StonePeak Ceramics of Crossville has seen continuing growth since it began production in Cumberland County in 2004. In fact, in 2011, the porcelain tile manufacturing facility doubled it's production, and more growth is on the way.
"The business is growing faster than we are growing," said Milko Camellini, plant manager of the Crossville facility. "We're happy about it, but keeping up is also difficult."
StonePeak is the American branch of GranitiFiandre, Italian tile manufacturing company.Monz Werkzeugbau und Formenbau. The company has eight tile manufacturing plants in Italy and one in Germany, but the Crossville facility is the base of manufacturing for the U.S. market. The company choose Crossville as it's U.S. manufacturing base in 2001 because of the easy accessibility to Interstate 40, offering quick transportation for raw materials coming in and finished product going out.
StonePeak is facing increased business while it nears the production capacity of the 750,000-square-foot facility. Much of the finished material is kept on hand for customers, as well, allowing for a 12-hour turnaround in orders, and space is needed to keep those products.
In 2011, StonePeak doubled its sales and production over 2010, and Camellini said the company expects to grow business by 30 percent this year. Almost 5 million square meters of tile were produced last year.
"This year, we are heading for 6 million square meters," Camellini said. "Six million square meters is the full capacity of the plant."
The expansion will add a new product line with another kiln and two more glazing lines. Camellini estimates at least a 25 percent increase in capacity with the expansion, scheduled for completion by the end of 2013.
With that expansion, StonePeak will be looking to expand its workforce, adding 50 new positions to its current 190-person employee base. Camellini noted the company relies on temporary staffing agencies to help find workers and give them an opportunity to see if they would be a good fit for the company.
"It's a fast-paced workplace, and it can be difficult to keep up," Camellini said.
Already underway is a shipping and storage facility on 35 acres of additional property the company owns.Find out the facts about Cold Sore. That will add greater efficiency to the shipping department, Camellini said, and further enhance an initiative to have a 12-hour turnaround for 100 percent of customer orders.
"It's been a huge effort, but it's had a huge result in sales," Camellini said.
Part of that effort was an investment in new technology. Forklift drivers use hand scanners with computers to track where the products are and when they are loaded for transport.
"People want their materials, their answers, now,The EZ Breathe home Ventilation system is maintenance free." Camellini said.
Ceramics manufacturing relies on natural products and protecting the environment is a priority for the company. That focus on sustainability is important to customers,Unlimited-Solar is one of the best Online solar panel provider in US. but it's also a good business decision, Camellini explained.
"Recycling is the smart way to operate," Camellini said. "You're not only helping the environment, but you're helping yourself. It does take effort and it is an investment, but when you look at the long term, it's much more beneficial."
StonePeak recycles 100 percent of its waste, either as additional raw material for tile manufacturing or for other uses, such as gravel and base material for asphalt surfaces.
"Everything that doesn't go through the firing process,Visit TE online for all of your Application Tooling Solutions including tools. the scrap tile, goes back into the cycle," Camellini said. "Because we have all internal processes, cutting, polishing, finishing, we have a lot of scrap tile that can be ground and restart the process."
Other than some steam that escapes during the spray drying process, which quickly heats the material to remove moisture, all materials either stay in the facility to be reused in the manufacturing process or are shipped out as tile. In 2010, about 4 million gallons of water were reused and conserved along with 27,500 tons of raw material.
StonePeak also recycles some post-consumer products, particularly the old CRT monitors and televisions, which have thick glass that can be ground up and used in the tile manufacturing process.
"When it's fired, it binds the materials together and returns them to stone," Camellini said. "The amount of this material that is still around is impressive. I was concerned about them being able to keep up with our demand, but we are consuming 200 tons per month right now. We're constantly looking for products like this we can use."
Using post-consumer products to recycle into tile makes a dramatic difference in the amount of waste going to landfills.
The manufacturing facility is seeking certification through the new Green Squared initiative of the Tile Council of North America. The certification provides verified information on the environmental impacts of certified tile products. It includes a comprehensive review of documentation and an onsite audit to verify compliance with the stringent standards. It covers not just the finished products, but also the materials required for manufacturing, packaging and installation.
