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M&A Momentum in Manufacturing: Risk Management Lessons from Travelers’ 2025 Study

Manufacturing mergers and acquisitions (M&A) are entering 2025 with renewed energy. Although overall volume slowed slightly last year, the sector still logged more than $200 billion in transactions across 1,667 deals, according to the 2025 M&A Study: A Travelers Special Report. Even more striking: the median deal value jumped 70 percent year over year, marking the first such increase in five years. Larger, higher-stakes deals are becoming the new norm — and with them come greater challenges for integration and risk management.
The Travelers study, produced in partnership with PitchBook, analyzed five years of transaction data and surveyed more than 150 manufacturing executives with risk-related responsibilities. The findings underscore a dual reality: while deal activity positions manufacturers for growth and innovation, it also exposes them to new risks across culture, workforce, technology, and supply chains.
What’s Driving Manufacturing M&A
Several forces are fueling M&A momentum. Policy shifts around U.S. reshoring, trade, and infrastructure investment are drawing more manufacturers into dealmaking. Regional hubs remain central, with the Great Lakes region driving more than 22 percent of activity in the past five years, while the South led in growth at 11 percent year over year. Consumer goods stood out as the only manufacturing sector to post deal count growth in 2024, particularly in personal products and food and beverage.
Technology is another catalyst. Companies are pursuing acquisitions to gain access to advanced technology such as robotics, 3D printing, and supply chain technologies that can reduce costs and improve efficiency. As the report notes, these innovations are reshaping the value proposition of manufacturing, even as they raise new challenges around cyber resilience, equipment valuation, and supplier vetting.
Private Equity vs. Strategic Buyers
The report distinguishes two dominant deal types. Strategic acquisitions — driven by manufacturers themselves — account for the majority of activity, motivated by access to talent, assets, and new markets. Private equity, while down to just over 44 percent of all deals (its lowest share in five years), continues to rely heavily on add-on acquisitions as a consolidation strategy.
Case studies from the report illustrate these dynamics:
- Cleaner engines through a strategic buy: A global power solutions company acquired a braking systems manufacturer to bolster its emissions reduction capabilities.
- Carve-out in building products: A private equity firm repositioned a cabinetry division into a standalone growth platform.
- IP disputes in 3D printing: A $100 million acquisition was followed by lawsuits over withheld payments and copyright infringements, highlighting ongoing intellectual property risks.
Workforce and Cultural Integration Challenges
Even when deals make financial sense, they can disrupt the people side of the business. Surveyed executives cited workforce and culture among the biggest pain points. Nearly two-thirds of respondents reported employee resignations or major role changes, while nearly half experienced layoffs and office closures. Cultural clashes, operational disruptions, and missed financial targets all ranked among the top perceived risks.
That said, executives were quick to point out the upside. Ninety-two percent of respondents described their overall M&A experience as positive, citing benefits like entry into new markets, customer expansion, cost savings, and increased brand visibility.
Risk Management Evolves Post-M&A
M&A activity has also been a catalyst for strengthening risk practices. Nearly every company surveyed (97 percent) reported changing its risk management approach after a merger or acquisition. Among the most common adjustments: adopting new technology safety protocols (54 percent), engaging new suppliers (52 percent), revising physical safety practices (45 percent), and modifying insurance coverage (43 percent). Encouragingly, 94 percent said their practices ultimately became stronger.
Lessons shared by executives offer practical insights: be prepared for hidden integration costs, anticipate supply chain delays, and don’t underestimate cultural and systems alignment challenges. These realities highlight why early and ongoing risk assessment should be a cornerstone of M&A planning.
Outlook for 2025 and Beyond
The manufacturing sector remains central to the U.S. economy, but success in today’s M&A climate requires balancing opportunity with vigilance. Reshoring and domestic production may build resilience, yet they bring short-term cost pressures. Advanced Technologies such as 3D printing and automation offer competitive advantages but raise complex integration and IP challenges.
Ultimately, the report concludes, companies that prioritize cultural fit, technological integration, and supply chain adaptability will be best positioned to thrive. Despite uncertainties, M&A remains a powerful lever for growth, innovation, and long-term competitiveness.
To access the full 2025 Special Report on M&As from Travelers, click here.
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This article was produced by the R&I Brand Studio, a unit of the advertising department of Risk & Insurance, in collaboration with Travelers. The editorial staff of Risk & Insurance had no role in its preparation.

