Building on a Manufacturing Legacy
Kerry Hayes has built a global manufacturing automation empire that spans seven countries across four continents. Born in Rotorua, New Zealand, in 1962, Hayes grew up in an environment shaped by industrial innovation. His father, Tom Hayes, founded Hayes International in 1960 and became one of New Zealand’s most recognized inventors, earning the Queen’s Honours and membership in the New Zealand Order of Merit for his contributions to business and invention.
The family business started in Tom’s garage and evolved into a global rollforming machinery manufacturer that exports 95% of its products to over 110 countries. This foundation provided Kerry with deep exposure to engineering excellence and international manufacturing markets from an early age.
“I come from a line of crazy inventors,” Hayes reflects. “When someone gives me a challenge, I’m up for it. That’s my biggest motivator.”
Professional Development and Early Career
After graduating from Rotorua Boys’ High School—which later inducted him into their Hall of Fame—Hayes joined the family business in 1980. He spent two decades progressing from completing his engineering apprenticeship to mastering marketing and operations, developing comprehensive expertise in roll forming technologies and global manufacturing markets.
The Hayes family business demonstrates remarkable customer loyalty, with more than 1,820 Hayes machines exported globally and 90% of business coming from repeat customers or direct referrals. This track record reflects the quality and innovation standards that shaped Hayes’ professional approach.
International Expansion and Technical Leadership
In 2000, Hayes launched his international consulting career, establishing himself as a technical expert in metal forming technologies. His most significant partnership began in 2003 with Tiger Profiles & Insulation LLC in the United Arab Emirates, where he served as Technical Advisor for 16 years.
During this period, Hayes designed and patented an automated forming and insertion process for Cam-locks in insulated panels for refrigeration applications. This innovation achieved nearly 100% market penetration in the Middle Eastern market due to its superior thermal efficiency in cold storage applications.
Strategic Business Ventures
Hayes has demonstrated a consistent ability to identify and capture emerging market opportunities through several key ventures:
Karista Consulting (2010): Specialized in sandwich panel composite manufacturing lines, establishing Hayes as an independent authority in advanced metal building technologies.
Insolare Group Ltd (2014-2023): Focused on renewable energy technology investments in the US market, demonstrating strategic positioning in sustainable innovation.
Karista Insulated Building Solutions (2019): Returned focus to New Zealand operations with specialization in poultry manufacturing sciences, applying decades of international experience to agricultural technologies.
Breakthrough Automation Technology
Hayes’ most significant achievement is Tractive Motion Technologies, founded in 2016 and launched in 2021. Initially based in Australia, this venture developed the world’s first fully automated, unmanned roller door production line—a breakthrough that has redefined manufacturing efficiency standards.
The technology represents a fundamental shift in production capabilities. Traditional roller door manufacturing requires 80-150 minutes per unit with significant manual intervention. Hayes’ automated system reduces this to just 4 minutes per unit with zero manual involvement.
The Tractive fully automated, unmanned roller door manufacturing line
The Tractive Innovation
In partnership with Bunka, one of Japan’s largest door manufacturers, Hayes created technology that delivers:
- Production time reduction from 80-150 minutes to 4 minutes
- Coil changeover capability in under 20 seconds
- Custom order interruption and completion within 1.5 minutes
- Complete quality control and traceability systems
This innovation earned a Japanese robotics innovation award, positioning Tractive to transform the global door manufacturing market. Hayes predicts that unmanned production will become the industry standard within five to ten years.
Steel coil changeover process. The Coilswift system automates changing coils in 20 seconds.
Current Global Operations
Hayes maintains executive leadership roles across multiple continents:
Switzerland: Board member of Tractive Group AG (2025), a financial investment and holding company expanding European market presence.
Austria: Executive Director of K.H. Technic GmbH (2023), specializing in robotics and automation for metal forming technologies, with strategic technical partnerships.
Global Network: Active business relationships spanning New Zealand, Australia, Austria, Switzerland, UAE, Japan, and the United States.
The world’s first Postage stamp style of protective film covering and insertion on the fly in an automated rollforming process.
Strategic Partnerships and Market Position
Tractive’s representation of the purlin line of century-old Rafter Equipment Ltd of Ohio in US markets combines established American manufacturing heritage with Hayes’ automation expertise, bringing new standards for efficiency, flexibility, and reliability to the North American market.
Innovation Philosophy and Market Impact
Hayes’ approach to innovation combines technical excellence with strategic market positioning. His multiple patents in automated manufacturing and robotics establish him as a thought leader in industrial automation. His business philosophy centers on:
- Long-term strategic relationships built on proven results
- Technological innovation that provides measurable competitive advantages
- Market transformation through superior efficiency and quality
- Global adaptability across diverse regulatory and cultural environments
Industry Leadership and Future Vision
Hayes operates across multiple time zones and regulatory environments, demonstrating exceptional adaptability and strategic thinking. His global network includes partnerships with industry leaders such as Bunka in Japan, reflecting the international scope of the roll forming and automation industries.
His innovations extend beyond door manufacturing. Hayes has transformed steel-fabricated Linear Fresnel Reflectors into mass-produced pressed metal assemblies and revolutionized broiler shed operations in the global poultry business, consistently delivering innovative solutions to complex industry challenges.
Manufacturing Evolution and Legacy
Kerry Hayes represents the successful evolution of New Zealand manufacturing expertise into global technological leadership. His progression from a marketing role in his father’s company to executive leadership of cutting-edge automation ventures demonstrates both personal achievement and broader industry evolution.
The Hayes family legacy continues through Kerry’s innovations in automation and robotics, maintaining New Zealand’s reputation for engineering excellence while meeting the technological demands of modern global manufacturing. His current portfolio of companies and international partnerships positions him at the forefront of manufacturing automation, with technologies that are reshaping entire industries worldwide.
Hayes envisions a future where automation and technical excellence drive manufacturing success. His work in unmanned production systems, automated coil handling, and rapid changeover technologies sets new benchmarks for industrial manufacturing capabilities. In an era where efficiency, customization, and sustainability define competitive advantage, Kerry Hayes stands as a leader whose innovations are defining the future of manufacturing.
