What We Did
Project Overview
Since 1998, American Polyfilm, a family-owned company, produces made-to-order blown polyurethane films serving medical, performance textiles, protective garments, food processing and petroleum markets.
Industrial
New Construction
Testimonial
What the client had to say about us
Testimonial
"We selected Munger because we’ve always had a good feeling about their people and with the way they do business. Their traits include straight talk at meetings, being easy to understand, receiving sterling reference checks, and they were skilled and graceful at accommodating our changes. They were our partner through all our decision steps."
Victor Cassella
President, American Polyfilm
Case Study
The Situation
Growing demand and a new line of medical products required additional manufacturing capacity and the consolidation of production, storage and administrative functions that were located in multiple sites.
Problem
The Challenges
1
To construct a new, state of the art, energy efficient facility, which features a 4-story steel tower that rises above the roofline to enable the blown film manufacturing process and to allow the film to cool and cure as it is drawn upward.
Solution
The Resolutions
1
The new 27,500 sq. ft. Varco Pruden pre-engineered steel building includes a continuous beam frame system with tapered beams and interior columns. The exterior integrates a 24-gauge steel, galvalume coated, standing seam roof system with 26-gauge, galvalume, steel panel rib siding.
2
The interior includes a panel rib liner in production areas and dividing partition wall between warehouse and production areas. A 54 ft. high x 30 ft. wide x 100 ft. long landmark production tower rises above the roofline.
3
Architectural elements include careful window placement, single slope roof, window and door canopies, galvalume siding, polished concrete floors in offices, ceramic tile in bathroom and shower stalls, stainless steel cladded reception counters, and interior glass and wall systems.
4
Energy efficiency is a building hallmark. Skylights and windows provide natural daylighting with LED lighting throughout the facility. The EnergyStar rated HVAC system creates a positive air pressure environment that is “pumped up” with more filtered air than the outdoor space and minimizes the amount of untreated air infiltrating the building when doors are opened. The sloped roofing system was designed to maximize solar gain for a planned future PV Solar system installation.
Outcome
the final product
The new facility will accommodate growing demand and bring significant business efficiencies by consolidating production, storage, and administrative functions that were previously spread across multiple sites. This consolidation has doubled production capacity to support business growth while saving time and money through improved process efficiencies. The state-of-the-art work environment has also boosted employee morale and created a professional atmosphere that enhances APi’s credibility with customers. The facility differentiates APi from competitors by minimizing the infiltration of untreated outdoor air, contributing to a cleaner and more controlled process environment. Additionally, by exceeding state energy efficiency building codes by 30%, the project qualified for a $90,000 rebate from Eversource.