Listen to this article

The new $15 million greenfield manufacturing facility for ResinDek. | Image credit: ResinDek

The growth in the warehousing market is reaching all corners of the warehouse supplier market. One of the core suppliers for warehouse infrastructure is engineered flooring supplier ResinDek. Cornerstone Specialty Wood Products, LLC, the manufacturer of ResinDek, and its parent company, Universal Woods, have invested in the construction of a new, $15 million greenfield manufacturing facility. Located in a suburb of Louisville, Kentucky, the plant will enable Cornerstone to increase its manufacturing output to more than double its current capacity.

ResinDek is used in the construction of mezzanine floors in a warehouse or any where you deploy autonomous mobile robots. The engineered flooring provides the ideal surface for the AMRs to operate.

Engineered flooring can be used for a number of warehouse and manufacturing facility use cases. | Image credit: ResinDek

“Our business has grown dramatically over the past two years, for which we are extremely grateful,” said Greg Doppler, inventor of the ResinDek flooring panel and president of Cornerstone. “As a result of this tremendous growth, we are approaching the upper limits of our current production capacity. This investment will ensure we are in position to deliver ResinDek products quickly to our valued customers well into the future.”

Composite engineered wood flooring panels have the proven structural integrity to support dynamic and static pallet jack load limits from 2,000 – 8,000 lbs and the rigorous demands of robotic traffic such as AGVs and AMRs. ResinDek flooring panels have been independently evaluated and approved for use in Types I-V construction and as part of a fire-resistance rated assembly by the IAPMO Uniform Evaluation Services.

“The new facility’s footprint is more than double the current footprint, enabling us to carry more inventory and manufacture products faster. That combined with a design that incorporates significantly more dock doors for shipping and receiving, will allow us to reduce lead times,” added Scott McGill, director of sales at Cornerstone.

“The new equipment will not only increase quality and manufacturing output, but also provide a wider array of opportunities within our new product development program. This will allow us to continue to offer a fantastic value proposition to our customers,” states McGill.

The new facility, located at 264 Eiler Avenue in Louisville, near the UPS Worldport and Louisville International Airport, will be staffed by the same production team working at the existing operation. In advance of its construction, Cornerstone added additional employees in 2021 in anticipation of the expanded production capacity. “Starting them ahead of the new plant’s construction allows them to become familiar with the ResinDek production process before the new facility goes live,” added Doppler.

Equipment is slated to be installed and commissioned throughout January 2022, with partial production beginning shortly thereafter. The new coating and curing machinery are scheduled for installation in the second quarter of 2022.

“We expect to be fully operational in the third quarter of 2022 and look forward to celebrating Cornerstone’s new capabilities with a Grand Opening ceremony at that time,” Doppler concluded.