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Pipedream’s New State-of-the-Art American Rubber Manufacturing Facility

By on January 11, 2015
Pipedream Basix

Pipedream now produces American-made PVC and TPR at their new, state-of-the-art manufacturing facility in Chatsworth, California. The manufacturer has been producing its own rubber in the US since 2007, but a challenge appeared in 2013 when the internal production of the Basix collection could not keep up with the high sales demand. Chairman and CEO Nick Orlandino immediately went to work to alleviate this issue, and a plan was quickly put in place using lean manufacturing principles to redesign and implement a new process. Orlandino acquired a 50,000 square foot building just a few blocks away from Pipedream Headquarters, and complete renovations were made – the new facility has seen state-of-the-art manufacturing equipment installed; each individual mould has gone through a re-plating process in order to sustain more pours; extruder machines have been revamped to offer better control of the fill process; and proprietary cooling systems were installed to reduce moulding times.

At the heart of the new manufacturing facility is Pipedream’s customized cooling system, a fully automated process designed to cool the product and recycle the moulds as quick as possible. In the previous facility, freshly poured product went through a 24-hour cooling process before the items were ready for finishing and packaging. Today, a brand new dildo is poured, packaged and ready to ship in just one hour! Moulds run on a conveyor belt through a cooling tunnel that blows cold air directly on the mould, allowing workers to remove the product immediately and freeing the mould for the next pour.

Facility overhead view

From the cooling tunnel, the extracted pieces are moved to a high-tech cooling bath, which quickly drops the rubber’s temperature and preps it for handling. An automated conveyor system transports the dildos from the cooling tank to the finishing area, where workers trim and smooth the product and prepare it for packaging. Once the items are packaged, they’re boxed in master cartons and ready to ship.

Cooling Tank1CoolingTunnel2

This improved procedure has increased fill rates by 140%. The manufacturer now has the capacity to produce 5,000 packaged and ready-to-ship products per day (25,000 a week) and expects to double this capacity with additional work shifts. Employees now have a bigger, well-organized workspace, and have been issued new tools and procedures to ensure the highest quality and most efficient production and packaging.

The new system has been tested, debugged, implemented, and is currently fully operating and running smoothly. Pipedream now has the ability to produce 1.2 million products a year on a regular 40-hour workweek, which will be easily doubled by adding a second shift.

Finishing3 Finishing2

In addition to new collections, such as Real Cock, which will serve as the first line conceived in the new facility, to debut at January’s 2015 ANME show, Pipedream also has the capacity to offer private label manufacturing for any sized customer. The new process, systems, and equipment will make Pipedream the largest manufacturer of rubber and TPR in America.

“With the flood of cheap, non-compliant Chinese imports in the market today, Pipedream has built the ultimate facility to bring manufacturing back to America. By doing so, we can offer better quality, compliant, body-safe products in large volume at competitive prices, and we can do it faster and more efficiently than any other manufacturer, “says Pipedream Chairman and CEO Nick Orlandino.” Pipedream is known for 95% fill rates on our entire product line, and this new facility will help us maintain this standard.”

“We’ve brought Tony on board, a 27-year industry veteran of rubber manufacturing and product development to help lead the way, and his vast knowledge of new materials and proven techniques will be a valuable asset to our team. Our Senior Vice President of Operations Pete Ledeboer has an extensive background in manufacturing for mainstream companies like Mattel, Kransco and El Dorado Stone, and he’s helped develop and implement large scale manufacturing processes that will help us make the highest quality products at the best prices.”

TonyHernandez

Ledeboer is equally excited about the new facility and can’t wait to help make Pipedream the leader in rubber production.

”I have been involved for twenty plus years with slowly moving manufacturing from the United States to either Mexico, China, Indonesia, or the next low labor market on the horizon due to labor costs,” said Ledeboer. “My goal, starting with the Basix area, is to remove as much non-value added cost to our product lines, using lean manufacturing principles, so that as many of our current and future products can possibly be made in the U.S.A. in a high quality, efficient manner.  Every time that we are successful at this strategy, it will help Pipedream achieve timely new product introductions, quicker reaction to market, less complex supply chain management, and ultimately, higher customer satisfaction.”

The Real Cock Range

This new 50+ piece collection offers the most realistic PVC dildos ever created in America. Made in the USA from phthalate-free, latex-free, hypoallergenic PVC rubber, there are 18 unique styles available in three colors – flesh, brown, and black. Each piece has been handcrafted and sculpted with meticulous attention to detail to offer the most lifelike beginner’s dildo ever imagined. You would never believe that these lifelike dildos are made with PVC – the firmness and consistency of the material along with lifelike textures, intricate decorating, and impeccable finishing make these dildos look better than the real thing!

Pipedream’s goal was to create an affordable alternative to their more realistic, (and more expensive), Real Feel Fanta Flesh collections. “We’ve taken the most affordable material on the market and transformed it beyond what most people imagine when they think of PVC,” said VP of Development Rob Phaneuf. “Though both collections are made with PVC, the Basix range features the traditional transparent look that’s associated with jelly toys – but the Real Cock collection looks and feels like a completely different range. From better Moulds to even better manufacturing to extremely detailed decorating, the entire manufacturing process has made Real Cock the best beginners PVC range on the market.”

Every dildo features a super-strong suction cup base for wall banging fun and harness compatibility. From 6-inches to 12-inches long, balls and no balls, double dongs and anal plugs – the variety of shapes, sizes, and styles truly ensures satisfaction for everyone.

The collection comes packaged in clear clamshell uniform packaging, alongside the world-renowned Pipedream marketing machine. With custom planograms, physical and digital catalogues, cutting-edge art and videos, branded signage, and hands-on training by request, Pipedream offers everything that distributors and retailers need for optimal merchandising, both in-store and online.

www.pipedreamproducts.com

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