New U.S. Manufacturing Plants Unveiled
In May 2024, the U.S. manufacturing sector saw significant growth with several new facilities unveiled. Key projects include ION Storage Systems' advanced battery plant in Maryland, GAF Energy's solar roofing facility in Texas, and Boviet Solar's $294 million investment in North Carolina. These developments represent substantial investments and job creation, highlighting a robust trend in advanced manufacturing across the country.
ION Storage Systems Powers Up Advanced Battery Manufacturing
ION Storage Systems has ignited a new era in battery technology with the commissioning of one of the largest solid-state battery manufacturing facilities in the United States. Located adjacent to their headquarters in Beltsville, Maryland, the state-of-the-art pilot line is set to produce 1MWh of battery cells this year, with plans to scale up to 10MWh by early 2025 and an ambitious target of 500MWh by 2028. This groundbreaking facility is not only a testament to ION’s innovative spirit but also a boon for Maryland’s economy, promising to create a significant number of skilled manufacturing jobs in the coming years.
Said Ricky Hanna, CEO of ION Storage Systems, “From the outset, our goal has been to develop an advanced solid-state battery that delivers enhanced power, reliability, and safety, all while being scalable in production.”
James Hardie Launches New Manufacturing Plant in Westfield
James Hardie Building Products Inc. has marked a significant expansion in the Northeast with the grand opening of its new manufacturing facility in Westfield, Massachusetts. The plant, which represents a $50M investment, spans 200,000 square feet and is set to employ up to 65 full-time employees. This site will be dedicated to applying ColorPlus® Technology proprietary pre-finish coatings to Hardie® fiber cement siding products. The facility, previously owned by National Envelope Company, began operations in January 2024 and is expected to have a substantial impact on the local economy.
Sean Gadd, James Hardie North America President, expressed his enthusiasm for the new site, stating, "We are incredibly excited to solidify our presence in the Northeast with our new Westfield facility."
GAF Energy Powers Up New Solar Roofing Facility in Texas
GAF Energy, a leader in solar roofing solutions, has inaugurated its new Timberline Solar manufacturing facility in Georgetown, Texas. The state-of-the-art 450,000-square-foot complex is set to meet the surging demand for the company’s innovative solar roof product, Timberline Solar™. This expansion marks a significant milestone for GAF Energy, boosting its production capacity by 500% and propelling it to become the world’s largest producer of solar roofing with an annual output of 300 megawatts.
Martin DeBono, President of GAF Energy, expressed his enthusiasm, stating, "Today is a great day for the future of solar and the future of Georgetown."
Boviet Solar Powers Up North Carolina with Major Investment
In a significant boost to North Carolina’s clean energy sector, Boviet Solar, a global leader in solar technology, has announced the establishment of its first North American solar panel manufacturing facility in Greenville, Pitt County. The company is set to invest over $294 million into the state’s economy, creating 908 new jobs in the process. The 1-million-square foot advanced manufacturing facility will enhance Boviet Solar’s capacity to produce high-end solar panels and photovoltaic (PV) modules.
Jimmy Xie, General Manager of Boviet Solar, expressed the company’s commitment to the U.S. market, stating, "Our dreams of producing our PV modules in the U.S. finally come to realization. We are proud of bringing our manufacturing excellence to our most important solar market, creating jobs, and making a positive impact on North Carolina’s economy."
Kohler Co. Expands with Innovative Manufacturing Facility in Arizona
Kohler Co., renowned for its kitchen and bath products, has recently inaugurated a cutting-edge manufacturing facility in Casa Grande, Arizona. This strategic expansion is marked by a significant multi-million dollar investment that underscores the company’s commitment to growth and innovation. The new plant spans approximately one million square feet on 216 acres, providing ample space for future growth. It is dedicated to producing the STERLING brand of bathing and showering products, addressing the increasing market demand and enhancing the customer experience.
The establishment of this state-of-the-art facility is set to create over 400 full-time jobs, contributing to the local economy and offering opportunities for career development. “The new plant provides the capacity to support our strong growth projections for STERLING to better serve our customers with the highest level of quality and delivery,” stated Norbert Schmidt, President-Kitchen & Bath North America for Kohler.
