As published in Toledo Business Journal - December 1, 2018

Aerial view of 20/20 Custom Molded Plastics’ expansion project in Holiday City

Aerial view of 20/20 Custom Molded Plastics’ expansion project in Holiday City

20/20 investing $42M
in Holiday City

20/20 Custom Molded Plastics, a structural foam molding company for large component parts, is investing $42 million in an expansion project at its Holiday City facility. The project involves constructing a new 245,000 square foot high-pressure facility in two phases, as well as investment in the world’s largest high-pressure injection press, weighing 6,670 tons, according to the company.

Rupp/Rosebrock, Inc., a Liberty City-based general contractor, is the construction manager at risk for the expansion. The project broke ground in March 2018 with phase one, a 146,000 square foot expansion, expected to be complete by the end of the year. Phase two of the project is expected to be complete by March 2020.

The company hopes to have the new high-pressure injection press operational by December 1.

David Rupp, one of the partners at 20/20, said, “The Holiday City expansion is to accommodate the new high pressure ‘mega’ part requirements. Until now, these large part ideas were just ideas, but now our customers have a machine that is capable of turning their ideas into parts. The high-pressure facility expansion is designed around a new 6,670-ton Cincinnati Milacron press to house the largest high-pressure machine in North America. In addition, there will be 10 additional high-pressure machines to mold our customer’s large part requirements.”

Rupp noted that although 20/20 specializes in large part, low-pressure injection / structural foam molding, its low-pressure customers now have large part applications that require high-pressure presses.

“The low-pressure industry has changed dramatically in the last four years, with some of the companies having been consolidated, or others closing. Many of our competitors are gone and those that remain have older equipment. We have invested in the new low-pressure technology and can do things our competition can’t do, and are now investing in high-pressure technology. We think we have a competitive edge and that is reflected in our growth,” said Rupp.

20/20 is a fully automated manufacturer with robots on every machine and, according to the company, has the largest variety of low-pressure machines in the industry. The company’s presses include 1,500-ton, 1,000-ton, 725-ton, 500-ton, and 375-ton machines with single part capabilities of up to 200 pounds. According to the company, it has incorporated the latest technology available for total control of the molding process. Its shot-to-shot consistency is monitored by custom controls, built to its specifications.

“Our machines have the largest shot capacity in the industry. We have five machines that have multiple extruders, which allows 20/20 to mold two different colors and multiple parts in the same machine. Our new high-pressure facility has the largest crane capacity in the industry. It has two hooks, one weighs 125 tons and the other is 75 tons. The new 6,770-ton high-pressure machine also has two extruders that can run two different colors and can shot a 205-pound part. In fact, the first part to run in this machine will be nine feet long, six feet wide, and five feet high, weighing 119 pounds,” said Rupp.

Aerial view of 20/20 Custom Molded Plastics’ expansion project in Holiday City

Aerial view of 20/20 Custom Molded Plastics’ expansion project in Holiday City

With the new 6,670-ton machine, the company will have the ability to mold parts it currently can’t. The new press will have a 208-pound shot where currently the company is maxed at 48-pound shots in its high-pressure machines.

The company manufactures for a variety of industries, and some of the products it manufactures includes pallets, bins, tool boxes, swimming pool panels, golf cart floors, waste water chambers, burial vaults, in-ground irrigation and utility chambers, shelving, drainage grates, and basement windows to name a few.

According to the company, its product development team brings expertise in manufacturing, which integrates the design, engineering, and quality control disciplines for superior part performance and cost effectiveness.

“We also provide our customers engineering services including part and mold designs, warehousing, and secondary services like sonic welding, hot stamping, etc.,” added Rupp.

The company also noted that it has developed an extensive list of new products in structural foam with its years of experience and its in-house engineering expertise and CAD software. These structural foam products save costs because of lower resin use than other molding processes, up to 15% part weight reduction, less expensive aluminum tooling, and a high level of manufacturing consistency. Once the specifications are set, the part can be molded accurately the next day or the next year. Its nozzle controls and sequences guarantee consistency from part to part and run to run.

Currently, 20/20’s Holiday City facility employs approximately 200 employees. The company is planning to add 75-100 employees in 2019, with the bulk of those occurring in thefirst quarter of 2019.

 

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