PAXINOS - The first production line at Polar Tech Industries' new plant in Reed Industrial Park along Route 487 could begin operating as soon as early November.
Barring any complications, a production line to create Polar Tech's RE-FREEZE-R-BRIX foam refrigerant packs will be the first up and running at Northumberland County's newest manufacturer, company officials said Monday. A production line to create the company's ICE-BRIX gel refrigerant packs should follow later next month.
Once operations begin, officials said products could be shipped within the first week.
Virginia Pawelczyk, production manager at the plant, said the first line will employ up to six people. About the same number will be hired for the second line, and more will be brought in as additional production lines and, toward November's end, the firm's foam plant are established.
Company officials said Sept. 22 when it was announced Polar Tech would be coming to the county that approximately 50 full-time jobs with hourly wages ranging from $12 to $22 would be created.
Polar Tech occupies the older of two buildings formerly used by Fleetwood Enterprises in the industrial park. On Monday, three full-time and three temporary employees were working to prepare the plant for the arrival of machinery, materials and more.
Production process
Bob Morelli, facilities manager, said Polar Tech would initially use one-third of the building and up to one-half in the future. The remaining space allows for storage, Morelli said, and additional growth.
The building was purchased in cash for $999,000, said Frank Garrigan, Polar Tech attorney, who is also the county solicitor.
"They didn't get any tax breaks from the county and they didn't receive any grants, that I'm aware of," he said.
Morelli explained the processes for creating three products among the company's dozens that will first be manufactured at the plant.
The foam bricks, he said, are fairly simple. Water is mixed with chemicals to keep it from crystallizing when it's frozen. The foam is soaked in a tub and shaped by steam. They're packed into plastic and sealed before shipping.
For the gel packs, the chemicals are mixed, metered and pumped into plastic bags, which are sealed, cut and packaged for shipping.
For the company's foam containers, which come in various shapes and sizes, a boiler creates steam, which is channeled through a machine that expands polystyrene beads resembling powder to a size of 1 mm to 2 mm. They're fed into a foam press and blown into aluminum molds, which are then clamped and shot with steam for greater expansion. Thousands of beads fuse together to create the shape. Once the containers are formed, they're cooled with water and dried and are ready to ship the same day.
Morelli said about 5 percent of foam damaged during production is recycled and reused.
Back in the building
Pawelczyk and Morelli are no strangers to the building. They were both employed by Fleetwood before the company closed its operations in the county - Pawelczyk as a manager and Morelli as a manufacturing engineer.
Together, they visited Polar Tech's headquarters in Genoa, Ill., to get a better grip on company operations.
"I just got the chance last week to go out there and look at it, study the machinery," Morelli said.
Pawelczyk held her forefinger and thumb apart about 2 inches when describing how many applications she thought were returned to Sunbury CareerLink.
"That whole time we were in Illinois last week, I know my phone and Bob's phone was going nuts from people back home here looking to get hired," she said.
Pawelczyk and Morelli are both surprised - and happy - to be back working in the facility, vacant since 2008.
"I honestly thought I would never be in this building again, but it's nice. It's not strange. I like it," Morelli said. "It's nice to see it being used and used efficiently."
Pawelczyk said applications are still being accepted through CareerLink. She expected the company to begin contacting applicants within the week.