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Entries for May 2016

25

(Janesville, WI) Elliot Hughes, Gazette

Less than five minutes after the Joint Review Board assembled Thursday, Janesville's newest tax increment financing district was created.

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21

(Milton, WI) Excerpts Courtesy of the Gazette

After receiving city approval, business owners hope their new brewpub will be operating in Milton's Goodrich Square by next spring.

The brewpub will be called Milton Brewing Company and located at 302/304 S. Janesville St., next door to Northleaf Winery.

Winery owners John and Gail Nordlof own the property and will lease it to brewpub owners Wayne and Betsy Lubke. The winery and brewpub will be separate but complementary businesses, Wayne Lubke said.

“We think that the customer base, the dynamics and the type of customers that come to the winery are similar to those types of customers that like to explore craft beer and brewpubs. We think the demographics are very similar,” he said.

A restaurant also is planned. Renovations at the property will add hundreds of square feet to accommodate a kitchen and brewing area, Lubke said.

The city council on Tuesday approved the brewpub under a few conditions, including that all venting must be toward the winery to the north and that no exits or windows will be built or added on the south side.

“Brewpubs and wineries are very popular in Wisconsin, so we are excited to have this kind of unique opportunity come to Milton,” Hulick said.

“It'll be another of the many reasons to find and come into Milton and spend time in Milton.” Lubke said. “We're very excited.”


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17

(Janesville, WI) Neil Johnson, Gazette

There is no river of chocolate flowing through Impact Confection's candy factory on Janesville's north side.

And no army of small men perform choreographed songs to warn against the dangers of gluttony, greed, television and consuming too much chewing gum.

But inside the walls of Impact Confections are conveyors that carry thousands of brightly-colored, sour candy gummy worms. The worms shimmy and shake their way through hundreds of yards of machinery staffed by dozens of workers in white lab coats.

And that's just one of more than a dozen types of candies Impact makes at a production facility that's like no other in Janesville.

Impact houses its production floor—and since late last year, its corporate headquarters—in a 180,000 square-foot facility it's operated at 4017 Whitney Way since 2011. 

During a recent tour, plant Manager Barb Estervig told The Gazette that Impact is seeing a boom in demand for candies it produces and plans to meet it head-on.

Estervig said Impact Confections candy making production is due for an expansion in equipment and candy handling rooms later this year or early in 2017.

That will gear up the company to nearly double candy production in Janesville.

Impact was formed in a 1981 in a residential kitchen in Roswell, New Mexico, initially as a specialty lollipop maker. The company grew from there to become a major candy producer.

Impact's biggest move came in 2004 with its purchase of Warheads candy, a brand that produces several lines of tart and extremely sour candies made in flavor intensities that range in sourness from tart to so-sour-you'll-break-into-a-cold-sweat.

In 2004, Impact also bought Melster, a candy producer that had operated in nearby Cambridge since 1919.

The two companies relocated production to Janesville in 2011, and production here has grown year over year to meet rising demand in major consumer markets in the U.S., Canada and Australia, Estervig said.

At the end of 2014, Impact moved its corporate headquarters from Colorado to Janesville, where it renovated the business offices and decked out meeting rooms, hallways and even stairwells in Technicolor hues reminiscent of the classic Hasbro board game Candy Land.

The offices look out over Impact's growing production, handling and packaging floor.

In Janesville, Impact now employs about 100 full-time, permanent workers and up to 250 seasonal workers. Estervig said the company will be looking to ramp up hiring, although she said she couldn't say whether the bulk would come through full-time hires or seasonal work.

“It's exciting. We've grown like a weed since 2011. We've got the space here in Janesville to eventually produce twice what we do, and we're going to start moving that direction soon,” Estervig said.

The company plans to buy a second mogul, a piece of candy making equipment the size of a large truck trailer that injects hand-mixed ingredients into trays full of corn starch that can be stamped into forms to create any shape of candy the company designs.

The mogul machine is used to make dozens of types of candies that Impact produces in its on-site kitchens, including sour gummy worms.

A second mogul machine would allow Impact to double capacity in Janesville as demand pushes higher.

