Fueled by a booming customer that's seeking to reshore 70% of its manufacturing from China, Intertech Plastics (Denver, CO) has completed $2 million investment in its plant, boosting capacity with two new Husky injection molding machines and a Thermal Care central chiller after growing revenue by more than 75% in 2012.
Tim Nakari, Intertech's senior account manager and marketing director, said the customer seeking to reshore work is a supplier of mobile device enclosures. Also driving growth at Intertech was new business from manufacturers of plastic totes, storage bins, laundry baskets, and trash cans.
"By centralizing both their manufacturing and warehousing, [Intertech] is able to provide them with a nice competitive sourcing advantage," Nakari said of the storage container clients.
The company's two new Husky machines, 1100-ton high-speed molding presses, will focus on Intertech's container business. The chiller is a Thermal Care dual TCW140 and TCW70 (140 and 70 tons) Centrifugal Central Chiller. Nakari noted that it is expandable and fully plumbed for an additional TCW70 if capacity increases down the road. Of particular interest to Intertech, was the system's "Free Cool" design and variable frequency drives for scalable capacity on all pump motors, for both tower and chiller loops, as well as variable frequency drives on the cooling tower fans.
"This unit will consume less than half of the energy than the unit it replaced," Nakari said. "It's providing our molds with more stable cooling, which translates to less manufacturing variability and better process quality. Plus it gives us the ability to expand as we add additional presses in the future." Nakari said Intertech believes it will save approximately $40,000 in energy costs as a result of this investment.
All of the company's presses, including the new Husky's, are equipped with full robotic automation and custom end-of-arm tooling. Yushin robots are equipped with dual arms, allowing them to pick from multiple cavities, including stack tools. Nakari also noted that each of the Husky's that have been installed have large accumulator packages to allow for high-speed injection.
Nakari said that average employment has increased by approximately 25% at Intertech over the last year. The company, founded in 1980, supplies consumer, medical, and specialty plastics markets. Capabilities include product and graphic design support, engineering, validation, in-mold decorating, screen/pad printing, molding, packaging, assembly, and fulfillment. Press sizes range from 55 to 1500 tons, and include machines from Arburg, Cincinati Milacron, Demag, Husky, Toshiba, and Toyo.