Lean manufacturing, training, new technology and some innovation are helping these woodworking manufacturers increase production while improving quality and efficiency. What follows are some of the methods put in place by the 2019 WOOD 100 class, which includes cabinet manufacturers, residential and office furniture producers, architectural woodworkers, wood component manufacturers, closet companies and more.

Now in its 30th year, the WOOD 100: Strategies for Success highlights the innovative as well as tried-and-true initiatives put in place by 100 North American wood products manufacturers to grow their businesses. Here's what some of them had to share for productivity enhancements:

California Woodworking, Oxnard, CA —  Key steps that led to the cabinetry and countertop firm’s success in 2018 include upgrades in the fabrication department and doubling the number of estimators from one to two, allowing the company to service more customers, said Luke Vickery, president.

California Woodworking also added a residential cabinetry division to its portfolio, as well as a showroom to display product offerings.

“In 2019, we are considering the purchase of another CNC machine. We are also considering opening a stone countertop fabrication facility,” Vickery said. “We also purchased software that assists our production line with efficiently sorting cabinet parts, which has led to increased productivity.”

Sales expectations for this year and next are “excellent,” he added.

JB Cutting, Mt. Clemens, MI — The components manufacturer invested in technology and focused on efficiency improvements to increase productivity and profitability.

“Although we stayed flat and didn’t show growth over 2017, we were more profitable by focusing on efficiencies and rework, said Debra Behring, president.

The company’s recent investments in technology include nested-based CNC routers, a flipper and buffing station for the press and another five-piece door machine.

Founded in 1995, JB Cutting specializes in 3D laminate and five-piece doors, drawer fronts and accessories for the kitchen, bath, home organization, store fixture, and healthcare furnishing environments.

Plato Woodwork, Plato, MN —  With more than a century under its belt, the custom frame and frameless cabinetry firm continues to be successful in today’s residential marketplace.

Contributing to Plato’s success has been a “focus on our true strengths, focus on key accounts, retention of employees and capital investments,” said Karl Pinske, president.

Among the technology investments by the company last year were a CNC router, moulder, and finishing equipment. Additional purchases in 2019, including straight edge and contour edgebanders, return conveyors, case clamps and solvent recovery systems, should increase Plato’s productivity and profitability even more, Pinske said.

2018 fiscal sales grew 8.9%, and the cabinetry manufacturer expects 2019 figures will exceed that number, with 2020 also projected to be a good year.

Elias Woodwork, Winkler, MB — “Product development according to market trends and then the ability to increase productivity were key to our growth last year,” said Jeremy Funk, executive vice president - Sales & Marketing.  “We also added more automation and expanded the workforce in key areas to satisfy customer expectations of product selection and quick turnaround times.” 2018 sales grew 17.7%.

Elias’ products are used in a variety of industries, including new kitchen and bath cabinets, refacing, commercial and residential millwork, renovations, and RVs. Elias manufactures cabinet doors, mouldings, dovetail drawer boxes, curved doors and components, refacing material, RTA cabinets and wood accessories.  The company also produces thermofoil and DLV doors and accessories at the 375,000-plus-square-foot facilities.

Top Producers

Bella IMC, Huntertown, IN

Sales are booming at Bella, which manufactures cabinets to order from its online customizable ordering system. “There is only one key step you can ever make that leads to success for any business and that is adapting and making the necessary changes to stay ahead of the curve. We constantly improve our processes in the office and on the manufacturing floor,” said Chad Shelton, president. New technology, including a Morbidelli CNC router, Stefani edgebander and Kaeser compressor, also helped “double our production output,” said Grant Weber, director of Operations & Sales.

AB&D Furniture Mfg., Homewood, IL

Sales have been steady for the 30-year-old manufacturer of OEM and branded library and office furniture. Investments in technology over the past few years, including CAD/CAM software and an automatic contour edgebander, enabled it to reduce its employee size from 25 to 15. “Now employees hired are for increased production,” said Randy Agate, president & owner.

Caseworx, Hudson, NC

Sales at Caseworx grew 43.8% last year, due to “more efficient communication and streamlined processes,” said John Bostian, GM. Projections for 2019 and 2020 are also very positive for the manufacturer of architectural millwork, plastic laminate cabinetry, laminate and solid surface countertops, and finished wood cabinetry.

TNT Door & Drawer, Covington, GA

The custom cabinet components manufacturer increased productivity through process improvements in material handling, layout strategies and other various processes, said Eric Crane, GM. The firm also made “data-driven decisions on capital equipment purchases,” including a Doucet rotary door clamp.

Appalachian Wood Products Inc., Clearfield, PA

Winner of a 2019 WMIA Wooden Globe Award, the components firm’s improved its production by investing in technology, including a DMC widebelt sander and planer-sanders from SCM, a Weinig gang saw system, and Timesavers planer-sanders.

Millwork 360, Tampa, FL

“From 2017 to 2018 we increased our sales 30% by drawing more out of our existing customer base, expanding into the Caribbean market, and re-configuring our production layout and lean processes to increase output and efficiencies,” said Jamie Burge, CFO. To aid productivity and maintain its 7-10 day lead times on custom moulding, Millwork 360 added a Weinig Powermat 700 moulder, its fourth moulder.  “Another key capex investment is our Factory Finishing Facility, which allows us to do all pre-finishing in-house. The majority of our doors are sent out pre-finished as a result, which adds 20% of revenue to our top-line door revenue.” Millwork 360 also saw its fiberglass door line grow in sales.

Lifetime Design Corp., Deer Park, NY

“In 2018 Lifetime Design made the strategic decision to implement Lockdowel hidden fasteners for our cabinetry. Not only did this allow easier transportation to the jobs, it saved us a considerable amount on labor,” said James Romanelli, president.  “Because we were able to hire people with little or no experience and train them to assemble cabinetry, it has been easier for us to hire and has allowed us to be more aggressive with our bidding –- and win more jobs.” The company is also able to meet tight schedules, and increase gross sales. 2018 sales for the commercial woodworking and architectural millwork firm grew 22.9%.

Rynone Mfg. Corp., Sayre, PA

Along with the addition of several new CNCs, President Richard Rynone credits a “continued concentration on lean manufacturing principles, product development, quality and excellent customer service,” with spurring the cabinet, casegoods and countertop manufacturer’s continued success. Sales for the multi-million dollar firm grew 2.9%.

Victor Robbins Group LLC, Hainesport, NJ

The architectural woodwork firm focused on hiring personnel, lean manufacturing progress through the implementation of multiple hand tool and supply stations, as well as company-wide improvements including finishing and software, said Robert Schultz, sales. 2018 sales grew 11.8%.

Cabinet Solutions, Brantford, ON

Sales grew 66.7% for the casegoods supplier to custom millwork firms, with 2019 and 2020 projections also looking good. “New ownership invested in software and streamlined the information flow to existing high-quality machinery,” noted Drew Neven, GM. New technology includes the 2018 purchase of Microvellum software, and an SNX contour bander in 2019.

Bernhard Woodwork Ltd., Northbrook, IL

President Mark Bernhard credits employee skills and new technology for the architectural woodwork and retail fixturing firm’s continued success. The firm installed a complete SCM manufacturing system “to streamline basic cabinet manufacturing for speed and price,” including CNC router, boring/doweling system and edgebander, as well as a case clamp and wrapper in 2018, with a sander and veneer press on tap for 2019.

Family Woodworks, Piketon, OH

“Upgrading equipment (including a planer, jointer and gang ripsaw) allowed me to be more efficient and increase production, along with maintaining a high-quality product,” said George Barlow, owner. The firm makes white oak picture framing and custom trophy bases for sale to art dealers and galleries, plus retail. 2018 sales grew 23.2%

Heritage Woodworks, Suffolk, VA

“We worked on standardizing and improving processes, which correlated to more consistent productivity and quality,” said Daniel Hooper, CEO. The custom cabinetry firm also invested in new technology, including a door machine and edgebander 2018 sales grew 30.1%.

Dartmouth Woodworks, Waltham, MA

The custom casework and millwork shop’s sales grew 33.3%, with 2019 and 2020 projections also “excellent,” said Ari Monias, shop manager. He noted the company “recognized areas that needed to be developed and is always open to ideas.” To aid productivity the company purchased a Homag widebelt sander last year, with 2019 purchases including an edgebander and vertical CNC.