The company could then meet growing demand for candies the company now produces, including, among others, Warheads candies, Melster wrapped saltwater taffy, marshmallow candies and a growing line of seasonal chocolate-coated candies that Impact coproduces under contract for chocolate giant Hershey, Estervig said.

“For consumers, candy is one of the few items that you can consider as pretty much recession-proof," Estervig said. “It's inexpensive, and people buy it when times are good or bad.”

As Estervig spoke, hundreds of fresh-made, orange marshmallow circus peanuts poured down a gleaming metal funnel the size and shape of an elephant's head and trunk and rifled through a conveyor into a machine sealed packages bound for the candy aisles of retail stores.

The marshmallow circus peanut has been a staple of mass-production candy for long enough that it has gained status as “heirloom” or “nostalgia” candy. It's in the same realm as candy wax lips and candy cigarettes.

The circus peanut's curious banana flavor, which is in no way reminiscent of how peanuts taste, is a decades-old enigma and perhaps the greatest selling point of the 2-inch candy.

Impact even jokes on its website that the circus peanuts it makes aren't necessarily famous but “infamous.”

Yet the circus peanut is no punch line at Impact. It's serious business.

In-house subsidiary Melster has made the corn syrup and sugar-based candy peanuts for decades, and Impact now dominates the market share for circus peanuts. 

All told, the company produces 6 million to 7 million pounds of circus peanuts a year using its candy-stamping mogul machine, Estervig said.

Some of the work at Impact, such as the company's wrapped saltwater taffy, is still done with hints of old-world candy making.

“You can't change some processes much. We still do it the way you see it on done on a carnival midway,” Estervig said.

Albeit, on a much grander scale.

The taffy-pulling and packing room is manned by at least a half a dozen workers who take warm, freshly mixed flavored taffy and manually stretch it into manhole sized slabs that they pile onto machines that work taffy from loops the size of rolled room carpets down to bite-sized pieces that are auto wrapped in waxy paper, just like at the county fair.

Like Impact's other lines, the taffy is packaged for wholesalers and distributors who supply to large retailers such as Dollar General, Wal-Mart and Target, Estervig said.

During the plant tour, workers in Impact's taffy-pulling room were stretching yard after yard of “Fall Festival” taffy.

Behind the room's thick plastic safety curtains, the air was thick with the smell of pumpkin spice.

Estervig said the overriding smell of sugar and confection inside Impact Confections is something most plant workers stop smelling 10 minutes after their shift starts. But for Estervig, those first 10 minutes are a reminder of the sweet industry she works in.

Earlier in her career, Estervig had worked at a processing plant that made Goodyear tires.

“I can tell you that the smell of fresh pumpkin spice taffy beats the odor of fresh rubber, hands down,” she said.


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16

(Town of Beloit) Neil Johnson, Gazette

As Alliant Energy engineer Kim Halverson drove along a gravel access road behind Alliant's Riverside Energy complex, he motioned toward dozens of steel posts in arrow-straight rows nearly 200 feet long.

The posts are a framework, part of a rack system that will support thousands of solar-collecting panels in a 2.3 megawatt solar energy facility under construction at Alliant's facility on Beloit-Rock Townline Road.

“I call it The Vineyard,” Halverson said.

It's not a bad analogy. Grapes on the vine might be nature's most capable sun-harvester. Yet the solar energy field in the town of Beloit might have one up on the grape.

Grapes can't move, but Hanwha's solar panels can.

Alliant is partnering on the project with Korean solar energy firm Hanwha Q Cells USA. The rows of solar collecting panels—7,740 in all—are geared to tilt in electronically-controlled motion to track the sun across the sky.

As early as June, Alliant plans to activate its seven solar-collecting arrays built on 17 acres of capped coal-ash landfill along the Rock River.

It's the largest solar field ever built for use by a Wisconsin utility and the first of its size here to use technology that moves solar panels to more efficiently track the sun.

Hanwha is paying to develop the $5 million project and will own and operate the solar facility. Hanwha plans to analyze the solar collectors' efficiency and output daily and seasonally.

That will give Alliant time to study how solar energy production performs at the facility, Halverson said.

If over the next decade the solar plant performs as expected, Halverson said, Alliant has an option to buy the site from Hanwha.

