process can leave rough edges and small debris. The process of bead blasting is defined as removing surface deposits by applying fine glass beads at a low pressure without damaging the surface. Workers move parts requiring blasting into a large enclosed chamber, and seal the doors so they can unleash thousands of tiny reusable beads to blast the fabricated unit.

When all welding and fabrication is complete for a single unit, the unassembled parts go into the painting process.

Miller has the capability of painting tow truck parts on site. Applying primer and paint before the unit is assembled is essential to eliminate duplication of effort and is important for a high quality paint job.

The last step in building a tow truck is final assembly. Anyone purchasing a wrecker body from Miller has the option of ordering the complete tow unit and installing it themselves, or ordering a factory install. The factory has a team of people who are dedicated wrecker body installers and are only required to mount the tow unit to the chassis. Of course, one catch is that anyone who orders a factory install is required to send the truck’s cab and chassis to Miller so that it can be married to the tow unit. Most tow truck operators have unique requirements for their trucks and require specific options and accessories. The installers are responsible for all aspects of the install, including mounting the wrecker body, connecting all wiring and hydraulics, and attaching additional parts and accessories, such as dollies, chains, cables, etc.

Many units that Miller produces are built from the ground up inside their Chattanooga factory. In some ways, Miller Industries operates like a classic American factory. The company primarily uses skilled craftsman to produce tow units. Few robotics can be found inside the factory, which are greatly outnumbered by human hands. As a result, Miller employs about 2200 workers, 300 of which are manufacturing tow trucks at their primary facility in Chattanooga. As advertised, Miller Industries is the largest manufacturer of towing and recovery equipment in the world. The company is an impressive consolidation of the greatest names in the towing industry, now working together to produce the most technologically advanced towing equipment available. Miller’s efforts in innovation, quality craftsmanship, and American made products are why we at Airport Towing have been loyal customers since 1988. Our company continues to seek the best products available so that we can better serve our customers and this month we were happy to learn how our equipment is built and what type of care and attention it gets before we put our name on it.