Melted recycled plastic is cut into billets and placed into the bottom half of molds before large hydraulic presses stamp out new pallets. The company, which makes both nesting and stackable units, features nine out of the 10 most popular pallet sizes.
CTC, these days, is selling about 25,000 pallets per month but has a goal of 48,000 per month.
DeMatto said plastic pallets represent a small portion of the overall pallet market. "When you compare it to wood, it's minuscule. It's minuscule, but it's growing and it's growing substantially and it's forecast to continue to grow," he said.
While some CTC recycled plastic is used internally for pallets, a majority of the material the company processes is sold to other firms. "We ship everything from single gaylords to full truckloads, bulk trucks to rail," the COO said.
The company relies on extensive testing, through both a certified lab and inline sampling, to achieve quality that DeMatto claimed rivals virgin resin.
"We basically run our recycled business like you would a virgin business," DeMatto said. "We test every box of material that comes in here thoroughly.
"We are pretty big believers in minimizing variation on input and that really minimizes it on the output. So we do extensive testing. We make sure we get our raw material bucket set up correctly and that makes things work a lot better.
"Polypropylene, while the market is down, we found that if you are light on your feet and you are always looking to innovate and get better, you can compete very well," he said. "This area has always been good for polypropylene scrap for us to gather and recycle."