Meanwhile, through a 10-year power purchase agreement, Alliant plans to buy solar electricity and push it out to the grid in tandem with electricity from Alliant's other generation facilities at the town of Beloit site.

Alliant would sell the electricity to customers at market rates.

Halverson, who is the project's manager for Alliant, said the solar arrays will collect and convert enough of the sun's energy year round to power the equivalent of 500 residential customers, which he called a “conservative” estimate.

Earlier estimates by Alliant were that the solar array could generate enough power for as many as 2,000 residential customers.

The solar arrays are being built in a semicircle with an access road at the rim of a terraced hillside that breaks the site in two halves--the high end and the low end of a manmade mound.

Unlike many of the mounds along the Rock River between Janesville and Beloit, the hump at Riverside complex wasn't built by ancient Winnebago tribes. It's a capped coal-ash landfill, a dumping ground where utility operators for decades buried remnants of coal burned at the now-defunct, Rock River generating power plant at the east end of the Alliant property.

“That's maybe the most significant thing about this site,” Halverson said. “It's the first time in Wisconsin anybody has built a solar energy site on top of a (reclaimed coal ash) landfill.”

SLOW TO SOLAR

The state Public Service Commission estimates that electric utilities in Wisconsin can now produce two megawatts of their own solar electricity—a sliver of less than 1 percent of the total power state utilities generate.

The utilities sell less than one-quarter of that capacity to customers, according to the PSC.

Solar makes up the smallest cut of electricity generated and sold by Wisconsin utilities through the use of renewable energy sources, including hydropower, wind and biomass.

Wisconsin is among 38 states in which state law permits utilities to buy solar power through purchase agreements with companies that own solar systems but aren't registered as utilities.

That's how Alliant and Hanwha's partnership is set up, and it's the largest such arrangement involving solar energy in Wisconsin.

The bulk of solar electricity is still generated by private residents, municipal energy cooperatives or businesses. Those are commonly rooftop panels on homes or commercial buildings.

Some utilities here are beginning to carry out modernization projects that would retrofit coal or gas-fired plants to operate more efficiently and cleanly.

Some utilities, including Alliant, are phasing out aging coal-fired plants and replacing the lost capacity with plants that use cleaner burning natural gas—an energy source which is in abundance in the region and can be supplied through pipelines.

Many power utilities are offering a growing blend of renewable energies. Some, like Alliant, are spending millions of dollars outfitting their own offices and electric plants with solar panels intended to increase the efficiency of their own operations.

Alliant plans to build another solar field alongside the planned, 700-megawatt, gas-fired power plant the company plans to break ground for this summer at the Riverside Energy complex.

Alliant has said it would use that solar plant to offset operations at the gas-fired plant.

That solar plant, along with one now being built, will eventually give Alliant access to up to 4.3 megawatts of solar power for sale and for its own use at the Riverside Energy complex.

While that would still be just a fraction of Alliant's overall energy portfolio—including all renewable sources—it's the biggest commitment yet by a Wisconsin utility to jump into solar.

Such moves are somewhat tied to the looming draw-down of coal burning for electric generation—part of a federal plan to cut emissions of carbon dioxide and other greenhouse gases

But in other ways, the shift is tied to goals the state has set through its Renewable Portfolio Standard, a benchmark that requires utilities to offer renewable energy.

The town of Beloit solar energy plant allows Alliant to make small steps toward meeting state benchmarks for offering renewable energy alternatives to customers.

Plus, the solar plant offers a suitable use for a former landfill parcel that otherwise would be unused.

RECLAIMED SITE

Normally, solar arrays are mounted on pilings sunk into the ground, but state and federal rules prohibit development on capped landfills that disturbs or breaks open the soil, Halverson said.

To meet state Department of Natural Resources approval, the project had to be specially engineered.

Designers decided to use pre-cast concrete ballasts, 1,655 of them, which are designed to float on the soil that caps the landfill and bear the weight of the solar panels and racking system.

The 7,740 solar panels weigh a total of 189 tons, according to Hanwha product specifications and project notes. Then there's the weight of the pre-cast concrete, reinforcing steel and drive shafts that make up the racks that hold the panels.