Nations Cabinetry, San Antonio, TX

“We were able to grow sales revenue by 6% through a focused approach to delivery, quality and team engagement,” said JW Coady, CEO of the cabinetry firm. “We constantly look for ways to add value in to our product streams by embracing innovation.” Technology purchased in 2018 includes a Holz-Her hybrid edgebander Koch drill/dowel, and Dynma fully automatic case clamp.

Precision Wood Products,  Inc., Camden, OH

The manufacturer of wood door and drawer fronts and specialty products upgraded its finishing and sanding operation, invested in equipment including an automatic chop saw, and made upgrades to shipping and packaging to reduce damage, said John Herig, regional sales manager. “We maintained a 10-day lead time and kept deliveries consistent.”

The Closet Works, Inc., Montgomeryville, PA

A lean manufacturing/Kaizen advocate, “We are continually exploring new technologies, systems and methodologies to improve our customer experience as well as our employee experience,” said David Cutler, president. 2018 sales for the manufacturer of custom organizing systems grew 10.4%.

S&S Woodcraft, Cold Lake, AB

Custom cabinetry and millwork firm’s sales grew 27.6%. “Our major focuses included, standardization, automation and improvement of flow within our facility,” said Christopher Savic, director. The company has seen a substantial reduction in inventory, shortened lead times, improved tracking and scheduling and a reduction of errors and defects.

The 2019 WOOD 100 is sponsored by Pollmeier Inc.

Read more 2019 WOOD 100: Strategies for Success

Marketing Initiatives

Business Strategies

Productivity Enhancements

Technology Integration

Product Innovations

Customer Service

Return to WOOD 100 main page

Read the special 2019 Leadership issue of FDMC online

New product innovations are opening doors to more business for these 2019 WOOD 100 companies. This year's class includes cabinet and casework manufacturers, residential and office furniture producers, architectural woodworkers, store fixture manufacturers, wood component manufacturers, closet companies and more.

Now in its 30th year, the WOOD 100: Strategies for Success highlights the innovative as well as tried-and-true initiatives put in place by 100 North American wood products manufacturers to grow their businesses. Here's what some of them had to share about their product innovations:

Decore-ative Specialties, Monrovia, CA —  The company was awarded Patent No. 9,845,637 for its invention of the Elk Grove Design, a unique 3-piece, custom cabinet door and drawer front, that is CNC routed and pressed with 3D laminate.

“Appearing to be 5-piece construction, these components are produced by a patent-protected process offering custom inside profiles, raised or recessed panels, and custom size frame widths,” noted Joel Boyles, vice president. The cabinet doors and drawer fronts are complemented with a  collection of mouldings and accessories.

Decore-ative Specialties provides custom cabinet components to the kitchen, bath, closet, garage, office, remodeling, and refacing industries. Product offerings include: RTA cabinets, doors, drawer fronts, drawer boxes, mouldings, accessories, finishing and hardware. Products are manufactured in wood, plywood, 3D laminate, melamine, and aluminum.

Northern Contours, St. Paul, MN —  The cabinet and commercial components manufacturer serves the kitchen and bath, home organization, refacing and contract furniture markets, with products including wood veneer, 3D laminates, acrylic, FENIX NTM and 5-piece doors. 2018 sales grew 14.0%.

“Our manufacturing expertise resides in membrane pressing, miter folding, laminating and edgebanding, machining and routing, and 5-piece door assembly,” said Melissa Sjerven, marketing director.

In 2018 Northern Contours acquired Nubold Industries in London, Ontario. “This added another manufacturing facility, with capability in membrane pressing and 5-piece door assembly. We also continued our successful approach to product innovation with key product introductions, focusing on the latest advancements in EIR and smart matte technology.”

More hot products

Stevens Industries Inc., Teutopolis, IL

“We focused on bringing our products to new markets, extending geographically and expanding end user markets,” said Amanda Emmerich, marketing coordinator & social media manager. The company specializes in highly detailed architectural millwork and casework, including embossed in registration panels, coordinating surfaces and products. 

Scane Custom Cabinets, Brea, CA

Sales at the custom cabinet firm grew 7.7%.  Among the key steps, “We began producing high gloss acrylic cabinets in addition to our normal finish types. The high gloss material allowed us to try new techniques with our edgebanding machine.” Cross-training on the edgebander “has made us more versatile and better equipped to handle the growing demand for high gloss acrylic cabinetry,” said Zach Scane, designer/operations manager.

W.W. Wood Products, Dexter, MO

“We have put an emphasis on reacting quick to market trends so that our product is always fresh,” said Kenneth Carmode, VP sales & marketing at the made-to-order cabinetry firm. “Additionally, quality is of the utmost importance as consumer expectations are at all-time highs.” The strategy worked, as sales grew 9.5% in 2018, and look good for 2019.

Rosehill Wine Cellars Inc., Mississauga, ON

“Staying current with the latest trends in this industry,” helped the custom wine cellar producer grow sales 6.6%, noted Gary LaRose, president. “We’re also producing unique designs to showcase our skill set.”  

The Wood Cycle of Wisconsin, Oregon, WI

The “Tree to Table” author works with area arborists for trees, which he then mills and kiln dries. “From this wood we make almost anything,” said Paul Morrison, president. “Our top area of work is large live-edge dining and conference tables and other furniture, but our business model is more broadly ‘find a good client and make whatever they need in wood.’” 2018 sales grew 11.8%.

Thomas James Cabinetry, Bracebridge, ON

Developing a new line of outdoor kitchens, hiring employees and taking the lead in sales and marketing has kept Darragh Hughes, partner/owner, busy. Sales grew 50% for the indoor and outdoor kitchens and custom furniture firm.

Wetimber, SA de CV, Mexico City, Mexico

Sales grew 25.0% for the maker of wood facades and exteriors, doors and windows, as well as accent pieces for interiors. “Utilizing ‘value engineering’, we are able to deliver superior products at a reduced cost,” said Craig Caughlan, co-director. Primary woods used include accoya, white oak and cedar from sustainable growths.

Fine Creations Works in Wood LLC, Farmingdale, NY

“We specialize in architectural millwork, cabinetry and components, as well as CNC contract and specialty work and new product development,” said Michael Lohnes, owner. The company’s success also comes from “combining longtime woodworking experience from valued employees and modern technology and machinery,” he added.

Osborne Wood Products, Toccoa, GA

Celebrating its 40th anniversary, the components maker supplies the cabinetry, remodeling and furniture markets. New products include those that mix media, such as acrylic or steel with wood. “We have come a long way since we started the business, and I look forward to building on our tradition of innovation and excellence for years to come,” said CEO Leon Osborne.

The 2019 WOOD 100 is sponsored by Pollmeier Inc.

Read more 2019 WOOD 100: Strategies for Success

Marketing Initiatives

Business Strategies

Productivity Enhancements

Technology Integration

Product Innovations

Customer Service

Return to WOOD 100 main page

Read the special 2019 Leadership issue of FDMC online

Member programs,  targeted marketing, online ordering and promotions, social media and increased networking opportunities are just some of the ways the 2019 WOOD 100 companies keep their names and brands at the forefront of customers' minds. This year's WOOD 100 class includes cabinetry and closet manufacturers, residential and office furniture producers, cabinet and casework manufacturers, architectural woodworkers, store fixture manufacturers, wood component manufacturers, closet companies and more.

Now in its 30th year, the WOOD 100: Strategies for Success highlights the innovative as well as tried-and-true initiatives put in place by 100 North American wood products manufacturers to grow their businesses. Here's what some of them had to share for marketing initiatives:

Closet America, Landover, MD —  The large manufacturer of custom closet and home organizational systems continues to find innovative ways of marketing its brand.

“We expanded our sales staff, diversified our marketing approach, and created a client-centric environment that puts the needs of our clients first,” noted Tim Brooks, marketing manager.

This year also saw the launch of the President’s Club for top designers and Closet America University, a new training facility for designers and installers to expand their expertise.

On the manufacturing side, Closet America continues to invest in technology, including a new Schelling panel saw.

Following a 17.6% growth in 2018, the company projects 2019 sales to be good, and 2020 to be excellent.

Ethan Allen, Danbury, CT —  The manufacturing and retail home furnishings giant has launched a Member Program to enhance customers’ experience and provide special benefits.

For an annual membership cost of $100, Ethan Allen Members receive everyday savings of 20%, plus free shipping and premier in-home delivery.

