NEW BERN, North Carolina — In the heart of New Bern, N.C., in the United States, stands a facility that is much more than a factory — it’s a hub of innovation in the audio broadcasting industry. Wheatstone’s philosophy of self-sufficiency represents a significant departure from an industry trend of outsourcing component production. “We do it all,” proudly states Andy Calvanese, Wheatstone’s VP of technology and engineering. This simple mantra encapsulates the ethos of a company that has built its reputation on the pillars of innovation, quality and control.
Wheatstone’s roots are deeply embedded in a culture of crafting and creativity. The company’s origin traces back to the inventive spirit of its founder, Gary Snow, who began his journey making specialized upgrades to guitar amps during his teenage years. “We’ve always been the kind of guys who like to build things,” explains Calvanese. This ethos of building and creating led naturally into the world of audio consoles and equalizers before eventually moving into broadcast consoles.
Wheatstone has grown in size and capability from its modest beginnings to the current 4,830 square-meter (52,000 square-feet) sprawling facility. “By 1980, we set up shop in a converted barn and quickly outgrew that,” Calvanese recounts. By 1994, the demand for its bespoke products necessitated a move to its current location in North Carolina, where the company has continued to expand and innovate. Its first appearance at the NAB Show in 1984 with the A500 console was a milestone, showcasing its commitment to unmatched sound quality, which remains unwavering to this day.
In an era dominated by outsourcing, Wheatstone’s strategy of maintaining control over every production stage is rare and advantageous.
Full-spectrum manufacturing
The Wheatstone factory is a complete ecosystem of production, testing and innovation. The process begins with raw stock and ends with the final product leaving the factory floor, ready for global distribution. “Raw materials arrive in the back door and wind through the factory to be pressed, molded, wired and tested, retested and tested again,” details Calvanese. This extensive process under one roof allows for strict quality control and responsiveness to industry changes.
Manufacturing in-house extends from basic components to complex systems. “We do just about everything in the factory, from machining, fabrication and screening to printed circuit board surface-mount,” says Calvanese. This includes making its own power supplies — a critical component that, according to Calvanese, underscores Wheatstone’s commitment to the highest audio performance and component longevity.
The factory is not just a place of manufacturing, but a hub of continuous innovation. The Wheat Lab, a critical component of its operation, allows for staging, preconfiguration and testing of multistudio systems. “We run the entire multistudio system through its paces, including GPIO triggers and machine starts and stops, before sending it to its final destination as a complete, ready-to-go network,” Calvanese explains. He adds that this capability ensures the systems’ reliability and significantly reduces the set-up time and technical challenges at the customer’s site. “Entire multistudio WheatNet-IP audio networked systems arrive at their destinations plug-in ready, and even the final setup can be done online by factory technicians.”
Why in-house manufacturing is key
In an era dominated by outsourcing, Wheatstone’s strategy of maintaining control over every production stage is rare and advantageous. “Manufacturing everything in-house lets us respond quicker to changes and gives us much better control over a volatile supply chain,” notes Calvanese. This approach was particularly beneficial during the pandemic when many companies struggled with supply chain disruptions.
In-house manufacturing also allows for rapid development and customization, a capability that Calvanese is particularly proud of. “Something can be sketched on a napkin on Monday and actually be a new design built and running on Friday,” he says. This agility is a significant competitive advantage in a fast-evolving industry.
While in-house manufacturing is critical for control of production and distribution, keeping a supply of products and components on hand is critical for the company’s support services. So, the factory also features a stock room of almost 500 square meters of shelving from floor to ceiling packed with a comprehensive inventory of products currently in production and components to support those products for years to come, “So anyone needing to replace faders, on/off switches, etc. we have it already on hand,” says Calvanese. “Same with past products — we still have modules for consoles we made 15 or even 30 years ago.”
Future directions and investments
Looking to the future, Wheatstone says it’s committed to staying at the forefront of broadcasting technology. “We are investing heavily in research and development,” explains Calvanese. The focus is on embracing new technologies such as virtualization and hybrid models that combine hardware with software solutions. These innovations are critical as they adapt to changing media consumption habits and production technologies.
Wheatstone emphasizes that its commitment extends beyond manufacturing to include “robust” customer support and an extensive warranty policy.
“We are known for our strong warranty and support, in part because we keep a huge inventory of components for product support for years to come,” Calvanese states. This approach ensures that Wheatstone can offer support and maintenance for its products long after they leave the factory. To the Wheatstone team, the factory in New Bern is a beacon of U.S. manufacturing excellence, embodying a philosophy where quality, innovation and control intersect to create products that are not only industry-leading but also meticulously crafted under one roof. Calvanese says that as the broadcast industry evolves, Wheatstone remains poised to meet these changes head-on, driven by a philosophy that integrates deep technical expertise with a proactive approach to market demands.
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