Dunn-Edwards Arizona Paint Manufacturing Plant

Dunn-Edwards Arizona Paint Manufacturing Plant


[MUSIC PLAYING] [MUSIC PLAYING] From the hot arid deserts
of Arizona, Nevada, and New Mexico to the cool, moist
sea coast of California, Dunn-Edwards paints are
formulated specifically for the climate of the southwest
to protect and beautify a wide variety of
architectural surfaces. Since its founding 85
years ago, Dunn-Edwards has provided more than 450
million gallons of paint to the region, enough to cover
more than 6,000 square miles of surface area. But why do so many
professionals choose to paint their most important
projects and their own homes with Dunn-Edwards paints? Because they know
from experience it’s the highest
quality paint available. In 1925, two young
wallpaper salesmen, Frank Buddy Dunn
and Charles Smith, formed the Dunn-Smith Company. And by 1927, it evolved into
the Consolidated Wallpaper Corporation of Los Angeles,
selling wallpaper and paint. By 1937, paint sales began
to exceed wallpaper sales. And the company opened
its own paint factory consisting of two used
stone mills, an agitator, a cooking kettle,
later, some rotor mills. Its crew consisted of one
man who made the paint and cooked the varnish. The next year, Arthur C. Edwards
bought into the business, becoming half owner. Sales immediately improved. And a business
philosophy was born– make the finest line of
paint, and give the best service at fair prices. It’s a philosophy that
endures to this day. Throughout the 1950s, hundreds
of thousands of new homes were built across California
and the southwest. Many of them were
painted with the brand the professional painters
recognized as the best available– Dunn-Edwards. The following decade
saw Dunn-Edwards continue to expand. [CAMERAS SNAPPING] Today, with more than 100
stores across the southwest, Dunn-Edwards remains the
foremost manufacturer and supplier of premium
architectural and industrial coatings in the region. With landmarks such as Staples
Center Arena, Caesar’s Palace, the Walt Disney Concert
Hall, and many other renowned structures all entrusting
their beauty to Dunn-Edwards, we understand the
importance of continuing our legacy of producing the very
highest quality paint possible. Towards that goal, in 2009,
Dunn-Edwards began work on a new state-of-the-art
production and distribution center in Phoenix, Arizona. The new facility includes
a manufacturing plant, product development, and
quality control laboratories, a distribution center,
store, and office space. Totaling over
335,000 square feet, it has a capacity to produce
30 million gallons of paint annually and can employ up
to 150 full time workers. For 85 years, Dunn-Edwards
has prided itself on providing world class
service and great paint. And we continue to
strive towards that. Here we’ll be able to
expand our capacity and improve our efficiency. This new facility in Phoenix
represents the next chapter in the story of Dunn-Edwards. At the heart of the new facility
is the state-of-the-art paint manufacturing plant that
produces the finest paint formulations in the world. The process begins with the
delivery of raw materials that include resins and
various paint additives. Storage capacity of more
than 400,000 gallons is used to store over 250
unique ingredients that are used in Dunn-Edwards
diversified paint lines. Many of the liquid raw
materials are stored in a 60 tank fishbowl system. Each fishbowl, which is a
275-gallon mini bulk tank stores a different additive. The weight of each
tank is precisely measured using a
floor scale which allows for accurate
delivery of small amounts of these ingredients
to a batch of paint. [MUSIC PLAYING] One method of dry
raw material addition is through our
advanced slurry system which converts
solid raw materials into liquid slurry that can be
pumped throughout the plant. This system allows solids to
be mixed 30% more efficiently. And Dunn-Edwards is the
only US paint manufacturer were to use this
slurry technology. Dry raw materials
that are not processed using the slurry
system are processed using high speed dispersers. Weight controlled
through load cells, these stainless steel tanks
provide high speed mixing to achieve specifications. The speed and height
of the mixing blades are automatically
controlled and tailored for specific formulations. These high speed
dispersion tanks use an integrated
dust capture function so that 100% of the
pigment is used in product and there are no
particle emissions. This makes good sense
both economically and environmentally. In the final mixing steps,
the end process materials and remaining ingredients
are mixed in let down tanks. These tanks gently agitate
up to 12,000 gallons of paint at a time to the final
product specifications before the filling
process begins. To design the process
control system in this plant improves the accuracy
and efficiency of paint manufacturing. There over 1,600
automated valves that are used to the materials
throughout the system. Every tank sits on its own
load cell which can precisely weigh the amount of
raw material that goes into every batch of paint. This automation ultimately
saves us time, reduces waste, and helps us create a
higher quality product. After the paint
has been produced, the job of packaging
and shipping begins. Dunn-Edwards automated
filling lines can package over
100,000 gallons per day. It starts with the de-palletizer
which automatically sorts empty cans from
pallets and places them on a conveyor to be filled. As cas speed down the conveyors,
they’re labeled and filled. The automated fillers
dispense paint into the cans based on
specific formula weights to ensure accurate fill levels,
cleaner fills, and lower product waist. One line alone is
capable of filling 44 one-gallon
containers per minute. Lids are placed on the cans,
ensuring proper placement and seal. Gallon cans are baled. Each and every can is identified
for manufacturing, quality control, and tracking purposes. The processes and technology
used in this paint plant are unsurpassed in
the paint industry. This allows us to
create a quality paint that’s consistent can
after can, batch after batch. Product is bundled
in four-pack gallons and nine-pack quarts of paint. Using a strong lightweight
recyclable polyethylene film, the bundler reduces packaging
cost by more than 50% and eliminates the waste
and energy costs associated with cardboard boxes and trays. As product completes
its journey, the palletizer stacks bundles
of one-gallon and quart cans onto pallets. The pallet wrapper wraps
the pallets with film. It uses a pre-stretched
carriage that allows the film to be stretched
up to 300% for optimal use and cost savings. This saves the equivalent
of approximately 60 miles of unstretched film per year. Larger five-gallon containers
go through much the same process as the gallon and quart cans. [MUSIC PLAYING] One step that is different
is the palletizing of the five-gallon buckets. Here, a robotic arm actually
lifts and stacks the buckets. It’s capable apologizing up
to 60 five-gallon buckets per minute. The robot offers a safer,
quieter, and more energy efficient alternative to
traditional palletizing technology. This plant can be described
as an ultra-low discharge facility, meaning waste
generation is minimized. In addition, the entire
design and construction followed LEED guidelines and
has achieved LEED certification. This is all in keeping
with Dunn-Edwards greener by design philosophy of being
as eco-efficient as possible. From the company’s first paint
factory in the 1930s to its industry-leading practices to
develop environmentally safer formulations, Dunn-Edwards
continues to set new standards of quality with the opening
of this state-of-the-art eco-efficient paint factory that
will pave the way into this new century. Dunn-Edwards was founded on
strict standards of excellence backed by stringent
quality control, testing, and eco-efficient principles
to assure the finest and safest paint products possible. Our highly precise
computer-controlled manufacturing process results
in the best formulated, most reliable paint and
coatings in the industry: can after can,
batch after batch. No wonder Dunn-Edwards paint
is the number one choice of painting and
design professionals. In fact, more
painting professionals paint their own home
with Dunn-Edwards than any other paint. We could think of no
better endorsement. Dunn-Edwards– the
number one choice of painting professionals.

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