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| From Left to Right: Dave Hoefer, Founder and Chairman; Lamination Plant Manager, Ken Mahaffa; Vice President of Sales, Bill Harris |
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| Caption: Pilgrim International's new $400,000 ITI custom vacuum lamination system is able to process four walls consecutively in excess of forty-feet. |
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| Caption: The new facility is able to handle walls in excess of forty-feet. |
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Middlebury, Ind. – Pilgrim International, Inc., is pleased to announce an over $1 million complete up-fit of its new 36,400 square-foot lamination facility, including an over $400,000 1040 Industrial Technology International, LLC. Vacuum Lamination system, at the company’s manufacturing operations in Middlebury, Indiana. The new state-of-the art lamination facility is a key element to Pilgrim International’s dedication to building the highest quality fifth wheels and travel trailers as the company moves towards the production goal of an all vacuum-laminate, aluminum-framed construction of its entire line-up. The new facility has created 30 new jobs and may flex to 50 workers—depending upon seasonal and market fluctuations.
Vacuum and Roll-Coat Lamination Taken to the Next Level
Lamination Plant Manager, Ken Mahaffa, has over 30-years experience. His career starting with Pilgrim International, Chairman, Dave Hoefer with Four Winds back in the 1970’s. This is when the lamination process first began to define quality. Mahaffa spent 14-years with Thor after the sale of Four Winds to that company and has also worked in lamination for Mallard Coach and Coachman.
He began work with Pilgrim in late 2005 and got the new facility on-line quickly. “We had the facility up and running and producing our lightweight Cirrus line by January of 2006. We rebuilt everything from the ground up and started with that smaller system on the Cirrus line to get things going.”
The company then invested in a state-of-the-art, automated, vacuum lamination machine and a new hot-melt, roll-coater and a new, more secure system string-spreader. “We now have three lines in production running a variety of product lines and sizes—two vacuum lamination and one roll-coat.” Mahaffa explained that Pilgrim differs from other manufacturers in the serious approach the company is taking towards assuring the finest lamination processes.
“Everything we do here in our continuous improvement process, we do as a team. This facility is a group effort in partnership with our venders. Be it the glue companies, panel companies or any other supplier involved, we are quality testing everything. We want to make sure everyone is on the same page.” He went on to say that all the large sidewalls, ceiling and floors of all product lines are now running down the vacuum lamination line, “Smaller panels still go through the roll coaters,” he said. The plant now has the capacity to vacuum bond and roll coat over 100 high quality panels per day.
According to Mahaffa, over the last seven months the capacity of the new facility has increased steadily along with the built-in quality systems. “I’ve started up lamination plants before but this is one of the fastest startups I have ever done. But it’s also been one of the easiest because of the fact that everyone involved in these new systems has been completely behind me. There’s been no question, it’s always been ‘if you need it do it—whatever it takes to make a quality product and get the job done.’ This is a company looking for excellence. We’re not playing second fiddle to the competition. Working closely with our vender partners we’re going top notch.”
Producing A Laminated Product with Little or No Warranty Issues
Mahaffa stated that the product is being received in the field extremely well with little or no warranty issues. “Our salesmen have come in and told us that this effort is paying off with some of the highest quality lamination in years. As far as I know there have been no recalls or delaminating issues.”
Mahaffa went on to explain that Pilgrim International is out to solve the industry’s lamination issues of toad skinning and distortion. “While a lot of people in the industry have had ‘toad-skinning’ and fiberglass distortion issues and have sat on their hands and pointed fingers at suppliers, we have been working closely with our suppliers to get right in the middle of the situation and move to the next level of quality.”
A Winning Management Team
“We don’t want to be the biggest, we want to be the best.”
With well over 100 years of combined recreational vehicle manufacturing experience, the veteran management team at Pilgrim International, with the combination of Board Chairman, Dave Hoefer; President, Steve Bennet; and Vice President of Sales, Bill Harris; have been instrumental players in the recreational vehicle industry since the 1960s. Having founded a number of companies such as Dutchman and Four Winds, that were successfully managed and merged to larger multi-divisional companies, this management team has the “Big Picture” industry savvy to compete against the conventional RV mass producers of today with quality niche products.
Founder Dave Hoefer championed the vision of Pilgrim International, Inc. Hoefer was the founder of Dutchmen trailers and fifth wheels and Four Winds motor homes. These two successful companies were ultimately sold to Thor Industries. Hoefer has been in the RV industry since 1962. His prior companies were known for producing high value, high quality products.
President, Steve Bennett, has extensive background in the steel fabrication business. His company is an integral supplier for steel hardware and furniture used in the Open Road brand. This key component will provide added value to Pilgrim products. Steve oversees the daily operations of Pilgrim International, Inc. and is responsible for future strategic planning, expansions and acquisitions.
Partner and Vice President of Sales, Bill Harris has been in the industry since 1972. The majority of this time spent on the supply side of the RV business. Harris also has a great deal of experience in the sales and marketing with Carriage Inc. and Gulfstream Coach, Inc. His vast experience will provide product expertise and marketing direction.
As Pilgrim International Chairman, Dave Hoefer recently stated, “We don’t want to be the biggest, we want to be the best.” This philosophy of quality is showing for the company in the open marketplace with satisfied dealers that have few warranty issues.
As veteran Regional Sales Manager for Pilgrim’s top-of-the-line flagship series of Open Road fifth wheels and travel trailers, Bill Bellaire, recently stated, “These guys get it. They know the key to this business is quality, satisfied dealers with no warranty issues, and customers that are getting a lot of product for their money with no problems.”
For more information contact Pilgrim International, Inc., at 14489 U.S. 20, Middlebury, IN 46540,
Ph: 574-825-8686, Fx 574-825-8166, or on the web at www.pilgrimintl.com - Protected dealer territories are now available for all lines of Pilgrim products. 10
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