During the holidays, employees at Pleasant Valley Teardrop Trailers in Sugarcreek, Ohio, were busy moving down the road to their new $2.5 million, 65,000-square-foot manufacturing facility.
The extra space is about five times the size of its former 12,000-square-foot plant about a quarter of a mile away. The move came in response to the fifth consecutive year of growth for the retro-looking teardrop trailers, such as the [email protected] and [email protected], designed and built by Pleasant Valley and marketed and distributed by partner Little Guy RV, based in nearby Massillon, Ohio.
“Not to be cheesy, but we’re like a bunch of kids on Christmas morning. We’d been thinking about it, talking about it and dreaming about it, and now it’s a reality,” said Pleasant Valley CEO Scott Hubble.
The new plant sits on six of the property’s 14 acres, allowing for future expansion. Hubble said Pleasant Valley can immediately double its output and, when necessary, “crank it up to three times” the current production. He added that by the end of 2015 he expects Pleasant Valley will have added an additional 20 jobs, bringing its workforce to around 65 employees.
The new facility both lengthens and widens one line of production, and adds an entire second line. Hubble is projecting the company will build 2,800 units next year of the company’s [email protected], [email protected], Silver Shadow, myPod, and other teardrop camper/trailers as well as its new Cirrus truck camper, which debuted at the National RV Trade Show in Louisville, Ky., in early December. That’s about 800 more than 2014, and a significant increase from the 700 units built in 2011.
Combined, the [email protected] and [email protected] account for about 65% of the units sold, pointed out Hubble, who added that the goal is to reduce the production backlog to about two months. Currently, orders are waiting until April before they are filled.
Besides the increased production, the new facility will also allow Pleasant Valley to perform additional manufacturing processes that it currently outsources, such as painting, to further increase its ability to control quality. The new plant will also house offices and have a dedicated 1,000-square-foot showroom with an adjoining sales office in the front lobby. A rotation of several Little Guy RV employees, including President Joe Kicos, COO Chris Baum, Vice President of Sales Dylan DeHoff and Regional Sales Manager Adam Kasamis, will work out of the sales office.
“We’ll also have a couple of campsites on the property for our current customers,” Hubble added.