Toray Plastics: US$40m expansion of foam manufacturing facility complete

22 Jun 2018 --- Toray Plastics has completed a two-year US$40 million expansion at its PEF Division in Front Royal, Virginia. The company officially launched a new extrusion line, a new irradiation unit, and a new salt bath unit with a ribbon cutting on May 22. Toray’s PEF Division is North America’s and Europe’s premier automotive supplier of blended polypropylene-polyethylene foam that offers consistent thickness and density.

The state-of-the-art equipment is housed in two new buildings that cover 74,000 square feet. The new extrusion line provides the company with manufacturing flexibility and the irradiation unit has doubled irradiation capacity. The new salt bath unit, the company’s third, has increased capacity by 170 percent. This will enable PEF to meet the growing demands of the markets it currently serves and to export Toraypef and ToraSoft products to China as well. The investment will also allow the Division to supply unique products to industrial markets.PEF’s third generation of ToraSofthas been under development for the past year and is targeted for commercialization now that the expansion is complete. Toray anticipates that the expansion will create 30 new jobs.

“This is a significant investment and a significant victory for the Commonwealth of Virginia, as Toray is one of the Northern Shenandoah Valley’s largest employers and a valuable corporate partner to the region and the state.” She added, “This administration is committed to supporting Toray’s continued success in Front Royal,” says Deputy Secretary Navarr, After speaking, Navarro presented Mike Brandmeier with a flag that had been flown over the state capitol.

Mr. Nikkaku noted that the expansion is the largest in PEF’s history. He said that he hopes Toray’s presence in Virginia will continue to benefit the state’s economy and Japan’s relationship with the United States.

Hoketsu commented that the PEF Division has accomplished a great deal over the past 20 years and that its future looks very bright. He expressed gratitude for the support of the state of Virginia, Warren County, and the town of Front Royal. He also acknowledged the project contractors, all of whom completed the work safely and on time. Hoketsu concluded by thanking the Division’s customers for their collaboration on growing the market and confirming Toray’s commitment to long-term growth.

The PEF Division was founded in 1996 to produce polyolefin irradiation cross-linked foam, Toraypef foam, and ToraSoft foam for the automotive interior trim and industrial markets.