Having experienced significant growth in demand for its ResinDek engineered flooring panels and shelving products over the past two years, Cornerstone Specialty Wood Products and its parent company, universal wood, invested in the construction of a new $15 million manufacturing plant. Located in a suburb of Louisville, Kentucky, the plant will allow Cornerstone to increase manufacturing output to more than double its current capacity.
“Our business has grown dramatically over the past two years, which we are extremely grateful for,” said Greg Doppler, inventor of ResinDek flooring panel and president of Cornerstone. “Because of this tremendous growth, we are approaching the upper limits of our current production capacity. This investment will allow us to be able to quickly deliver ResinDek products to our valued customers in the future. »
“The footprint of the new facility is more than double the current footprint, allowing us to carry more inventory and produce products faster. This, combined with a design that incorporates many more dock doors for shipping and receiving, will allow us to reduce lead times,” added Scott McGill, Sales Manager at Cornerstone.
“The new operation will also be equipped with the latest state-of-the-art e-beam coating and curing equipment that we have always used to produce our ResinDek protective coatings and finishes, only at much higher throughputs and volumes than ‘before,’ Doppler explained. “It will also allow us to achieve quality even higher than the high standards that our current coating and curing line currently achieves.”
“The new equipment will not only increase manufacturing quality and yield, but will also provide a wider range of opportunities within our new product development program. This will allow us to continue to deliver a fantastic value proposition to our customers,” added McGill.
The new facility, located at 264 Eiler Avenue in Louisville, near UPS Worldport and Louisville International Airport, will have the same production team working at the existing operation. Prior to its construction, Cornerstone added additional employees in 2021 in anticipation of increased production capacity. “Starting them before the new plant is built allows them to get familiar with ResinDek’s production process before the new facility goes live,” Doppler said.
The equipment is expected to be installed and commissioned throughout January 2022, with partial production commencing shortly thereafter. The installation of the new coating and curing machines is scheduled for the second quarter of 2022.
“We expect to be fully operational in the third quarter of 2022 and we look forward to celebrating Cornerstone’s new capabilities with a ribbon-cutting ceremony at that time,” Doppler concluded.