FERNLEY, Nev. (KOLO) -- In your next Made in Nevada report we're featuring a business that is helping fuel our areas insatiable demand for new homes by producing energy-efficient vinyl window and door systems.
Production Supervisor Chris Hanson holding regrind
Deceuninck North America finished construction on its 125,000 square foot warehouse at 240 Nevada Pacific Parkway in Fernley in September of 2016 and started operations the following month.
"Right now we're sitting on 26 acres of property so we're able to triple in size," said Deceuninck Production Supervisor, Chris Hanson.
Tripling the size of the warehouse would make it a sizable 375,000 square feet. Company leaders apparently see the potential for home growth across the western part of the United States and it's fiercely working to build the best window and door frames.
"We produce roughly 1,000,000 pounds a month," said Chris.
Now, we're going take you through the process from start to finish how the frames are made.
Chris held a white powder in his hand as he said, "This is our regrind. It's actually been pulverized. It was once an actual window profile. Kind of like sugar consistency."
The material is Polyvinyl Chloride or PVC. It's a plastic polymer. It comes by the train cart load and is pumped out through a pipe to one of two large silos.
"Each silo holds 350,000 pounds of PVC compound. Combined, they hold 700,000 pounds, that's almost about three weeks supply for us," Chris said.
Then, the PVC is pumped through pipes from the silos into the warehouse and eventually to one of the many hoppers.
"Gravity fed down. Goes through a magnet that will pull out any impurities or metal. It comes down and it's fed into the extruder here," Chris said.
The extruder barrel turns the PVC powder into plastic with heat between 330 and 350 degrees Fahrenheit, friction, and pressure.
The hot liquid is pushed through a mold and slowly cooled until it hardens into a solid shape.
The plastic then enters a large water container to continue the cooling process. It eventually emerges and is met by small dryer tubes to remove the lingering water.
It is then cut into the size needed and stored until it's shipped away for sale.
Several lines like the one explained above run at the same time.
Each part is made to precision and will eventually be pieced together to fit into a window or door frame, which will help feed the growing housing needs across the western portion of the United States.
Thirty-four people report to work at Deceuninck, but the Company is hiring two more people to work the night shift.
The European-based company has 32 facilities similar to the one in Fernley spread between 30 different countries.
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