“The new membership program puts our customers front and center,” said Farooq Kathwari, chairman and CEO. “Our members will no longer have to plan projects around short-term sales and promotions; instead, they will enjoy consistent, predictable and attractive everyday savings on products for any room in their home,” he added. “This level of value, enhanced by our complimentary design service, creates a customer experience that’s second to none.”

More top marketers

Jim Farris Cabinets, Pasadena, TX

Owner Jim Farris’ strategy was simple and succinct. “Reaching out to past customers when things were slow,” he said, helped the high-end cabinetry and furniture design and fabrication firm keep profits and productivity on the path to success, with 2019 and 2020 sales both projected to be good.

Birdie Miller Designs, Stockton, NJ

Sales projections continue to be good for the custom cabinetry, furniture and interior woodworking firm. Owner Birdie Miller said he relies on social media, phone calls, and customer referrals to spread the word about his products. Miller is also the creator of the EuroButt faux butt hinge. Sales grew 8.3% in 2018.

Saroyan Hardwoods, Huntington Park, CA

“Marketing the company in new, innovative ways, bringing in additional experienced personnel, and organizing the sales force,” have helped the hardwood products manufacturer continue its success, said Jeffrey Saroyan, sales manager. “We sell our premium products for a variety of commercial, residential, and hospitality projects nationwide.” Equipment purchases, including a flooring line, should help sales grow even more in 2020 for the flooring, moulding, and custom millwork producer. 

Timberline Cabinet Doors Inc., Cedar City, UT

The company’s wood doors, drawer fronts, custom mouldings, RTA cabinetry and closet components are made to specification and “sold to contractors, home builders, and the general public through our easy-to-use online ordering system and 3D cabinet designer,” said Brett Messer, COO. 2018 sales grew 5.7% at the firm, which also focused on creating a team atmosphere, training and upgrading equipment, including a custom Voorwood shape and sand.

Hardwood Floors, Hillsboro, WI

“We look for customers that have an eye on product quality and timely service with a personal touch,” said Salena Ball, owner of the hardwood flooring and paneling manufacturer. 2018 sales grew 20.0%, with 2019 sales also looking good.

A Better Closet, Calera, AL

Sales for the closet and home storage solutions manufacturer grew 27.9% in 2018, and projections are excellent for 2019 and 2020. A key emphasis on customer service, plus increasing the advertising budget to 6% of its gross sales, helped spur growth, said Robert K. Duff Sr., owner. New equipment included a Kaeser rotary screw compressor.

URDrawer, Clearwater, FL

“By creating a function on our website customers can upload an exported file from their kitchen design software to seamlessly order their drawers and or quotes/orders can be inputted per line item to get exact pricing at that point of time,” said Randy Koch, GM. Customers also can track production status. Sales for the dovetail drawer and pullout storage firm grew 47.7% in 2018.

Morantz Custom Cabinetry Inc., Ft. Lauderdale, FL

The firm markets complete home packages – cabinetry, closets and custom furniture – to high-end builders and designers of large budget and “snowbird” clients. “The client has a reliable go-to shop for all their needs and we provide an integrated plan and budget that is totally inclusive,” said Harold Morantz, president. 2018 sales grew 28.0%.

Loudoun Stairs, Purcellville, VA

The stair and rail maker improved its social media marketing, and promoted its new designs, capabilities, on-time delivery and customer service via all digital platforms, noted David Cooper, Automation Manager. “We have an overall willingness to accommodate the customer with a quality product, new custom designs, and state-of-the-art machinery,” including a new Biesse panel saw.

Country Cabinets, Northfield, MN

“We took the time to educate customers on the investment they would be making with us and our company. We worked on gaining their trust before asking for any money down,” said Mary Mittelstaedt, operations/project manager at the cabinet firm. “We also gave them a tour of our shop to show them the quality of work we do, why we do what we do, and why they should go with us.” 

The 2019 WOOD 100 is sponsored by Pollmeier Inc.

Read more 2019 WOOD 100: Strategies for Success

Marketing Initiatives

Business Strategies

Productivity Enhancements

Technology Integration

Product Innovations

Customer Service

Return to WOOD 100 main page

Read the special 2019 Leadership issue of FDMC online

Today's wood products manufacturers must work faster, harder, and smarter than their competitors while providing service, quality and added-value to the wood products. What follows are some of the methods put in place by the 2019 WOOD 100 class, which includes cabinet manufacturers, residential and office furniture producers, architectural woodworkers, wood component manufacturers, closet companies and more.

Now in its 30th year, the WOOD 100: Strategies for Success highlights the innovative as well as tried-and-true initiatives put in place by 100 North American wood products manufacturers to grow their businesses. Here's what some of them had to share for customer service strategies:

Mystic Scenic Studios Inc., Norwood, MA —  There’s no such thing as a “standard” job for this custom fabricator of commercial interiors, restaurants, retail, broadcast TV sets, museums, trade show and corporate theater, and theatrical scenery.

“Nothing happens without first having a great crew, which has been a focus, coupled with looking for opportunities to maximize productivity via improving our CNC manufacturing capabilities,” said Jim Fitzgerald, CEO. “We deliver high-quality products on time, every time, so everyone has to keep their eyes on servicing our clients as best we can. Lastly, being selective about which clients we work with has been a big factor in driving sales.”

Sales grew 17.7%, as the company invested in finishing, panel processing and solid wood machinery, including: an edgebander, additional CNC routers, SawStop saws and an additional shaper.

Panel Processing Inc., Alpena, MI —  Custom flat panel fabrication has been Panel Processing’s specialty for more than 45 years. The company serves a variety of markets with its fabrication abilities, “and the list continues to grow as we expand our experience and capabilities,” said Stacy LaFleche, national marketing manager.

The company’s success, she said, “has been a combined effort of our customer service department pushing themselves along with our engineering and manufacturing departments working together to increase efficiency and effectiveness.”

Panel Processing recently added a TFL line at its Oregon facility to facilitate service and delivery to West Coast customers. “Additionally it provided us an opportunity to introduce a new product line for 2019,” LaFleche added.

Yoder Lumber Co., Millersburg, OH —  Yoder Lumber is a third-generation family-owned manufacturer of quality Appalachian hardwood products. The company has three modern sawmills, extensive drying operations, an automated grading/sorting line, and the capabilities to produce a wide range of components, said Jack Morton, sales & marketing manager.

“Yoder Lumber’s attention to detail is unmatched. We always put our customers first and go above and beyond to ensure we exceed their expectations,” he said.

In addition to offering customized S4S, mouldings and dimensional hardwood furniture components, Yoder excels in producing custom architectural wood solutions for retail and restaurant environments. The company also offers live edge slabs for purchase.

Woodgrain, Fruitland, ID —  A fully integrated wood home building materials company, Woodgrain has three sawmills that feed into the core of the business: millwork, wood doors and wood windows, with locations throughout the United States and Chile.

“We are a vertically integrated company which allows us to control quality and customers’ expectations,” said Tanner Dame, marketing manager. 

“We have focused on getting closer to the customer, looking for ways to offer help and support without being asked for it in advance. We want to be a resource that they can rely upon,” he added.

Along with mill acquisitions last year,  “This year we acquired a small trucking company which had three tracks and trails,” Dane noted. “Along with that, we acquired a silo to collect sawdust at our Fruitland facility.”

More service specialists

Keystone Wood Specialties, Lancaster, PA

The cabinet components manufacturer has unveiled Instant Pricing, which enables cabinetmakers, remodelers and contractors, to submit a quote request or an order and receive pricing in less than 30 seconds, “any day, anytime, anywhere.” The pricing is created through a webOE system accessed on Keystone’s main website.

Atelier Boisteck Inc., Montreal, QC

Sales for the manufacturer of cabinetry, architectural millwork and other custom woodworking projects grew 6.0% and look to be even better in 2019 and 2020, said Jean-Francois Asselin, president. Crediting the company’s customer service, Asselin said, “I’m always available for my customers.” The recent addition of an edgebander and dust control system will aid productivity.

Duval Fixtures Inc., Jacksonville, FL

Owner Corey Dawson credits the company’s customer service, along with a concerted sales effort, for helping spur the custom commercial cabinet and architectural millwork producer’s sales growth of 17.7%. Projections for 2019 and 2020 sales are also “excellent” for the company. Aiding production is a new CNC router.

Miller Cabinetry & Furniture LLC, Grabill, IN

Providing quality woodworking at an affordable price sounds like a simple strategy, but it’s been a successful one for the custom kitchen and bath cabinetry and furniture producer, said Stephen Miller, owner. Sales grew 4.4% in 2018, and projections for 2019 are excellent, with 2020 expectations also good. Recent equipment purchases include a Timesavers sander.

