Composite Technologies Co. LLC has launched a $3 million expansion to open a second manufacturing operation in Dayton, Ohio with plans to buy injection molding equipment and compounding lines as the company expands its business of molding pallets and selling resin from recycled plastics.
The 200,000-square-foot plant should begin operating in April. CTC will continue to run its original plant, which measures 130,000 square feet. Both factories are in Dayton, about two miles apart.
Composite Technologies specializes in compression and injection molding pallets and custom products from recycled and wide-spec virgin resin. The company claims to be one of the world's largest compression molders of recycled polypropylene and polyethylene.
CTC compounds its own material. In early 2009, the company started to sell X-Pro-brand PP compounds from recycled feedstock on the open market, said Tony O'Driscoll, vice president of sales and marketing.
Historically, we molded parts from our own resins. That's the reason we're pretty comfortable with the resin, [since] we know what we're getting because we made it for ourselves as well, O'Driscoll said.
Growth in the pallet business and outside resin sales promoted the expansion, said CTC President Ken Stacherski, who credits CTC's core experience in recycled materials. We've got the unique capability to take material in any form and turn it into finished products, whether it be injection molding, compression molding or resin sales, through compounded resin, he said. We are most efficient because we make our own material and can also make the components that can be manufactured from that material.
The new plant has a rail siding, for easy bulk shipping of X-Pro resin. CTC also will be able to provide mineral-filled, natural and colored compounds, Stacherski said.
CTC began as a compression molder of pallets. By using lower-priced material, the company has been able to crack the $10 price for its X-Porter pallet. CTC also has developed a patented technology for long-fiber-reinforced plastic molding.
Two years ago, CTC purchased its first injection molding machine, a used Milacron press with 3,000 tons of clamping force. The new building will allow the company to buy more injection presses, probably smaller machines to make components for the pallets, Stacherski said.
Composite Technologies currently employs about 100.
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