Let’s delve into the key facts behind the incredible new Modix plant build located in Kaukauna, WI. Modix USA, spearheaded by Sebastien Schmidt, has emerged as a pioneering force in the foam molding industry since its inception in 2011. Specializing in the building of non-conventional shape molding presses, Modix USA serves the molders of a diverse array of engineered foams such as EPS, EPP and the like.
With this construction project, the aspirations and challenges of Modix USA were substantial. Their objective? To construct what they believe to be the inaugural net-zero energy manufacturing plant in North America. Achieving this lofty goal required the selection of many innovative construction methodologies and materials, such as Insulated Concrete Forms (ICFs) combined with a steadfast commitment to sustainable, energy-efficient design principles.
This plant was constructed with 10” concrete core Logix Pro walls which were chosen over traditional steel structures primarily due to their energy efficiency and overall sustainability. AMC Foam, with Vice President Conrad Hoeppner’s assistance, played a crucial role in this project, showcasing the power of collaboration in achieving groundbreaking results.
Heat-Sheet Heavy (R10), another engineered insulation product made by AMC Foam, was used to insulate under the slab and served as the placement grid for the pex pipe that heats the slab. This new Modix plant is entirely heated by the hydronically heated slab in the building. And the gas powered boiler heating the water for the hydronic heating system is actually surprising small (1 ft x 2 ft x 1ft)!
An R50 SIPS roof completes this super energy-efficient building envelope.
In due course, Modix USA’s new facility seamlessly commenced operations. It stands not merely as a manufacturing plant, but as a testament to sustainable manufacturing practices. Equipped with a photovoltaic bank capable of generating 40 KW of power, the facility basically achieves complete energy autonomy.
In owner Sebastien Schmidt’s mind, this triumph is not exclusive to Modix USA; to Schmidt it holds broader significance for sustainable manufacturing on a global scale and exemplifies the transformative potential of EPS foam as an environmentally responsible material with approximately 89% of EPS now either recyclable or amenable to recycling.
Now, let’s explore some of the takeaways from this project
- Embrace Sustainable Materials: Modix USA’s use of EPS and other engineered foams demonstrates the potential of sustainable materials in industrial applications. Companies can explore innovative materials that reduce environmental impact.
- Leverage Local Expertise: The collaboration with local experts and suppliers for construction and installation underscored the benefits of tapping into nearby resources, reducing logistics costs, and supporting the community.
- Prioritize Energy Efficiency: The implementation of a photovoltaic bank and radiant heating system highlights the importance of investing in energy-efficient technologies to achieve net-zero energy goals.
- Adopt ICF Construction for Sustainability: The decision to use Insulated Concrete Forms (ICFs) over traditional materials for better insulation and energy savings is a practical tip for those looking to build sustainably.
- Promote Recycling and Sustainability: Sebastien’s focus on the recyclability of EPS showcases how promoting and implementing recycling practices can enhance a company’s sustainability profile.