St. Croix Valley Hardwoods, Inc., Luck, WI

Excellent customer service, including “the ability to assist customers with outdated materials,” and fast, on-time delivery services have helped the hardwood components maker grow sales 14.6%, said Julie Erickson, operations manager. The move to a new, state-of-the-art building, plus the purchase of a Leadermac moulder and drawer box assembly equipment, will also aid efforts for the maker of dovetailed drawers, mouldings, edge-glued panels.

Bubugao Stairfloor Manufacture, Scarborough, ON

Soubiao Hu attributes the company’s ability to provide quality products, online ordering, and good customer service with helping the custom stair and flooring manufacturer’s sales grow 37.5%.

Chic Carpentry Co., Richmond Hill (Toronto), ON

The custom cabinet manufacturer “doesn’t  produce a crazy amount of cabinets yearly like other cabinet shops, but we try our best to make our cabinets as unique as possible, because our clients are unique,” said Alex Khosravian, owner. He credits the 48.9% sales growth to “being honest with clients, having the best customer service (based on clients’ feedback), and being responsible.”

Continental Woodcraft, Worcester. MA

Sales grew 16.7% for the architectural millwork and caseworks firm, due in part to being proactive, having good quality control and excellent customer service, said Glen Martin, vice president. The company also invested in a CNC panel saw to improve productivity.

Kitchens and Closets by DEA, Gilbert, AZ

Owner Eric Marshall credits “hard work and long hours getting our customers happy,” with helping the closet and home organization firm grow sales 74.9% in 2018. DEA provides products for the master bedroom, kids playroom, pantry, garage, laundry and other areas the home. It also designs and installs Murphy bed systems.

True Cut Cabinetry, Vaughan, ON

“We do our best to stick to our word, as simple as it may sound,” said John Fiore, project manager. “Whether is be with lead times or pricing, nobody likes to be hit with delays or increased costs. We take pride in being able to complete a job within the timeframe and price that we quote at the start of the project.” He added, “We also try not to specialize in only kitchens, or only retail stores. Broadening our scope of work leads to less slow periods throughout the year.”

Twin Oaks Cabinets, Neosho, MO

Good customer service is critical to success, and “Making the customer feel like #1,” is one of the strategies Doug Addy, administration director, said is used by the custom residential cabinetry and light commercial cabinets producer. “We also say and live by ‘Cabinetry crafted to become your family’s fondest memories.’” The firm also invested in case clamps, shapers and sanders to improve productivity.

Bernie’s Furniture & Cabinetry, Madison Heights, VA

The custom furniture and cabinetry firm’s sales grew 18.7%, and look to be even better in 2019 and 2020. “We’re custom building to their satisfaction,” said Bernard Campbell, principal. He adds that when customers say they can buy factory-built products cheaper, “I would realize they were not shopping for quality.”

Premium Woods LLC, Lincoln, NE

Sales for the laminate and wood caseworks manufacturer grew 7.7% in 2018, and President Bob Long expects 2019 and 2020 will be even better. The company credits its customer service, “creating systems and following them,” with helping spur sales. Aiding productivity in the shop are the purchases of a Gannomat case clamp, and a drawer box clamp.

Randy’s Cabinets and Woodworks, Grand Rapids, MN

Owner Randy Niewind credits great customer service, “and we will always go above and beyond,” with helping the cabinet firm’s sales grow 3.1%, with greater sales expected in 2019 and 2020. Aiding the effort are the recent purchases of a paint booth, automatic fences and CNC equipment.

The 2019 WOOD 100 is sponsored by Pollmeier Inc.

Read more 2019 WOOD 100: Strategies for Success

Marketing Initiatives

Business Strategies

Productivity Enhancements

Technology Integration

Product Innovations

Customer Service

Return to WOOD 100 main page

Read the special 2019 Leadership issue of FDMC online

Changes in workplace procedures, market area growth, acquisitions and expansions and are just a few of the ways these WOOD 100 firms grew sales and improved their long-term business prospects. What follows are some of the methods put in place by the 2019 WOOD 100 class, which includes cabinet manufacturers, residential and office furniture producers, architectural woodworkers, wood component manufacturers, closet companies and more.

Now in its 30th year, the WOOD 100: Strategies for Success highlights the innovative as well as tried-and-true initiatives put in place by 100 North American wood products manufacturers to grow their businesses. Here's what some of them had to share about their business strategies:

Cardinal Fine Cabinetry Corp., London, ON —  One of the area’s largest millwork producers will soon be even bigger, following an expansion to meet the growing demands of the residential market, said Paul Bilyea, president. “We saw an increase in our talent with the inclusion of three small bespoke businesses that formed within our company. This added a great value to the vocabulary of what we do.”

In recognition of its efforts and success, Cardinal Fine Cabinetry was named one of Canada’s top growing companies in The Globe and Mail’s 2019 Report on Business, recording a three-year revenue growth of 63%.

“We want to continue [our] success by providing the best possible service and product to our community,” Bilyea said.

He credits much of the success to the employees, which include apprentices. Pictured are three of them (Alisa, Heather and Katelynne) at the Build-A-Dream event in London.

Genesis Products Inc., Elkhart, IN —  “In 2018, Genesis Products made great strides towards focusing on new product development and launches, as well as, major improvements to quality and manufacturing excellence,” said Abbie Thomas,  creative manager - Marketing.

2018 sales grew 5.4%. “Product innovation and overall customer experience led towards growth in new markets and market share gains,” she added.

Genesis serves a broad range of industries including: cabinet and storage, store fixture, office and education, recreational vehicle, furniture and transportation.  It has 9 facilities, with 950,000-plus square feet of production, assembly and warehousing space. “The flexibility and size of these facilities allow us to respond quickly and efficiently to our customers’ manufacturing and supply chain needs.”-Dream event in London.

Parenti & Raffaelli, Mt. Prospect, IL —  Sales are booming for the family-owned architectural millwork firm, which focuses on high-end commercial spaces, but also specializes in residential, hospitality and healthcare.

“We manufacture all types of architectural millwork, from simple casework to blueprint matched panel elevations,” said Samantha Gurrola, vice president of Sales. “We pride ourselves in quality without compromise, and excellent customer service.”

She added, “We have a great team in the office, shop, and field. We all work together and set each other up for success.” The company recently relocated its facility and upgraded it to be fully air conditioned, with ergonomic workstations.  “We also have an excellent project management and shop scheduling system.” 

Lexington Manufacturing, LLC, Coon Rapids, MN —  “We invested in our people and developed a clear vision for them to understand where we are headed,” noted Bill DeWitt, account manager. “We also developed a more robust strategic planning process.”

Sales at the architectural door and profile wrapped components specialist grew 8.0% in 2018, and are expected to be even better in 2019 and 2020. Enhancing the company’s value-added machining capabilities are the recent additions of an automated laminating line, automated paint line, automated sanding line, and new panel saw.

Lexington is an OEM supplier to the residential window and architectural and commercial door markets, including offering fire-rated door components for 45, 60 and 90 minute openings.

More master plans

Diplomat Closet Design, West Chester, PA

Sales at the home organization firm grew 3.3% in 2018, with projections “excellent” for 2019 and 2020. “We focused on team and personal goals, company culture and core values,” said Ryan Lindstadt, president. The firm also revamped its manufacturing facility, including Cabinet Vision software, a Weeke/Homag CNC with offload and labeling, and invested in marketing. “We also invested heavily in our staff and getting the right people on the bus,” added Laura Bryan, director of marketing.

Woodhaven Woodworks LLC, Springfield, IL

Owner Todd Scanlan credits his skilled employees with helping the custom wood and laminate cabinetry and mouldings producer grow sales 40.3%, with projections also “excellent” for 2019. The company also invested in an SCM moulder and finishing equipment to aid production.

Creative Surfaces, Sioux Falls, SD

The commercial casework, cabinetry fixtures, countertop and signage firm invested in its employees, adding sales staff and engineers. “We are one of the top companies in the United States that manufactures and installs all of our own projects. Everyone that works for us is highly skilled in their trade,” said Denise Pins, marketing & sales coordinator.

United Cabinet Works, Sugarcreek, OH

Owner Roy Yoder credits the hiring of a business coach to help in marketing, and understanding percentages and profit margins with helping the cabinetry manufacturer’s sales grow 66.7% in 2018.

