Chryspac’s collaboration with GenEon Technologies is a story of innovation, problem-solving, and precision — particularly when it comes to the complex wire assembly behind GenEon’s Immerse-A-Clean Wand. What began as a challenging prototype has evolved into a streamlined, reliable manufacturing process that supports both product performance and company growth.

According to Syd Williams, Co-Founder and Vice President of Client Services and Marketing at GenEon Technologies, the partnership dates back more than a decade. “Our relationship with Chryspac started around 2013, 2014,” Williams explains. At the time, GenEon was developing a first-of-its-kind portable on-site generator system, but they needed the right partner to bring it to life. “One of the things that we were struggling with was, who are we gonna get to partner with to put it together?”

That challenge led them to Chryspac, and ultimately to a collaboration that would reshape their manufacturing process.

From Prototype to Production

Before Chryspac’s involvement, GenEon’s wire assembly was still in its earliest stages. “It was a non-working prototype,” Williams says. The complexity of the product made development especially difficult. The Immerse-A-Clean Wand operates using a brine solution and electrolysis cells to generate a powerful sanitizing and cleaning agent, but that environment creates a major technical hurdle: protecting sensitive wiring from corrosion.

“Brine and electronics don’t work well together […] corrosion is a major concern and can lead to performance and electrical issues,” Williams explains.

At the heart of the challenge was a critical connection point, where embedded wires inside a hose (referred to as an “umbilical cord”) meet the electrolysis cells. “The issue was, how do you connect the wires to the cells without corrosion occurring?” he says. “We tried a lot of different materials […] to create a solution to protect that wiring connection.”

Working alongside the design firm Brooks Stevens, Chryspac played a key role in helping solve the problem. Together, they developed a specialized epoxy binding and a custom mold to protect the wiring and ensure durability. “A big part of that […] is that connection from the wiring to the cell in that protective epoxy binding that protects the electronics and the cells,” Williams notes.

A Collaborative Approach to Problem-Solving

One of the defining aspects of the partnership has been Chryspac’s ability to collaborate across teams and disciplines. “Their ability to collaborate with not only the manufacturer, but also design firms […] to create a solution to unique problems […] that’s one of the big takeaways,” Williams says.

This collaborative mindset extended beyond initial development and into refining the manufacturing process itself. As production ramped up, Chryspac suggested and implemented improvements that made assembly more efficient and consistent.

“We were able to work with them to refine that manufacturing process,” Williams explains. “We were able to work with them to develop specialized tools that were needed to make the process easier and simpler and safer.”

These tools included custom cutting solutions and precision processes tailored to the product’s unique design. Just as importantly, Chryspac documented each step, ensuring transparency and consistency. “They were very proactive […] we weren’t surprised at any point in the process.”

Enabling Growth Through Reliability

As GenEon scaled, the reliability of Chryspac’s wire assembly and manufacturing became a major advantage. By taking ownership of the production process, Chryspac allowed GenEon to focus on innovation and growth.

“We don’t have to worry about the manufacturing process,” Williams says. “Once we place an order with them, we don’t have to worry about product quality.”

That confidence is backed by a strong track record. “We’ve never had to recall or have any major customer issues with the quality of the product or with the quality of the manufacturing,” he adds. Any rare issues that did arise were quickly addressed through joint problem-solving. “When something was identified […] we were able to stop everything, look at it together, come up with a solution […] and move forward.”

Meeting the Highest Standards

For GenEon, quality is more than a personal value — it’s a requirement. The Immerse-A-Clean Wand is an EPA-regulated product, meaning every component must meet strict standards and tolerances.

“There’s not a lot of room for variations,” Williams explains. “It has to meet specific tolerances.”

Chryspac’s ability to operate within these constraints has been a key part of the partnership’s success. Their expertise ensures that every wire assembly and component meets both regulatory requirements and customer expectations.

A Trusted Partner

Looking back, Williams is clear about the impact Chryspac has had on GenEon’s success. “Without a doubt, I’d recommend them,” he says. Beyond technical expertise, it’s the consistency, communication, and collaborative approach that make Chryspac stand out.

From solving complex wiring challenges to refining the manufacturing processes and supporting long-term growth, Chryspac has proven to be more than an assembly partner — they’ve become an essential part of GenEon’s innovation journey.