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Fiberglass door manufacturer Ryan-Al Door Systems Inc., headquartered in Diamond Bar, California, is moving manufacturing of shed products, such as doors and windows, to the United States from China, the company reports.

The company is moving its manufacturing operations from Zhejiang, China, to the Caldwell County, North Carolina, town of Lenoir. The company plans to start manufacturing its products for the shed industry in July.

“We are extremely excited to be moving our manufacturing facility to Lenoir and Caldwell County,” says Ryan-Al Door President and CEO Rick Trainor. “Having a pool of qualified labor and the financial support provided to us by the North Carolina Department of Commerce and Caldwell County will surely enable us to ‘hit the ground’ running.

“Everything that we planned is ahead of schedule, and we’re now at a point where we are waiting for our machinery to arrive. Being located in Caldwell County leads us to believe that this strategic location will open many more opportunities from a distribution standpoint.”

The company is also looking to move its distribution operations from Myrtle Beach, South Carolina, to Lenoir.

Ryan-Al received a North Carolina Department of Commerce Building Reuse grant for renovations to a Lenoir facility for manufacturing its products.

The $44,525 grant comes after a $150,000 One North Carolina Fund grant announced by Gov. Roy Cooper. Both grants were facilitated by the Caldwell County Economic Development Commission.

“North Carolina competes for business with locations around the world,” Governor Cooper says. “Ryan-Al’s choice to move operations from China to North Carolina demonstrates the many advantages our state offers manufacturers of every size.”

For the Building Reuse grant, Ryan-Al Door pledged to invest $1.7 million and hire 29 new full-time employees in a two-year period of time, with an average annual wage of more than $39,500, well above Caldwell County’s current average of $34,744 per year. The company’s three-year target will have full-time employment well above 50.

“This Commerce Department grant is fantastic news and dovetails nicely with the governor’s announcement,” Caldwell County EDC Executive Director Deborah Murray says. “We were so grateful to have Commerce Development representatives visiting the site recently to see, firsthand, the impact this grant will have for Ryan-Al Door and for Caldwell County workers.”

Trainor says the move from China back to the U.S. has been a long time coming. He got into the fiberglass door business in 2008, and by 2010, the company’s efforts had shifted toward the shed industry.

“Even though our focus had started to change to service the shed industry in 2010, I was not satisfied with the quality of product that we were producing to adequately provide for this market,” Trainor says. “We had issues sourcing suppliers for the proper type of raw materials and were very inefficient in our production capabilities.

“Being very frustrated and not satisfied with the quality of product that we were producing, the thoughts of moving the factory back to the U.S. were starting.”

By 2012, Trainor says the company had found improved raw materials in the United States.

“Manufacturing offshore surely proved valuable, but the time has come change direction,” he says “We feel that proper distribution is also a key ingredient in the success to the builders in market. By manufacturing outside of the USA, this causes a very large investment in inventory, large shipping expenses, and at times, excessive wait times for the customer—all additional cost and inconveniences that we believe will be offset by manufacturing in the USA.

“Strategically situated distribution centers will most certainly benefit the customer base as well.”


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