"The business is growing faster than we are growing," said Milko Camellini, plant manager of the Crossville facility. "We're happy about it, but keeping up is also difficult."
StonePeak is the American branch of GranitiFiandre, Italian tile manufacturing company.Monz Werkzeugbau und Formenbau. The company has eight tile manufacturing plants in Italy and one in Germany, but the Crossville facility is the base of manufacturing for the U.S. market. The company choose Crossville as it's U.S. manufacturing base in 2001 because of the easy accessibility to Interstate 40, offering quick transportation for raw materials coming in and finished product going out.
StonePeak is facing increased business while it nears the production capacity of the 750,000-square-foot facility. Much of the finished material is kept on hand for customers, as well, allowing for a 12-hour turnaround in orders, and space is needed to keep those products.
In 2011, StonePeak doubled its sales and production over 2010, and Camellini said the company expects to grow business by 30 percent this year. Almost 5 million square meters of tile were produced last year.
"This year, we are heading for 6 million square meters," Camellini said. "Six million square meters is the full capacity of the plant."
The expansion will add a new product line with another kiln and two more glazing lines. Camellini estimates at least a 25 percent increase in capacity with the expansion, scheduled for completion by the end of 2013.
With that expansion, StonePeak will be looking to expand its workforce, adding 50 new positions to its current 190-person employee base. Camellini noted the company relies on temporary staffing agencies to help find workers and give them an opportunity to see if they would be a good fit for the company.
"It's a fast-paced workplace, and it can be difficult to keep up," Camellini said.
Already underway is a shipping and storage facility on 35 acres of additional property the company owns.Find out the facts about Cold Sore. That will add greater efficiency to the shipping department, Camellini said, and further enhance an initiative to have a 12-hour turnaround for 100 percent of customer orders.
"It's been a huge effort, but it's had a huge result in sales," Camellini said.
Part of that effort was an investment in new technology. Forklift drivers use hand scanners with computers to track where the products are and when they are loaded for transport.
"People want their materials, their answers, now,The EZ Breathe home Ventilation system is maintenance free." Camellini said.
Ceramics manufacturing relies on natural products and protecting the environment is a priority for the company. That focus on sustainability is important to customers,Unlimited-Solar is one of the best Online solar panel provider in US. but it's also a good business decision, Camellini explained.
"Recycling is the smart way to operate," Camellini said. "You're not only helping the environment, but you're helping yourself. It does take effort and it is an investment, but when you look at the long term, it's much more beneficial."
StonePeak recycles 100 percent of its waste, either as additional raw material for tile manufacturing or for other uses, such as gravel and base material for asphalt surfaces.
"Everything that doesn't go through the firing process,Visit TE online for all of your Application Tooling Solutions including tools. the scrap tile, goes back into the cycle," Camellini said. "Because we have all internal processes, cutting, polishing, finishing, we have a lot of scrap tile that can be ground and restart the process."
Other than some steam that escapes during the spray drying process, which quickly heats the material to remove moisture, all materials either stay in the facility to be reused in the manufacturing process or are shipped out as tile. In 2010, about 4 million gallons of water were reused and conserved along with 27,500 tons of raw material.
StonePeak also recycles some post-consumer products, particularly the old CRT monitors and televisions, which have thick glass that can be ground up and used in the tile manufacturing process.
"When it's fired, it binds the materials together and returns them to stone," Camellini said. "The amount of this material that is still around is impressive. I was concerned about them being able to keep up with our demand, but we are consuming 200 tons per month right now. We're constantly looking for products like this we can use."
Using post-consumer products to recycle into tile makes a dramatic difference in the amount of waste going to landfills.
The manufacturing facility is seeking certification through the new Green Squared initiative of the Tile Council of North America. The certification provides verified information on the environmental impacts of certified tile products. It includes a comprehensive review of documentation and an onsite audit to verify compliance with the stringent standards. It covers not just the finished products, but also the materials required for manufacturing, packaging and installation.
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