Its product has been in distribution in just two limited regions of the U.S. for less than two years and has been generating revenues only for about nine months. But Nyloboard LLC CEO Patrick Doyle has high hopes for sales in 2011 and beyond for the company's alternative decking board made from 100 percent recycled carpet fibers.
Our hope is for a 50 percent or better increase in sales in 2011, said Doyle, whose company currently sells Nyloboard only in Hawaii and the Southeast, which it can easily serve from its 200,000-square-foot plant in Covington, Ga. Doyle was interviewed in September at the Remodeling Show and Deck Expo in Baltimore.
The market response has been phenomenal because of the aesthetics of its hardwood-like appearance. We think we can add a plant on the West Coast in 12-16 months.
The company also will expand its offerings from only caramel-colored decking to include gray and cocoa colors. The new colors will be shown at the International Builders Show, slated for Jan. 12-15 in Orlando, Doyle said.
Competitors of all types, many promoting green products, have emerged almost overnight in the alternative decking market. But Doyle said his firm has an advantage because Nyloboard is pressed, not extruded, has a hardwood appearance and naturally resists mildew and water, as it is made from 100 percent carpet fiber and bonding resins that are free from volatile organic compounds.
The 7-year-old company shifted into decking products two years ago when demand dropped more than 90 percent for its marine-market sheets used to make hulls and cabinets on yachts because of their water-resistance and lightweight nature.
Decking is one of the few industry segments in building and construction where sales are on the increase, said Doyle.
He said Nyloboard which comes with a 30-year limited warranty and uses a proprietary coating for fade-resistance can be installed with conventional building tools, performs much like wood in finishing and fabrication, and has superior screw retention and stronger nail-withdrawal resistance.
In addition to decking, the company also offers trim, flooring, signs and sheathing that can be used for wall panels, flooring and roof applications; in trucks, trailers and recreational vehicles where rot-resistance is important; and in the marine industry as a core material for floors, covers, seats, and reinforcing points where compression and screw retention are critical.