For John Costa, investing in the future of Costa’s Mitre 10 Trade Centre was a family decision. Alongside his sister Vitina and father Mario, John is part of a family business with a long history. After nearly 60 years in business, the second-generation owner knew the business had to keep evolving to remain competitive. With MiTek as a long-standing partner, Costa’s is now transforming its truss manufacturing operation, investing in new machinery, modernising its workflow and preparing for what comes next.
A family business with a long history
Costa’s began in a small shop on Francis Street, where John’s father and uncle started the business nearly 60 years ago. What began as a sand and soil supplier grew into a timber business in the 1970s, before expanding into truss manufacturing around 1989 or 1990.
Today, the business operates from Hoppers Crossing in Melbourne, employing close to 100 people. John and his sister Vitina are heavily involved in the day-to-day running of the company, alongside their uncle, Gerry, who at 82 still comes into work every day.
Making the decision to invest
The current market is challenging, but John believes Costa’s is in a strong position because of its willingness to change and develop.
“We don’t stand still,” he says.
That mindset led to a significant decision. Much of the company’s existing equipment was approaching 30 years of age, and the family had to decide whether to remain in the truss manufacturing business.
“If we were going to stay in the truss business, we needed to invest,” John explains.
The result is a major transformation of the company’s manufacturing operation, with a planned investment of approximately $10 million in equipment and a further $6–10 million in a new building.
Costa’s worked with MiTek to develop a plan around the production capacity it wanted to achieve, the equipment required and how the new operation would be housed. The process involved reviewing layouts, considering the workflow and working through how the investment could be implemented.
For John, it was not simply about buying new machinery. It was about creating a business that could compete competitively in the broader market.
A new way of working
The transformation began in September 2025, with the installation of a new Matchpoint blade saw. Roof Tracker tables followed in December, with the next stage bringing a Ranger and a second blade saw online in May 2026.
The final stage, planned for December 2026, is expected to include FlowMax.
The new equipment is part of a broader change in how Costa’s produces trusses. The business has worked with MiTek and its automation team to develop a new workflow and layout, designed around the company’s vision for the future.
“We wanted to go from a small or small medium truss plant to an operation that could compete against the bigger players,” John says.
The investment is already making a difference. Since implementing the two blade saws and two Rangers, John says the business has increased its production by around 70 per cent over the previous four months, with productivity up by approximately 80 per cent without increasing staff numbers.
The business is also focused on cost competitiveness. With the new equipment, John believes Costa’s is better positioned to compete with larger manufacturers.
Investing in people as well as machinery
For John, the benefits of the transformation extend beyond production.
“Our staff now find it a pleasure to come to work with new equipment,” he says.
The investment has brought a renewed sense of energy to the team, with John describing it as a “new lease of life” for the business.
That matters in a family business where people are a big part of the operation. The new equipment is helping create a more modern workplace whilst giving the team the opportunity to work with new technology and processes.
A partnership built over 30 years
Costa’s has been working with MiTek for around 30 years and John sees that relationship as an important part of the company’s ability to evolve.
When the family made the decision to invest, they turned to MiTek to help develop a plan and work through the implementation.
“We sat together with MiTek and they were really great in helping us and coming up with a plan and how we’re going to implement it,” John says.
For Costa’s, the relationship is about more than equipment. It is about having a partner that understands the business, its goals and the practical requirements of making a major investment.
That long-standing relationship has supported the company through its transition from a traditional timber supplier into a more advanced truss manufacturing business, and now into its next stage of growth.
What’s next for Costa’s?
With the truss manufacturing transformation underway, John is already looking at the next opportunity.
The immediate focus is on integrating Flowmax into the truss operation and getting the new plant to the level of capacity the business is aiming for. After that, the company will turn its attention to wall manufacturing and explore the potential for panel manufacturing.
“I think that’s a big step for us next,” John says.
It is a natural progression for a business that has continued to adapt throughout its history. From sand and soil to timber, then trusses and now potentially wall panels, Costa’s is continuing to look at what it can do next.
For John, the goal is straightforward, build a business that is ready when the market turns and keep finding ways to expand and improve.
“I think when the market does change or when there is a kick in the market, we’ll be ready to go.”
At Costa’s, the future is being built one investment at a time, with a family business, a dedicated team and a long-standing partnership with MiTek behind it.