Trex nixes 3rd plant, expanding others WINCHESTER, VA. — Composite decking maker Trex Co. Inc. has put recently announced plans to build a third plant on hold, instead choosing to expand its plants in Virginia and Nevada.
"After studying a number of options, we have concluded that the most efficient next step is to expand our two present locations. The economies of scale available with this choice clearly outweigh those of building a third site at this time," President Robert Matheny said in a company news release.
Winchester-based Trex announced plans to build a third plant in its annual report, released only two months ago.
However, the company instead purchased 39 acres of land near its 26-acre property in Winchester. The acquisition included a 184,000-square-foot facility that will be used for warehousing, the release said.
Trex also is planning a 150,000-square-foot plant at that site that would house six extruders, bringing the total number of lines in Winchester to 14.
The Fernley, Nev., site currently is home to a 160,000-square-foot plant that operates six extrusion lines. Construction is set to begin later this year on an additional 100,000 square feet that would accommodate another six extruders, according to the release.
"While we are delighted at the extraordinary demand for Trex decking, we are always mindful of the need to carefully manage this growth. We also continue to evaluate locations for the construction of a third, large-scale manufacturing facility," Matheny said.
Trex reported $74.3 million in 1999 sales.
Layfield moving to new Edmonton site
EDMONTON, ALBERTA — Layfield Plastics (1978) Ltd. is building a plant in Edmonton to fabricate geomembranes, tarpaulins and liners.
Layfield will spend C$2.8 million (US$1.86 million) on land and the 42,000-square-foot facility. The firm expects to relocate its current Edmonton production to the new plant by late November or early December, according to Layfield's director of product development, Andrew Mills.
Mills said in Edmonton his firm welds plastic sheet into large structures. Typically it buys rolls of flexible vinyl sheet from 6-8 feet wide and welds them into panels of 20,000-30,000 square feet. The panels are further assembled in the field.
Besides PVC, Layfield buys PVC alloy sheet, proprietary polyolefin sheet and reinforced polyethylene tape to convert into geomembranes and similar products.
Mills said the company needs more space to assemble the large panels. It broke ground on the new building May 23.
Layfield also operates a geomembrane fabrication factory in Bellingham, Wash., and a blown polyethylene film and bag plant in Richmond, British Columbia. The latter, Layfield's Poly Films division, also makes a small amount of PE sheet for its geomembranes and tarpaulins.
Layfield was established in Edmonton in 1955 and acquired by Tom Rose, the firm's current president, in 1978. Since the acquisition, Layfield has grown from a 10-person company to one employing about 170.
Mills would not disclose annual sales.
Marley Mouldings to invest $40 million
MARION, VA. — Marley Mouldings Inc. is brimming with confidence. In fact, the Marion-based manufacturer of polystyrene and chlorinated PVC moldings, picture frames and window and door components is so confident in its sales growth that it has planned a five-year series of expansions totaling $40 million.
The project will more than double the company's current capacity.
Phase one will include a new, 150,000-square-foot plant in Bristol, Tenn. — Marley's fifth in three states, said Gary Peacock, vice president of operations.
Construction is to begin in October and the plant should be operating by June 2001, he said.
Marley still has plenty of room for growth at its 28-acre site in Bristol, and the company plans to use it all. Current plans call for two expansions totaling 250,000 square feet, Peacock said.
"We're looking at site expansion in 2003 [and] 2005," he said.
The company, which employs 720 at its four facilities, ultimately will employ another 400 at Bristol. Marley already occupies nearly 1 million square feet of manufacturing and warehouse space.
"Between now and 2005 we will double the capacity of our operations," Peacock said.
Last year, Marley added a total of 75,000 square feet of space and 30 extruders to facilities in Waco, Texas, and Marion.
To top it off, the firm also is nearing completion of another 25 percent increase in capacity in Marion, Peacock said.
Marley is a subsidiary of Etex Group SA, a Brussels, Belgium, building materials manufacturer.