Because the ground on landfills can shift more than on other sites, project engineers designed metal I-beams to tie the solar panels and racks into the concrete slabs using a special, bolted boot that can adjust the racks up and down if the soft terrain shifts.

That would prevent the rows of solar panels from becoming skewed and washing other nearby panels in shadows, Halverson said.

A NEW LANDMARK

Looking east across the solar arrays is the former source of the coal ash that filled Alliant's landfill, the now defunct Rock River Generating Station.

It's a large, red brick powerhouse on Townline Road with white and red candy-striped stacks.

That's a well-known landmark for regional air traffic and for anyone driving along Interstate 90/39 between Janesville and Beloit.

The plant, owned by Alliant, hasn't run in any capacity for more than a decade.

Soon after the solar arrays begin operating and even before Alliant finishes building its planned, 700-megawatt gas-fired plant at the Riverside complex, the old coal plant is going to be gone.

Alliant decided early in 2015 to demolish the old plant and nearby outbuildings. Halverson said the plan is to tear down the plant and its smokestacks before the end of the year.

Halverson said Alliant tried to convince investors to buy the huge facility for reuse, potentially as an indoor sports complex.

The Southern Wisconsin Regional Airport has a flight pattern that runs above Alliant's Riverside Energy complex, and the new solar field will act as a visual reference for pilots the way the old coal plant now does.

Halverson said the solar panels would produce a flash similar to sunlight reflecting off water that at times would be visible to airplane pilots.

But he said the Federal Aviation Administration has determined the solar arrays will be beneath the threshold for visual ground distractions.


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14

(Milton, WI) Hillary Gavan, Beloit Daily News

Blackhawk Technical College’s Advanced Manufacturing Center was full of smiles on Friday as six teams of high school students competed in “Junkyard Wars.”

Beloit Turner, Edgerton, Evansville, Janesville Craig, Janesville Parker and Milton students all were greeted by piles of junk including farm implements, car parts, flea market finds and more. During a sixth-month period Blackhawk Technical College (BTC) instructors rounded up a total of five dumpsters full of scraps for the big day. Students were then told they had three hours to try to create art. “Junkyard Wars” was based on a cable television program of the same name.

Blackhawk Technical College (BTC) supplied the welding and fabrication equipment, and one welding student per team to assist the high school welders with more complex equipment.

BTC welding instructors Mark Prosser and Jeremiah Johnson said "Junkyard Wars" was a great recruitment tool. Although the high school students are currently enrolled in metals classes at their high schools, they said it was a great way to learn what BTC has to offer while delving into the creative side of welding.

“It’s very exciting. We love getting area high school students in and experimenting in all our programs. It’s definitely a new way to think about welding as producing art,” said BTC Vice President of Learning Diane Nyhammer.

Turner High School students Reed Farr, Nick Skokut, Mark Zamora and Anthony Babcock explained how they were creating a “giving tree.” They used a large pipe as the trunk, vehicle springs as leaves and cam drive rods as the branches. They had even found a metal swing to suspend from their tree. Reed Farr said the team was working well together and having a lot of fun. They plan to take their creation back to their high school to show it off.

Mitchel Delabarre, a former Turner student who is currently attending BTC, was at the event to advise the Turner students on safety.

“Santa needs his helpers,” Delabarre said.

Although artistic expression was important, he said winners always get points for adhering to safety rules.

Turner student Reed Farr said coming to BTC was a great opportunity. He said he loves welding and dreams of opening his own welding shop one day after studying business management.

“I love being able to fuse metal together and the workmanship,” Reed Farr said.

Delabarre said being in the welding shop was like home to him, and the skill he gained there was something he wanted to share with younger Turner students.

Beloit Turner teacher Nolan Otremba said the students were thrilled to use their creativity as opposed to learning in the classroom. At Turner, he said, there is no shortage of students interested in welding. He noted his metals 1 and metals 2 classes are full.

The team from Milton won the contest, with their creation of a motorcycle. Beloit Welder’s Supply gave each member of the winning team a $125 gift certificate. All participants in Friday’s event also received a $15 gift certificate from Tractor Supply Co. from the American Welding Society.

Blackhawk Technical College is part of the Wisconsin Technical College System. BTC has five campus locations in Monroe, Milton, Beloit and Janesville offering more than 50 programs including two-year associate degrees, one- and two-year technical diplomas and short-term technical diplomas.