Reborn Cabinets, Anaheim, CA

The cabinetry firm’s sales grew significantly. “Even though marketing and customer service are main drivers, we attribute our success to the quality of our team. Culture is very important to us. Of our 10 core values our first two specifically relate to building a winning team, and creating the ultimate work environment for that team,” said Anthony Nardo, president. “Everything we do is metric driven and we not only share those results but teach our staff how to utilize the information to their advantage.”

Evergreen Cooling Technologies, Winlock, WA

A new customer acquisition and an expansion into carbon composites helped grow sales 2.6% at the supplier and fabricator of cooling tower grade lumber, plywood and treating services, said Jeff Padrta, president. The firm also invested in new drill presses and saws.

Hollands Custom Cabinets, El Cajon, CA

Sales at the residential cabinet and commercial casework and millwork firm grew 24.1%. “We continue to focus on the customer’s experience with our company.  This means focusing on quality, service and price,” said Jed Richard, president. “Key steps are having great employees (taking care of them), great machinery  (reinvestment of capital) and continued focus on productivity. Grow your business, grow your people.”

Maple Landmark Inc., Middlebury, VT

“Our core competency is our ability to efficiently operate in a mixed-model environment with short leads times,” said Mike Rainville, president of the toy and other small wood products firm. A focus on lean and training has enabled the firm to increase productivity 12% and add complexity, without adding new hires.

McClung’s Lumber, Salem, VA

New technology, including a Thermwood CNC, helped the architectural millwork firm increase capacity without adding employees, said TJ Stratton, Operations manager. “Combining that with refining our systems and the way orders moved through the shop allowed us to cross $2 million in sales threshold.” 2018 sales rose 16.7%.

Cal Door & Drawer, Morgan Hill, CA

Hiring outside sales reps while maintaining quality and service contributed to 2018’s 13.6% sales growth, said Edward Rossi, CEO. Investments in a Mereen-Johnson milling line and 5-head Biesse sander also aided production of the 8,000-10,000 wood, RTF, and edgebanded doors and drawer boxes shipped daily and nationally. Plans are to add a Flex line edebander and double-action panel saw for faster processing.

Frank Chervan Inc., Roanoke, VA

Reduced delivery times helped sales for the contract seating manufacturer grow 9.0%, said Gregory Terrill, president. “We have continued to build upon our vertically integrated, completely domestic production model. This is our core competitive advantage,” he said. “We can respond to demanding customer needs because we control the value stream from raw inputs to finished goods.”

Casework Solutions, New Century, KS

“A renewed team culture of shared values and vision,” helped the cabinetry and countertop firm grow sales 19.0%, said Randy Frey, owner. The company also redefined key result areas for all team members, redefined workflow pipelines and task processes and focused on “clear and continual communication,” of the core values and goals.  

Fusion Wood Products LLC, Elkhart, IN

“We pride ourselves in being an ally to the customer during every phase of production,” said Nate Rhoden, managing member. “We focus on people first by developing strong relationships with customers and providing a positive work environment for employees.” The strategy works, as the panel processor and profile wrapper’s sales grew a whopping 413.6%.

Doors and Drawers, Dexter, MI

Sales grew 3.5% for the commercial cabinet and fixtures maker, which recently completed construction of a 6,000-square-foot warehouse. “This allowed us more room for actual manufacturing and has greatly increased our efficiency and safety,” said Chuck Manitz, owner.

Classic Millwork and Cabinets Inc., Westmont, IL

The custom commercial millwork firm looks to continue its upward sales growth, with projections good also for the next few years, said Ray Turffs, president. The company added office and shop staff, as well as some new equipment, to aid the production of millwork for retail stores, office spaces, restaurants/bars, schools and salons.

R&B Grove Casework Inc., Baltimore, MD

Tony Kordell, project manager & senior estimator, credits “Always being on time, from bidding to submittals/shop drawings, to deliveries and complete installations with zero punch list,” for contributing to the laminated cabinetry, casework and countertop firm’s success. R&B also invested in a box truck for deliveries as opposed to contracted delivery service, with a new CNC router and edgebander planned for this year.

Custom Millwork & Display, Inc., South Bend, IN

“We have aligned ourselves with a network of very good vendors, suppliers and other quality millwork shops,” said Jerrel Mead, president. The strategy worked, as 2018 sales grew 35.1% for the providers of architectural millwork to the commercial and educational sectors.

El Paso Wood Products, El Paso, TX

The firm’s diversification into components continues to pay off, said Francisco Fernandez, vice president. “Currently half of our business is cutting 3/4-inch CDX plywood for furniture frames.” Hiring an outside industrial engineer and continuous improvements also spurred the 3.7% growth.

The 2019 WOOD 100 is sponsored by Pollmeier Inc.

Read more 2019 WOOD 100: Strategies for Success

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Read the special 2019 Leadership issue of FDMC online

Jimmy Thornberry, President, Powell Valley Millwork

An inspirational business leader and president of Powell Valley Millwork, Jimmy Thornberry represents the second of a three-generation family business that incorporates innovative management and production processes in the manufacture of poplar moulding and millwork.

Prior to entering the woodworking industry, Thornberry and his father, Jim, owned and operated surface mines throughout eastern Kentucky. “We decided to leave the industry in the early 1990s to find a new business that was renewable and generated a tangible product while utilizing equipment and people. We began working in the secondary wood manufacturing sector in 1992 and have enjoyed success for nearly 30 years,” he said. 

“Our success is predicated upon the high caliber people we have been fortunate to work alongside: employees, vendors and customers having the same values, goals, and work ethic,” he added.

One of the statements used internally and externally at the Clay City, Kentucky-based Powell Valley is “Find a way to yes,”  Thornberry said. “We strive to satisfy the needs of our employees in their daily work. We also want to live up to our customers’ expectations and help them with their obligations.  If we find a way to yes, we have done all we can.”

Another well-known mantra is SQYPH: Safety, Quality, Yield, Production, and Housekeeping. “If we take care of those objectives, we will be successful for generations to come,” he said.

An environmentally sustainable, zero-wood waste facility, “Powell Valley has experienced significant growth in the last five years increasing capacity, acquiring market share, and developing new product lines. I want to continue that trajectory with our team and reinvest in our land, building, equipment, and personnel.”

Thornberry also works to promote the industry as a whole. He has served on the board for the Kentucky Forest Industries Association, and continues to remain active. “Our entire industry should promote the goods and services we provide while being good stewards of our natural resources.”

Thornberry and the company are also active in the community and contribute to many organizations, including Spark Ministries, which serves as a “catalyst to bring people back to life and give them purpose.” Outside of work, he enjoys spending time with his wife, children and grandchildren. “I also enjoy exercise, golf, travel, bird hunting and raising beef cattle on our farm in Lexington, Kentucky.”

Quick Glimpse:

• Education: Bachelor’s degree in Management and Finance from the University of Kentucky
• Number of years at the company: 27
• Number of years in the industry: 27
• Words that best describe you: Patient, thorough, analytical, and dedicated
• Business mantra: We have several including SQYPH: Safety, Quality, Yield, Production, and Housekeeping.
• Best advice: Tell me and I forget, teach me and I may remember, involve me and I learn.
• Who have you tried to emulate: I look to my father’s business acumen and accounting background as a model for Powell Valley or any business we operate.  I think of my late friend Bo Smith as a thought leader in the industry.

About the Wood Industry Market Leaders: This marks the 11th year Woodworking Network has paid tribute to outstanding men and women that have made an impact, not only at their companies, but within the various wood products industries. Since 2009, more than 70 industry professionals have shared their influencers, insights and strategies.  Read more about the 2019 and past honorees at WoodworkingNetwork.com/Market-Leaders.

Meet the 2019 Wood Industry Market Leaders, a diverse group of individuals that are making a difference.

These distinguished men and women are meeting – and beating – the global and domestic competitive and economic challenges affecting their companies and the industry as a whole. As the following profiles illustrate, they also demonstrate the creativity, determination, perseverance and savvy skills to ensure the viability and sustainability of their wood products businesses for years to come. 

As with previous Market Leaders, the noteworthy endeavors of this year’s group also extend beyond the workplace, as the individuals volunteer their time and efforts for the betterment of the industry and their communities.

On the links below are the stories behind this year’s leading executives, including the influencers, insights and strategies that helped earn them recognition.

