Expansion Phase #3 for the plant in Baytown (Texas, USA)

22.03.2021

New automated fabrication systems and equipment to enhance efficiency, productivity, quality and reduce lead times.

DUNA-USA has begun a new stage of its multi-year expansion plan, designed to optimize efficiency and further reduce lead times. This is the third chapter in three years for DUNA’s Baytown, TX facility, and is part of the company’s long term strategic growth plan.

Planned plant improvements include an automated system for cutting and loading CORAFOAM® blocks to reduce fabrication time and manual handling. The investment also includes new processing equipment for producing low density composite core panels with state-of-the-art tolerances and accuracy. Perfectly square panels, with high tolerance represent the response of DUNA-USA to the increasing demand for high-quality performing boards within the composite core market. Automated packaging machinery is also planned to be implemented with the main purpose to assure total quality management till delivery at client location. This is also aimed to accelerate the process and eliminate material damages from manual handling, while enabling better packaging with less plastics in accordance with the company’s sustainability program.

To accommodate the new equipment, the existing premises have been increased by almost 9.000 ft² (840m2) and the laydown yard has been extended with new paving by almost 1.5 acres (6000m2).

“We’re introducing new equipment and technology to confirm our commitment to continuous improvement” - states Andrea Benedetti, CEO of DUNA-USA - “We are very excited to see DUNA-USA’s footprint expanding in North America and look forward to obtaining improved efficiency and further benefits for our Customers.”
Construction began in Q1-2021 and is expected to be completed by Q3-2021. This expansion follows major previous updates including a land purchase, new building construction and company-wide ISO-9001 certification for both US plants in Baytown, TX and Ludington, MI in 2019.

“2020 was a demanding year and 2021 looks pretty challenging too” - says Marta Brozzi, President and CEO of the Group - “The sole effect of this on our growth plans is to strengthen our determination towards investments in new technologies, quality, knowledge and safety for each location of the group including the plants in North America”.