Crystal Window & Door Systems Expands with New Manufacturing Center in North Carolina
Crystal Window & Door Systems, a prominent manufacturer in the window and door industry, has announced the establishment of a new manufacturing center in Johnston County, North Carolina. The company plans to invest $83.6 million in the town of Selma, which is expected to create 501 jobs. This new operation will specialize in aluminum and vinyl extrusion, as well as window and door fabrication, complete with in-house finishing capabilities such as powder coating paint. “Crystal Windows started in 1990 from my dream of building my own business,” said Thomas Chen, Chairman and Founder of Crystal. "With hard work and perseverance, Crystal is now a national manufacturer that continues to grow. Our expansion to North Carolina is a terrific next phase of that growth."
Green New Energy Materials, Inc. Expands with New Facility in North Carolina
Green New Energy Materials, Inc., a Delaware-based leader in battery component manufacturing, has announced a significant expansion with the establishment of a new lithium-ion battery separator manufacturing facility in Denver, North Carolina. The company is set to invest $140 million into the project, which is expected to generate 545 new jobs in Lincoln County1. This strategic move marks the company’s first manufacturing presence in the United States and aims to meet the increasing demand for high-performance battery separators used in various challenging battery applications.
Christopher Chung, CEO of the Economic Development Partnership of North Carolina, expressed his enthusiasm for the project, stating, “With the largest manufacturing workforce in the Southeast and an East Coast location offering easy access to supply chains and customers, Green New Energy Materials are sure to thrive here.”
BorTec USA Invests in Tennessee for First U.S. Production Facility
German-based manufacturer BorTec USA has announced the establishment of its first U.S. production facility in Northeast Tennessee, marking a significant investment of over $3 million in Washington County. The new heat treatment plant, located in Johnson City, is set to create 35 new jobs and will primarily produce wear and corrosion-resistant pipes for the oil and gas industries. This move signifies a strategic expansion for BorTec, a subsidiary of the BorTec Group, and more than doubles the company’s global headcount.
BorTec USA CEO Ralph Hunger expressed the company’s decision to choose Tennessee, highlighting the state’s favorable business environment. “Tennessee offers a highly favorable business environment, with low tax burdens, reasonable operating costs, and an abundant skilled workforce.”
Georgia Welcomes New E-Mobility Manufacturing Facility
Governor Brian P. Kemp announced a significant investment by GF Casting Solutions AG, a division of Georg Fischer AG, into a new manufacturing facility in Augusta, Georgia. The investment, totaling more than $184 million, is set to create 350 new jobs in Richmond County. The state-of-the-art, LEED-certified facility will be located at the Augusta Corporate Park and is expected to begin operations in 2027. Specializing in cast aluminum parts, the facility will focus on large structural components for the automotive industry, contributing to the thriving e-mobility market.
Carlos Vasto, President of GF Casting Solutions, expressed enthusiasm about the expansion, stating, “Building a High Pressure Die Casting Facility is a very long-term investment. The new facility will complete our footprint to become truly global in the e-mobility market.”
CAVA Culinary Expansion: New Facility in Virginia
CAVA, the trailblazing Mediterranean fast-casual restaurant brand, has unveiled a new 55,000-square-foot manufacturing hub in Virginia’s Shenandoah Valley. With a substantial investment of $35 million, the Verona facility is set to bolster CAVA’s dips, spreads, and dressings production for both its restaurant chain and consumer packaged goods division. Brett Schulman, Co-Founder and CEO of CAVA, expressed his enthusiasm for the new venture, stating, "By centrally producing our dips and spreads, we reduce complexity in our restaurants, improve costs overall, and maintain the quality, consistency, and integrity of our chef-crafted recipes at scale."
Torus Powers Up with New Utah Facility
Torus, a trailblazer in sustainable energy storage solutions, has marked a significant expansion with the opening of its new headquarters and manufacturing facility in South Salt Lake, Utah. Spanning 44,000 square feet, the state-of-the-art site is a hub for the company’s advanced production technologies and commercial solutions, including innovative flywheel and battery energy storage systems. The grand opening event, which took place on May 16, drew nearly 400 guests and featured technology demonstrations, tours, and community engagement activities.
Sources
“New U.S. Manufacturing Operations Announced in May 2024.” Industry Select, May 17, 2024, https://www.industryselect.com/blog/new-us-manufacturing-plants-unveiled-in-may-2024
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