The 2019 Wood Industry Market Leaders are (pictured, beginning top right):

• Caroline Castrucci, vice president of Administration at Laurysen Kitchens Ltd.
• Tom Happ, president of Closet Works
• Caroline Hipple, president of Norwalk Furniture
• Jimmy Thornberry, president at Powell Valley Millwork
• Keith Morgan, owner of Bespoke.

The 2019 Market Leaders marks the 11th year Woodworking Network has paid tribute to outstanding men and women in the North American woodworking industry. To date, more than 70 people have shared their stories with us. (View the list of past Market Leader honorees).

	Caroline Castrucci, vice president of Administration at Laurysen Kitchens Ltd.
	Tom Happ, president of Closet Works
	Caroline Hipple, president of Norwalk Furniture
	Jimmy Thornberry, president at Powell Valley Millwork
	Keith Morgan, owner of Bespoke

For additional information on the Wood Industry Market Leaders or to nominate an individual for recognition, email karen.koenig@woodworkingnetwork.com. Also visit WoodworkingNetwork.com/Market-Leaders to read more on this year’s class, as well as past Market Leader honorees.

LANGLEY, B.C. -- Hardwoods Distribution Inc. has announced the completion of its previously announced acquisition of substantially all of the assets, and assumption of certain liabilities, of Pacific Mutual Door Co.

The transaction was completed for a purchase price of U.S. $34.5 million and other consideration, subject to final working capital adjustments.

Pacific is a wholesale distributor of interior and exterior doors, custom millwork, and related building products. For the trailing twelve-month period ended July 2019 Pacific's revenues were U.S. $58 million .

Pacific operates five strategically located facilities in Nashville, Kansas City, Missouri, Olathe, and Osborne, Kansas, and Albuquerque, New Mexico.

“We are pleased to welcome the employees of Pacific to HDI”, said Rob Brown, president and chief executive officer of HDI. “This strategic acquisition brings with it a highly profitable business model, and increases our existing presence in the attractive door and related millwork product category.”

HDI is North America’s largest wholesale distributor of architectural grade building products to the residential and commercial construction sectors. The company operates a North American network of 67 distribution centers, as well as one sawmill and kiln drying operation. See http://www.hdidist.com

Marvin has announced that it has acquired the assets of A.W. Hastings in Enfield, Connecticut, and is now the owner of its distributor in New England and Eastern New York.

A.W. Hastings has served as Marvin’s exclusive representative in New England and Eastern New York for more than 40 years. The companies’ shared values have contributed to years of success and this acquisition now brings centralized, one-step service and support resources to Marvin customers in these markets.

“The future is bright at Marvin, and we are actively pursuing initiatives that not only contribute to our growth and long-term success, but also align with our values,” said Paul Marvin, CEO. “Joining these two centers of excellence provides further opportunity to deliver on our purpose: to imagine and create better ways of living.”

https://www.marvin.com/

CHESTER, S.C. -- Roseburg Forest Products celebrated the opening of its new plant in Chester featuring the world’s highest-capacity laminated veneer lumber (LVL) continuous press. President and CEO Grady Mulbery and Roseburg owner and chairman Allyn Ford welcomed South Carolina Governor Henry McMaster and other state officials and business partners to the ribbon-cutting ceremony and plant tour.

Upon full production, the line will produce up to 285,000 square meters of LVL per year, made possible by microwave preheating and continuous press technology. Dieffenbacher supplied the LVL press and the upstream 600 kW microwave, said to be the most powerful preheating system of its type in LVL production.

To produce high-quality LVL, the veneers are evenly heated to 60–90C in the microwave over the entire mat thickness. The special design of the Dieffenbacher CPS press infeed means the distance the mat has to travel “without pressure” upon leaving the microwave until reaching the maximum pressing pressure is less than 2,500 mm. This prevents pre-curing of the resin. Fast-hardening glue can be used to increase production speed and capacity.

Compared to production on a multi-opening press, the continuously produced LVL boards reportedly have more consistent mechanical board properties and significantly lower thickness tolerances. Subsequent sanding is not necessary. For example, unsanded LVL boards can be used directly as scaffolding planks, and unsanded veneers can easily be pressed into high-quality boards.

Dieffenbacher LVL technology reportedly enables board thicknesses of up to 120 mm and allows MUF adhesives to be used in the top veneer overlapping area. Boards with these properties have been produced in practice at Dieffenbacher plants at Nelson Pine in New Zealand and at Pacific Woodtech in the U.S. See http://dieffenbacher.com

At the close of the third quarter of 2019, analysts at Lodging Econometrics have reported that the total construction pipeline in Canada soared to an all-time high with 289 projects and 38,453 rooms. Construction pipeline projects are up 17 percent and rooms are up 28 percent year-over-year.

Currently, there are 85 projects with 10,337 rooms under construction. Projects scheduled to start construction in the next 12 months have experienced a large 47 percent increase in both projects and rooms, year over year, standing at a record high of 125 projects/14,574 rooms.

Projects in the early planning stage stand at 79 projects with 13,542 rooms. This is an 8 percent increase in projects and a 46 percent increase in rooms. This substantial rise in rooms has increased the average hotel size in the early planning stage from 127 rooms a year ago to 171 rooms currently.

In the third quarter, Canada had 47 new project announcements with 5,760 rooms. This is the largest count that LE has recorded in the country for a single quarter and is a 42 percent increase quarter over quarter.

Through the third quarter, Canada opened 44 new hotels/5,330 rooms with an additional 7 new hotels/641 rooms scheduled to open before year-end. In 2020, the Lodging Econometrics forecast for new hotel openings show 59 new hotels with 6,440 rooms expected to open. In 2021, Canada is forecast to open 70 new hotels/7,714 rooms. If all the new hotels forecast for 2021 come online, it will be the largest count of new hotel openings since Lodging Econometrics  began tracking the region in 2008.

Ontario is the most active province for pipeline projects in Canada, which is at a record-high, with 147 projects/19,442 rooms. Next is British Columbia, also at a record high, with 47 projects/6,520 rooms and then Alberta with 31 projects/4,889 rooms. Together these three provinces account for 80 percent of the rooms.

The top cities are led by Toronto with 49 projects/7,525 rooms, at a record high and claiming 20 percent of all the rooms in Canada’s total construction pipeline. Following distantly are Niagara Falls with 14 projects/3,125 rooms, Ottawa with a record 14 projects/2,226 rooms, Vancouver with 14 projects/1,660 rooms, and Montreal with a record 13 projects having 1,773 rooms. These five cities alone account for 42 percent of the rooms in the total pipeline. See https://lodgingeconometrics.com/

Covenant Millwork minded the details, and more, in its recent work for a high-end hotel.

The Louisville, Georgia, shop won the overall Cabinet Makers Association Wood Diamond Award, and the project also won for the category Commercial: Hospitality.

Kent Holdeman and Ron Shultz own the company. Holdeman is in charge of the millwork shop and Shultz takes care of the cabinet shop. The millwork shop builds custom doors and windows, mouldings, and flooring.

“We are a small custom millwork and cabinet shop doing high-end residential work mostly,” Schultz said. “Once in a while we’ll get asked to build some specialty items such as the two reception desks, executive desk bases, serving island, eight interior doors (each about 10 feet tall), wall paneling, and miscellaneous mouldings we built for the Madison Hotel project in D.C.

Most of the cabinet work is inset and beaded face frame but they also do frameless. Quite a few of the jobs here are a mix of both styles, Schultz said.

“We have another shop cut our plywood parts on their CNC router since we do not have a router at this point at the cabinet shop,” he said.

They use Cabinet Vision software to design their projects.

“We have a Weinig gang-rip saw and Weinig six-head moulder, radius moulder, and all the other typical equipment found in a millwork shop,” Schultz said. “We also have our own kiln so we can dry any wood that needs to be dried. We do quite a bit of reclaimed oak and heart pine flooring and sometimes it will need to be run through the kiln before milling it.

Covenant also has a Northtech upcut saw with a Razorgage system for cutting solid wood parts to length and also to haunch the beaded face frames on the Hoffman hauncher.

They also have a Grizzly 43-inch widebelt sander, Grizzly 14-inch sliding table saw, and Powermatic 10-inch table saw. They do all their own finishing.

“We started the business in 2006 and today we have six employees working for us. We have been extremely busy for the last several years and right now we have work lined up till mid-2020,” Schultz said.

Hotel project

As for the winning design, Schultz said it was an interesting project to work on and to see it all come together.

“We were just one of the teams working on the project,” he said.