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13

(Janesville, WI) Neil Johnson, Gazette

Industrial supplier W.W. Grainger has started to push past the Great Recession blues and into growth mode in Janesville.

The impact is apparent in construction work to the company's business offices at its sprawling facility at 401 S. Wright Road.

And the change is perhaps most tangible right now in Grainger's 320,000-square-foot warehousing and distribution space, which less than a year ago was half empty.

Now, one Grainger subsidiary, vehicle fleet supplier Imperial Supplies, is filling that open warehousing space.

After relocating to Janesville from Green Bay earlier this year, Imperial has hired 47 warehouse workers, all but a few of them local workers, and it's ramping up distribution operations here.

Imperial officials said Thursday that Imperial could double its workforce in Janesville in just a few years as the company continues a growth spurt that led to it relocating from a smaller warehouse space in Green Bay to Janesville.

Grainger announced the addition of Imperial's distribution to Janesville late last year. It's one change that has pushed Grainger's employee headcount at its Janesville facility to 960.

That's more employees than the company had in 2015, prior to a wave of outsourcing that sent 30 Grainger support jobs to Panama. And it's more employees than the 920 that Lab Safety had at Grainger's Wright Road facility in 2008, when Grainger opted to combine its supply lines with Lab Safety. 

The facility now has the second-highest employee count of any of Grainger's 384 U.S. locations, Grainger officials said during a tour and a ceremonial grand opening of its Imperial operations Thursday.

That's a change from the period between 2013 and 2015, when Grainger was shedding jobs to outsourcing and was moving its distribution work out of Janesville after selling to implement manufacturer Ariens three subsidiaries that distributed out of the Janesville facility.

Almost all Grainger employees affected by that sale got jobs at Ariens in Grainger's Janesville facility, Grainger spokesman Joe Micucci said.

Grainger in the last few months has been holding hiring fairs amid a whirlwind of interior construction to reconfigure and add space in its business offices, half of which it shares with Ariens.

Ariens leases office space at Grainger, and the two companies are separate. Its offices are split for legal reasons. Ariens also leases about half of Grainger's warehouse space in Janesville.

A construction project that spanned last fall through March this year added 300 office spaces in Grainger's facility, and another office build-out on the second floor is underway.

On the fourth floor, a newly renovated area reorganizes sales, marketing, finance e-commerce and distribution and customer support divisions. Already, a few clusters of office workers have been set up in overflow areas.

“We're literally starting to grow faster than our construction can keep up with,” Grainger Vice President Bill Koenig said Thursday.

Grainger is based in Lake Forest, Illinois, and it supplies a range of facilities maintenance products, mainly to other businesses.

In the Midwest, companies have begun to expand in the past two years, and Grainger is seeing growth in demand for its products, particularly through e-commerce, Koenig said.

Koenig would not specify how much Grainger could grow, but he said the fact Grainger is adding more office space signals the growth could be significant.

"Anyone walking around here should be able to see that," he said. “We're planning to grow in this market, and we will because it's a great market for labor,” Koenig said.

He said Imperial is poised to grow the same way.

“There are still lanes here that aren't open yet, so, as you start getting more product to receive, we need more people to put it away, and more people to pick, pack and ship it. That's the growth,” Koenig said.

Imperial's shift in distribution work from Green Bay to Janesville came because Imperial was out of space at its facility in Green Bay.


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13

(Beloit, WI) Beloit Daily News

For the 10th time, building products distributor ABC Supply Co. Inc. has been honored with the Gallup Great Workplace Award.

The award recognizes the top workplaces throughout the world in terms of employee engagement, which Gallup describes as “being emotionally invested in, and focused on, creating value for the organization.”

“When this company was started, it was with a dream to take care of our customers better than anyone else,” said ABC Supply Co. chair and co-founder Diane Hendricks. “Our dedicated associates all over the country have made that dream a reality. They are the reason for ABC’s success.”

ABC Supply, headquartered in Beloit, is one of 35 companies in the world to be recognized with the award in 2016 and one of just three companies to receive the award every year since it was created.

