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Eastern Alloys of Kentucky, LLC - Henderson, KY.
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From the Start
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Richard J. Bauer
founder and chairman of
Eastern Alloys, Inc
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Since production of the first heat of ZAMAK3 alloy at Eastern
Alloys' Maybrook, NY facility, the company's singular goal has been to supply
superior products supported by exceptional service. That was 35 years ago, and
while many things have changed over that period there are certain constants
that are timeless. Not surprisingly, that credo remains the foundation of the
company's success.
Today, Richard J. Bauer, Eastern's founder and Chairman,
expresses the notion this way, "You know, we never set out to be the biggest.
We just wanted to give customers the best product possible and support their
success any way we could." So then it's reasonable to reflect upon the impact
of ".any way we could". Eastern's customer focused activities include market
leadership in ZA-Alloy production and process technology, comprehensive
technology transfer programs, environmental advocacy, specifically, the
Washington Conference on Zinc, and innovative marketing and business
development programs that have created substantial new growth. More recently,
the company has added a sophisticated price risk management facility designed
to help customers protect selling price and/or margin by effectively managing
exposure to the inherent risks of the commodity markets. In today's
hyper-competitive marketplace Eastern Alloys develops strategies that make a
positive contribution toward the financial strength of a growing number of its
customers.
Richard J. Bauer reflects on the company's continued good
fortune noting that, "We did these things because we knew that our opportunity
to succeed depended directly upon our customer's success."
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The challenge of a new market
This unwavering commitment to the marketplace has fueled the
company's growth over a period that stretches across five decades. In fact,
Eastern's customer-centric business model succeeded to the extent that during
the nineties the company simply outgrew its flagship New York operation
creating new challenges for the future. While others in the zinc alloy business
were struggling with rigors of increasing market volatility Eastern Alloys
initiated an expansion strategy. It was apparent that a new facility was the
only option.
The responsibility to find the site for Eastern's second plant
fell to Richard H. Bauer, President & Chief Operating Office. Dick Bauer,
the younger son of the company's founder, joined Eastern in the early eighties
after a career in metal trading that followed a B.S. in Metallurgy from
Michigan Tech. In any event, an extensive site evaluation had a happy ending in
Henderson, Kentucky. As it turns out Henderson was an ideal match.
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Richard H. Bauer
receives ceremonial shovel
from Judge Sandy Watkins.
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The folks from the Henderson County Economic Development
Commission were incredibly supportive and stayed with the process from the site
location and development phase to construction through to the launch ceremony.
On April 11, 2000 Eastern Alloys of Kentucky, LLC was officially commissioned.
At the ceremony Dick Bauer addressed the approximately 250 invited guests. He
shared with them that from the start, "Henderson felt right". Explaining the
rationale behind the selection of Henderson over competing sites he said,
"Henderson provides access to major interstate connectors in all directions,
the Henderson County Riverport Authority provides barge access to raw material
from global suppliers through the Port of New Orleans, plus Henderson is about
500 miles from just about anywhere." To the people of Henderson he shared his
appreciation by likening the spirit of the community to the name of the
Riverport's tugboat, Can Do.
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A new benchmark
By any measure Eastern Alloys of Kentucky, LLC is a remarkable
achievement. It is the newest integrated green site zinc alloy manufacturing
and recycling complex in North America. With deference to Richard J. Bauer's
focus upon being the best, not the biggest, Eastern's new plant is the most
comprehensive, technological advanced facility of its kind in North America.
Phase I is configured on a 17.5 acre parcel 300 yards from the Ohio River.
Primary alloy production is anchored by a 386,000-pound capacity
immersion tube furnace and four 30,000-pound natural gas fired furnaces.
Purpose-designed, engineered, and constructed by Lindberg/MPH, the immersion
tube furnace is the largest of its kind in the world with the second largest
(336,000 pounds) pumping out metal everyday at Eastern's Maybrook plant. Ingot
products are produced on a high speed, semi-automatic ingot caster. The ingot
caster bristles with proprietary technology and is designed to accommodate
automatic ingot stacking, and packaging. Sows are cast in water-cooled molds
located at the west end of the immersion tube furnace.
Another unique aspect of EA-KY is the use of Inductotherm
(coreless) electric induction furnaces to produce super high quality Galvalume
in addition to supply the zinc alloy operation with liquid aluminum units. The
twin 5.5 ton capacity Inductotherms are rated at 1750 KW and can melt 7,000
pounds of aluminum per hour. Each is equipped with a separate power supply.
Phase I also includes a discrete, environmentally compliant
dross and scrap-recycling complex.
Linking the melting and casting equipment is a network of high
capacity ductwork feeding into a trio of continuous pulse cleaning bag houses.
Depending upon demand the bag houses can be operated independently, in pairs,
or in series.
The building was designed for efficient, straight-line material
flow. Raw material is received through one specific dock with finished products
shipped from another. Two North American Industries multi-hook bridge cranes
facilitate intra-plant material handling. The cranes have a span of almost 65
feet and travel the length of the building. One is fitted with 15 ton and 7.5
ton hooks while the second crane has 15 and 5 ton hooks. Two cranes create an
added dimension of material handling flexibility.
Notwithstanding the level of installed technology it's the
good folks at Eastern Alloys of Kentucky, L.L.C. that make it all work. From
AVP Construction, the general contractor, to the tradesmen and construction
labor, this new facility was built from the ground up by the local community.
More importantly, virtually everyone on staff is from the Henderson or nearby
communities.
During the April 11, 2001 dedication, Richard J. Bauer thanked
the community for its support and expressed his sense of gratitude noting that,
"We have been made to feel like Henderson is home."
To date ZAMAK 2,3, 5 and 7, ZA-8, ZA-12, ZA-27, ZA-5, ACuZinc 5,
Galfan, Galvalume and galvanizing brightener products have been produced and
supplied from Eastern Alloys of Kentucky.
Eastern Alloys of Kentucky, LLC represents an important
benchmark. It is the convergence of experience, vision, and commitment.
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Richard H. Bauer, President & COO, welcomes invited
guests and dignitaries to Eastern Alloys of KY with
Richard J. Bauer, Founder & Chairman, at his left.
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Eastern Alloys, Inc. is a member of the London Metal Exchange, or
LME, ILZRO, Interzinc, NADCA, and DDC.