Graycor provided design-build services for Polyplex’s first manufacturing facility in the United States. Based in India, Polyplex is the world’s fourth largest producer of plastic film. The strategic selection of the 44-acre Decatur location was made as a result of several key factors including the area’s existing industrial infrastructure, access to trained manpower and key raw materials, and close proximity to major U.S. customers.

The Plastics Plant project consists of six primary buildings on site. These structures included a 34,000-square-foot packaging/shipping warehouse, a 14,500-square-foot central utility building, a 15,000-square-foot resin plant, an 84,000-square-foot film plant, a 12,500-square-foot value-added building and a 6,000-square-foot office building.

This design created many logistical challenges with fitting of the equipment and 30 different piping systems totaling more than 22,000 feet into the smaller design. The construction team utilized 3D models to sequence the installation of the piping.

The project involved extensive coordination efforts between Graycor and Polyplex with owner-furnished, owner-installed (OFCI) as well as owner furnished, contractor installed (OFCI) equipment.

The team successfully completed the project with highest level of quality and achieved an exceptional safety record of 557,258 total man hours worked with zero lost time.

ENR recognized the Polyplex Manufacturing Plant for project excellence with the Best Projects Merit Award for Manufacturing.