President and CEO Keith Rozolis shared that ABC Supply’s success is a result of being an associate-first company. ABC’s goal is to create opportunities for people to grow and succeed.

“At ABC, if you work hard, there’s nothing you can’t accomplish. And we know that if we take care of our people, they will take care of our customers,” Rozolis said. “Our associates embrace this idea every day, and it shows in their passion and commitment to each other and to our customers. We are like a big family, committed to helping each other achieve our goals and dreams, and that is what makes ABC special.”


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06

(Janesville, WI) By Nick Crow, Gazette

Parker High School senior Hunter VanZandt decided early on in high school that college wasn't for him.

VanZandt has decided he wants to be an electrician.

"I'm going to get into an electrical apprenticeship through the union after high school," he said. "College isn't for everyone. The trades are a good way to go for a lot of job opportunities."

It's students such as VanZandt that companies such as J.P. Cullen & Sons hope to reach. Cullen held its second construction career fair Thursday at its 330 E. Delavan Drive headquarters to introduce students to careers in construction.

Joe Schwengels, construction superintendent and apprenticeship committee president at J.P. Cullen, said partnering with local schools helps identify future workers in the skilled trades.

"One of the benefits (to having the career fair) is trying to get the information out to the schools so that they help promote a career in construction," he said. "We need to raise the awareness both to the schools and the parents on the opportunities that a career in construction presents. Number two is having a way to create that pipeline through working with the schools."

"With the economy improving and the construction industry growing, we're coming out of a recovery area," Schwengels said. "A lot of people have drifted away from the trades. So we're either not finding the right qualified people or enough people industry-wise."

The fair featured hands-on demonstrations in ironwork, masonry, carpentry, concrete, welding and heavy equipment, Schwengels said. It drew students from 14 school districts throughout Rock, Walworth and southern Dane counties.

"One of the things a lot of students and parents see in construction or perceive wrongly is the lack of opportunity, but in reality it's the reverse," Schwengels said.

Mike Williams, training coordinator for the International Union of Bricklayers & Allied Craftworkers, said his trade needs younger workers to replace the ones who retire.

"It's just trying to find the young people willing to do the physical labor," Williams said. "The millennials, I guess. There's just not a lot of guys that do it anymore."

Williams said it's important for the trades industries to engage young people.

"It's a growing system that we're needing to fill," Williams said. "I think college is great, and I have nothing against it, but I think there's been too much emphasis in the schools on it. The skilled trades are a very rewarding career, and we're seeing more and more that we're going to need the future minds starting to get an interest in it."

Joe Kruser, a Craig High School teacher, echoed those sentiments.

"We have a pretty good emphasis on the trades in our schools now, and the community is involved trying to change the perception for parents and the school system and make them realize that the trades are a good career path," Kruser said.

He said misconceptions persist that construction careers pay low wages, have poor work conditions, are for less-educated people and offer no room for advancement.

"I can get up there and talk to them about trades, but them getting information in this setting right from the source is outstanding," Kruser said. "It's good to be here to open students' eyes."

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02

(Edgerton, WI) Excerpts Courtesy of the Gazette

Edgerton School District is one of five area districts receiving a $25,000 state grant to create Fabrication Laboratory, according to a news release from the governor's office. Each grant requires matching funds from the districts.

A Fabrication Laboratory, or Fab Lab, is a space for students to get hands-on experience on concepts related to science, technology, engineering and math, or STEM. The Edgerton School District hopes to have its Fab Lab set up by fall, Superintendent Dennis Pauli said.

“Providing our students a Fab Lab experience will introduce them to STEM content and skills required to compete in a global market place,” Pauli said, according to a district news release. “The Fab Lab will be a state-of-the-art classroom designed to transform thinking, promote innovation and support the district's commitment to providing students a rich variety of STEM opportunities.”

The 2015-17 state budget includes $600,000 for 25 Wisconsin school districts receiving grants through the Wisconsin Economic Development Corporation, according to the release.

STEM occupations are projected to grow 17 percent through 2018 and pay 26 percent more on average than non-STEM jobs. They've grown three times faster than non-STEM jobs over the last 10 years. By 2018, it's estimated more than 1.2 million STEM jobs in the country will be unfilled because of a lack of trained applicants, Pauli said in the release.


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