Demand Leads to New Electric Offering and Plant Expansion

Mack Trucks has demonstrated a strong commitment to the medium-duty market since the Mack® MD Series launch in 2020, offering the company’s legendary durability and reliability paired with unparalleled comfort in Class 6 and 7 options.

Produced at a manufacturing facility in Virginia focused on delivering on Mack’s promise of delivering dependability, exceptional driver comfort and superior performance, Roanoke Valley Operations (RVO) is now home to the MD Series and Mack MD Electric, launched in March 2023.

Launching operations during the pandemic posed challenges for the RVO team; however management and the workforce were able to overcome those obstacles and achieve a high degree of success with customers, who welcomed the trucks with an enthusiastic reception, says Antonio Servidoni, VP of Roanoke Valley Operations at Mack Trucks.

PRODUCTIVITY BUILT IN

Mack’s decision to offer a medium-duty truck based on heavy-duty expectations led to the approach of configuring RVO to deliver precisely what their customers needed. According to Servidoni, when the MD Series came on the market, buyers were able to find Class 6 and 7 trucks built with the same durability, reliability and comfort of Mack's Class 8 vehicles. The MD Series appeals to a broad range of truck applications and buyers, and the MD6 doesn't require a commercial drivers license for non-hazardous loads.

Once the Mack MD Electric was introduced in 2023, customers had another medium-duty option to choose – this one with zero tailpipe emissions to align with both Mack’s and the company’s customers’ long-term goals. Boasting the same heavy-duty quality as the diesel-powered MD Series, the MD Electric is available in 4x2 configurations featuring a sharp wheel cut, and an industry-best short bumper-to-back-of-cab measurement of 103 inches. The MD Electric is already being delivered to customers across the country.

“We’re excited that the Mack MD Electric is in full production and that customers are beginning to take delivery of it,” says Jonathan Randall, president of Mack Trucks North America. “We built on the success of the diesel-powered Mack MD Series to bring an electric vehicle to the medium-duty market to help customers meet their sustainability goals with the same Mack promise of durability and reliability.”

MEETING MACK CUSTOMERS NEEDS

Every aspect of the RVO experience is geared towards meeting and exceeding customer expectations. Each vehicle goes through rigorous quality control every step of the way, under the watchful eye of trained, certified auditors.

“Every single truck goes through an audit process before they go to the customer,” Servidoni says. “Every torque is controlled through Wi-Fi validation and inspected through a rigorous in-house production inspection system so that the force applied to every joint, bolt or nut meets standards.”

Before leaving RVO, everything in the truck is validated according to the original specs. When the Mack is ready to roll, it’s put into a sophisticated outbound system to make sure it gets to the customer who ordered it.

“We safeguard quality control of everything,” says Servidoni.

MORE MACKS

The addition of a new truck meant increased demand, which meant a need for increased space. This April, the ground will break on a 72,000-square-foot addition expected to be completed in Q4 of 2025.

In addition to adding square footage, Mack's investment will go toward equipment and tooling. When the project is complete, the facility, which was previously used for other purposes, will be 352,000 square feet.

"We transformed the building,” Servidoni says. “It was quite a good fit for this segment, the height was great, and we were able to give our team a perfect environment in which to work."

The increased capacity is necessary to meet increased demand for the MD and MD Electric. The current plant employs 420 workers in two shifts, which should grow to around 500 once the expansion is complete.

"We need to evolve as a plant," Servidoni says.

Like most models, MDs evolve based on customer needs andexpectations. Servidoni says research and resources have been poured into creating the best driver comfort along with a robust safety package.

With an overwhelmingly positive response to the MD Series and MD Electric, the RVO team is positioned to use the upcoming expansion to further meet the evolving needs of Mack customers.