“The curved mouldings on the two reception desks were a challenge to do. There are about 11 different moulding profiles that make up the top curved part of each desk. The desks are not identical, there is quite a bit of difference in the shape of each one.

“The metallic rose gold finish with high gloss clearcoat was a real challenge to do. I wish I had shop rate for every hour I spent thinking about that in the middle of the night.

“The tapered solid brass legs on the reception desks were also custom made just for the desks as were the mahogany acanthus leaf corbels for the executive lounge desk, we outsourced both of these items. The finish on the interior doors wasn’t as hard but it was a little labor intensive also. The serving island wasn’t so much of a challenge but it was fun to see it come together.”

Winners of the 2019 Wood Diamond Awards contest were announced by the Cabinet Makers Association during the AWFS Fair in Las Vegas. The annual design competition promotes professional development and encourages peer recognition of outstanding workmanship in a variety of categories.

Projects can be viewed in a slideshow. Details on the projects can be found at cabinetmakers.org/2019winners.

FOREST GROVE, Ore. –Woodfold Manufacturing has acquired the intellectual property rights and key equipment of Panelfold Inc.'s accordion door line. Terms of the acquisition were not disclosed.

Woodfold, which also manufactures accordion doors, said the product line acquisition "will bring synergy and natural line expansion," to its current range of products. Woodfold's product line includes custom accordion doors, luxury hardwood window shutters and hardwood roll-up (coiling) doors.

"It is anticipated that once the necessary adjustments to manufacturing have been accomplished at the Woodfold plant in Forest Grove, Oregon, then full-scale production of the most popular and viable lines will commence under the Woodfold brand name," the company said.

An ESOP company, Woodfold has been manufacturing door and window components to the commercial and residential markets since 1957.

Founded in 1953 and based in Florida, Panelfold had supplied accordion doors and operable walls into a range of markets across North America. The company filed a WARN notice in September and ceased manufacturing in early November.

Although earlier indications showed challenges ahead for the construction and architectural industries, the latest Confindex by the Construction Financial Management Assn. gives cause for optimism. There’s an upbeat sentiment for the third quarter, with those surveyed indicating that deal flow remains solid.

Although the Architectural Woodwork Institute’s Cost of Doing Business Survey Business Sentiment Index indicates architectural woodworkers are a little less optimistic, the CODBS finds median sales have increased and are the highest in at least 10 years, while average operating margins are back up. And while the Architectural Billing Index shows business conditions were generally sluggish in September, the latest figures available, the American Institute of Architects noted fewer firms indicated a decline in billings, compared to August figures, while seeing an increase in the number of contracts signed for new projects.

The situation is similar for custom woodworkers of cabinets and casegoods. A recent survey by the Cabinet Makers Association and FDMC found more than 50% of respondents predicted their 2019 sales would be better than 2018, and 90% are optimistic that 2020 will be about the same or better than this year. While investments in technology will help improve the productivity and profitability of these small- to mid-size shops, challenges remain, particularly in regard to labor supply.

Click to enlarge the infographic, plus find more market data in the December 2019 FDMC Wood Industry Almanac.

Architecture firm billings sluggish, challenging conditions

The Architectural Billing Index (ABI) shows Work-on-the Boards. An index score above 50 indicates growth. While architecture billings moderated in September, design activity shows signs of remaining sluggish at U.S. architecture firms, according to a report from the American Institute of Architects (AIA).

The ABI score for September was 49.7. During September, both the new project inquiries and design contracts scores were positive, posting scores of 59.0 and 54.4 respectively. “Though still in negative territory, the moderating billings score along with the rebound in design contracts and inquiries serve as a continued note of caution for the industry,” said AIA Chief Economist Kermit Baker. “Continued weakness in the larger economy still doesn’t bode well for future design services, which will likely see continued volatility in the months ahead.”

Quick Stats

NAAWS 3.1, a collaboration between the Architectural Woodwork Manufacturers Association of Canada and the Woodwork Institute, became effective last July and replaces previous Architectural Woodwork Standards.

The Architectural Woodwork Institute and Stairbuilders and Manufacturers Assn. are collaborating on a wood stair, handrail and guard systems standard, AWI/SMA 0643.

The AWI’s 2019 Cost of Doing Business survey finds the average architectural woodwork firm has grown in profit, with the gap narrowing between them and the higher-profit firms.

The overwhelming majority of respondents to the CMA/FDMC benchmark survey said they market through word of mouth and referrals. An increasing number are also using social media and digital marketing to promote their work.

The AIA’s Architectural Billing Index for September shows weak billings in the Northeast and Midwest,  with growth for firms in the South and West. Those specializing in residential, particularly multifamily, fared better than those with commercial/industrial and institutional specializations.

Market Data Sources:Architectural Woodwork Institute (AWI), The American Institute of Architects (AIA), U.S. Census Bureau, Cabinet Makers Assn. (CMA), Statistics Canada, Architectural Woodwork Manufacturers Association of Canada (AWMAC), Woodwork Institute, Houzz, FDMC magazine, Construction Financial Management Assn.

Category: Architectural & Custom: commercial & residential interior millwork, casework, furniture & cabinetry.

Global demand for windows and doors is forecast to rise 4.5% per year to $214 billion in 2021, fueled by building construction and a demand for high-value products. According to the Global Windows and Doors study by The Freedonia Group,  China will post one of the fastest rates of market growth.

In the United States, new home construction will help boost sales. Market advances will also be fueled by gains in consumer spending on home improvement projects, and by increased demand for more aesthetically pleasing and energy-efficient windows and doors, sold at higher price points.

The research company projects vinyl windows and doors will record faster sales gains than metal or wood products through 2021, although an ongoing preference for wood in higher-end residential applications will help spur growth for the material.

A related Windows and Doors Market Forecast by Freedonia has U.S. demand for windows and doors projected to grow 4.8% annually to $34.3 billion in 2021, with the residential market expected to offer the best growth opportunities.

As with cabinetry and furniture, tariffs are also having an impact on the window and door market, with questions looming over a possible impact on the ratification of the United States-Mexico-Canada Agreement (USMCA). 

Click to enlarge the infographic, plus find more market data in the December 2019 FDMC Wood Industry Almanac.

Quick Stats:

Residential window and door growth, which slowed slightly in 2018, is projected to hold relatively steady in 2019 and 2020, according to WDMA/Farnsworth Group research. Sliding patio door growth is forecast to decrease in 2019 and taper slightly in 2020/2021. The research also notes hinged patio doors, a lower volume unit compared to others, is expected to drop significantly in 2019 and continue declining through 2021. Commercial shop-built windows are also projected to decline in growth through 2021. On a positive note, shipments for architectural interior flush doors and stile and rail panels are forecast to show growth through 2021.

A Freedonia Group study on the $28 billion U.S. window and door market identifies smart glass – which can electronically darken or lighten –as an opportunity for manufacturers to increase the value and functionality of their products. Smart windows can be designed with “intelligent” sensors that respond to changes in temperature, angle of the sun, and cloud cover, among other factors such as security breaches, as well as to architectural features such as overhangs.

Market Data Sources: The Freedonia Group,Window & Door Manufacturers Assn., The Farnsworth Group research, U.S. Department of Commerce, U.S.-International Trade Administration, Statistics Canada (StatCan), Government of Canada, Statista, Traqline/Stevenson Co.

Category: Includes wood/metal/vinyl clad windows, architectural, interior & exterior doors, related components.

Despite increased publicity of these products on home improvement/flipping shows, sales for wood and laminate flooring both dropped in 2018. According to Catalina Research, the hardwood flooring market dipped 3.7% in 2018, to $3.52 billion. Laminate flooring, which faces greater competition from low-cost imports as well as LVT (luxury vinyl tile) and WPC (wood plastic composite), dropped 6.7% to $922 million.

The generally positive remodeling outlook should help domestic sales; more than three-quarters of laminate flooring and about half of the hardwood flooring sales in 2018 were to the residential remodeling market. Further advances for laminate flooring may come through material and technology advances, including digital printing and water-resistant products. Laminate flooring may also benefit from the diligent monitoring of imported goods to ensure they meet emission regulations. Of the roughly $11.6 billion floor coverings imported into the United States in 2018, hardwood flooring accounted for slightly less than $1.5 billion and laminate flooring for about $614.0 million, according to estimates from the U.S. Department of Commerce and Catalina Research.

Click to enlarge the infographic, plus find more market data in the December 2019 FDMC Wood Industry Almanac.

