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June 05, 2020 09:25 AM

Agri-Industrial Plastics adds eighth multilayer coextrusion machine to fleet

Jordan Vitick
Special Projects Editor
Plastics News Staff
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    Agri-Industrial Plastics Co.
    Agri-Industrial Plastics has eight multilayer coextrusion machines specifically for nonautomotive fuel tank production and 20 monolayer accumulator-head industrial blow molding machines.

    Industrial blow molder Agri-Industrial Plastics Co. is adding a new six-layer, continuous coextrusion blow molding machine to its fleet, which now includes eight multilayer coextrusion machines specifically for nonautomotive fuel tank production and 20 monolayer accumulator-head industrial blow molding machines.

    The new machine is a KBSmart120, which manufactures low-permeability multilayer gas tanks with a single clamp and robotic parison transfer to improve production efficiencies. This is the third KBSmart120 machine from Kautex Maschinenbau GmbH for the company. Other models include KB240 and KBSmart61 machines.

    Kautex KBSmart machines are designed to produce plastic fuel containers up to 40 liters.

    Fairfield, Iowa-based AIP is a custom industrial blow molder of large-scale parts, including nonautomotive fuel tanks for the recreational equipment, lawn and garden, and agricultural industries. AIP produces around 1 million fuel tanks each year.

    The machines are assembled in Germany, tested to ensure they meet the company's standards prior to shipment, then unassembled and shipped to AIP, where the team puts them back together. The added machine was ordered in early 2019 and arrived in the fall. It is planned to go into production in late summer or early fall, said Geoff Ward, AIP engineering director.

    "The decision to expand our coextrusion multilayer blow molding capacity was all about meeting the growing demand of our customers — both existing and new," President Lori Schaefer-Weaton said in a news release. "With a lead time of approximately one year, we must forecast the market potential well in advance."

    Not forecast was the threat of the coronavirus pandemic, which has impacted AIP through decreased orders and several customers shutting down. But AIP never shut down.

    "It's hard when you're ready to get a machine up and going and volumes are decreasing due to some unforeseeable thing like a recession or obviously a global pandemic. However, we are very optimistic about our customers coming back and coming back strong within the next 12 months," Schaefer-Weaton said in a follow-up telephone interview with Plastics News. "We still feel like this [new machine] was a very wise investment, and we will be ready to support all of their requirements and also be well-equipped to take on additional customers and new business. We do feel good about this market and our continued investment in this arena."

    Solar sustainability

    In addition to the new KBSmart120 machine in 2019, AIP completed a solar project. The blow molder is Iowa's first advanced manufacturing company powered by solar energy and Tesla Powerpack, and it has the state's largest rooftop solar installation.

    Tesla Powerpack works by AIP producing energy when the sun is shining and dispatching the battery technology when peak usage is highest. It reduces carbon dioxide emissions by more than 10,200 metric tons over 25 years, equivalent to more than 11 million pounds of coal.

    "This project was the first installation in Iowa, combining an expansive solar array with Tesla Powerpack energy storage technology to shave our peak electric usage. This technology will help us control our energy costs, while also contributing to long-term sustainable solutions for the environment," Schaefer-Weaton said. "These projects are a direct reflection of our commitment to a sustainable business model that will carry us into the future."

    The company was founded by Richard "Dick" Smith in 1978. Schaefer-Weaton, Smith's daughter, has been president of the company since 2013. Smith is chairman.

    AIP has around 200 employees at its 354,000-square-foot manufacturing facility on its 20-acre campus in Fairfield. The company was No. 36 on the most recent Plastics News ranking of North American blow molders, with sales of $51 million.

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