Quick Stats

Statista projects revenue in the estimated $27.011 billion U.S. floor covering market to grow annually by 0.5% (2019-2023). Revenue in the $3.153 billion Canadian market is also expected to grow annually by 1.4% during the same period. Likewise, Statista projects the $2.127 billion Mexican flooring market to grow annually by 6.6% (CAGR 2019-2023). (Revenue in USD) 

In 2018, Canada exported $441.4 million in wood flooring and other millwork (NAICS 321919) and imported $352.7 million, according to figures from Statistics Canada.

In the National Wood Flooring Assn.’s 2020 Industry Outlook survey, more than 64% of manufacturers, distributors, retailers, and contractors forecast an increase in wood flooring demand, with about half predicting a rise between 3-7%, and 14% projecting growth of more than 8%. Nearly a quarter of respondents, however, were pessimistic about 2020. Published in Hardwood Floors magazine.

What’s trending in wood flooring? According to NWFA’s 2020 Industry Outlook survey, it’s wider, longer planks in light colors. White oak continues to be the go-to-species, in part due to its availability. Textures are still in demand, although the survey predicted a decrease in hand-scraped finishes due to their difficulty for cleaning. Gray, natural and other light colors continue to be popular.

The U.S. hardwood flooring industry employs 45,000 people, contributes $4 billion to U.S. gross domestic product, and generates $8.5 billion in U.S. economic output, according to a recent Economic Impact Study commissioned by the Hardwood Federation.

With their ability to mimic the look of real wood, LVT and WPC were named the biggest threats to wood flooring by contractors in NWFA’s 2020 Industry Outlook survey.

Market Data Sources: National Wood Flooring Assn. (NWFA), Hardwood Floors magazine, Catalina Research, Floor Covering Weekly, U.S. Department of Commerce, Conlumino/Global Data, Statistics Canada, Hardwood Federation, North American Laminate Flooring Assn., Statista.

CONWAY, Ark. -- Mass timber manufacturer Structurlam Mass Timber Corp. has announced today it will expand its operations into the United States, with a plant in Conway set to open in mid-2021. The Canadian-based company, in which Walmart has made an investment, will spend $90 million to purchase, retrofit and equip a former steel plant and create 130 new jobs, and will source softwood lumber from Arkansas-grown Southern Pine trees.

Mass timber is a category of building construction featuring structural laminated wood components for walls, roofs, floors, beams and columns. A key economic benefit of mass timber is the ability to design, model and prefabricate the structural elements of a project offsite, accelerating on-site production schedules by up to 25 percent compared to traditional onsite building with steel and concrete

Structurlam is reported to be the first manufacturer to bring mass timber to the North American market and the first to introduce CLT in the production of industrial ground protection matting products used in the energy and power transmission sectors.

The new U.S. location will answer the demand for mass timber building products and industrial matting products in the southern, central and eastern United States, and will complement British Columbia operation serving the Canadian, Pacific Northwest, California and Intermountain markets, said Hardy Wentzel, CEO of Structurlam.

Agriculture is Arkansas's leading industry with timber making up a third of the overall income. The state has a strong stewardship program in place to protect timber as a renewable resource, planting 1.6 trees for every tree that is harvested.

Walmart will be the first customer of Structurlam's Conway facility. The world's largest retailer plans to use more than 1.1 million cubic feet of Arkansas-grown and Arkansas-produced mass timber in its new Home Office campus in Bentonville, Arkansas, making it the largest campus project in the U.S. using mass timber.  

Structurlam selected Conway for its proximity to 19 million acres of sustainable forestland that covers more than half of the state's total land area. The new plant is located close to transportation corridors that reach large southern and eastern markets. Other considerations included a site-ready location and available workforce. See structurlam.com.

Increasing urban population across the Asia-Pacific region will have a major influence over the door market forecast over the coming years, according to a report from Global Market Insights, Inc. Asia-Pacific has about 60 percent of the world’s population, accounting for about 4.3 billion people. This includes the most populated countries in the world such as China and India. There has been a sizeable migration flow in and out of the region which has led to rapid urbanization.

According to a research by Global Market Insights, Inc. the market valuation of doors industry will exceed $165.79 billion by 2026 with following a CAGR of approximately 5.2 percent from 2019 to 2026.

India has been projected to add 416 million people in the urban areas while China will be adding 255 million by the year 2050.

The government of India had launched a flagship scheme in 2015 called Housing for All by 2022, which aims to build about 20 million homes in urban areas and 30 million houses in the rural areas by 2022. The government had also sanctioned the construction of more 3,21,567 affordable houses under the program in March 2018, representing a consistent deployment of affordable uPVC or wood-based doors.

The European Union has been aiming to preserve energy by making efforts to reduce the greenhouse gas from the building sector. The rate of innovation is required to increase in order to deliver nearly 90 percent reduction in greenhouse gas by the set deadlines. As part of these efforts, the European Union will be facilitating binding national targets and action plans for building refurbishments up to 2050.

Expenditure on renovating buildings in Europe can have a major macroeconomic effect in terms of capital investment and employment. There have been several initiatives taken across the building sector and especially on building upgradations. About 40% of the final consumption of energy takes place in houses, shops, offices and other buildings as they offer the second-largest untapped potential for energy savings. This will result in a massive increase in the building restructuring in the European region and boost the demand for doors. See https://www.gminsights.com/industry-analysis/doors-market

MANASSAS, Va. -- USA Millwork has announced it has acquired Mission Bell, an architectural millwork manufacturer in California. Mission Bell was founded in 1959, and is known for such high profile work for tech companies, hospitals and universities. The acquisition brings the number of USA Millwork locations to five with a combined manufacturing footprint of nearly 400,000 square feet. Additionally, the acquisition adds west coast capacity to enhance service to USA Millwork’s customers throughout the country.

“We are honored to be able to add Mission Bell to the USA Millwork portfolio. For over 60 years, the Scianna family has built one of the elite millwork businesses in the country and we are honored to be able to carry on their tradition of excellence,” said Patrick Dickinson, CEO of USA Millwork.

“Mission Bell’s reputation for intricate high-quality products and its ability to meet demanding schedules has won them an outstanding reputation in the industry. The merger of Mission Bell and USA Millwork allows us to add capacity, capabilities, and industry-leading practices to better serve customers across our existing national platform.”

Mission Bell specializes in quality architectural woodwork, millwork and custom casework. Their work extends from the most intricate one-of-a kind quality woodwork fixtures to standard production cabinets.

Glenn Ripley, Mission Bell’s CEO, who will be joining USA Millwork as president, said, “USA Millwork’s vision for building a best-in-class millwork company with a national footprint dovetailed with our vision of growing Mission Bell both within and beyond the Bay Area. With the USA Millwork platform, we can leverage Mission Bell’s technology, manufacturing capabilities, installation services and a nationwide supply chain to design and build custom millwork and case goods across a range of sectors."

Moving forward, Dickinson and Ripley will work hand-in-hand to run USA Millwork. Ripley will oversee back office operations, process improvement, and integration, while Dickinson will continue as CEO focusing on business development and day-to-day execution.

USA Millwork was founded in 2017 with the purchase of four regional leaders in millwork and casegoods. The consolidated company provides planning-to-completion services for complex, large-scale projects across the country in a variety of industries including corporate, healthcare, hospitality, entertainment, government, retail and multi-family.  The USA Millwork portfolio includes Cabinets by Design (Georgia), Freelance Millwork (Colorado), IBS Millwork (Virginia), Mission Bell (California) and O’Keefe Millwork (Wisconsin). See http://usa-millwork.com

CHICAGO - The Fenestration and Glazing Industry Alliance (FGIA) is a newly formed joint organization by the American Architectural Manufacturers Assn. (AAMA) and the Insulating Glass Manufacturers Alliance (IGMA). The FGIA became effective Jan. 1.

The group's vision focuses on improving home and building performance through better glass, window, door and skylight technologies and standards. The group said it will work to lead the glass, glazing and fenestration industry through research, consensus-based standards, product certification, advocacy, and education and professional development. FGIA will unveil its new logo and branding at the inaugural FGIA Annual Conference, to be held Feb. 10-13 in Ft. Lauderdale, Florida, along with a new promotional video.

For more information visit FGIAonline.org. Follow the group on social media at: Twitter @FGIAonline, Instagram @FGIA_online, LinkedIn @FGIAonline, and Facebook @FGIAonline.