CHATSWORTH, Calif.—Pipedream Products has opened a new, state-of-the-art manufacturing facility in Chatsworth for PVC and TPR toys, including the company's new Real Cock line which debuted at ANME in this month. The manufacturing facility is located near Pipedream's Chatsworth headquarters, in a 50,000-square-foot building which has been renovated and supplied with equipment including improved extruding machines and re-plated molds. A new proprietary cooling system has been installed to expedite the manufacturing process, cutting the cooling time for freshly poured product to a fraction of the previous 24-hour cooling time.
"Now, a brand-new dildo is poured, packaged and ready to ship in just one hour," Chairman and CEO Nick Orlandino said.
Under the new system, molds run on a conveyor belt through a cooling tunnel that blows cold air directly on the mold. Workers can remove the freshly molded product immediately, freeing the mold for the next pour. From there, the extracted pieces are moved to a high-tech cooling bath, which quickly drops the rubber’s temperature and preps it for handling. An automated conveyor system transports the dildos from the cooling tank to the finishing area, where workers trim and smooth the product and prepare it for packaging. Once the items are packaged, they are boxed in master cartons for shipping.
The improved procedures have increased fill rates by 140 percent, and the new facility can produce 5,000 packaged and ready-to-ship products per workday. The new system is currently fully functional and Pipedream reports that the company can produce 1.2 million products a year on a regular 40-hour workweek, which can be increased by adding a second shift.
Although Pipedream has been producing its rubber products in the U.S. since 2007, high demand for products in the Basix line starting in 2013 led to manufacturing shortfalls, in turn leading to the establishment of the new facility.
“We’ve brought on Tony Hernandez, a 27-year industry veteran of rubber manufacturing and product development, to help lead the way, and his vast knowledge of new materials and proven techniques is a valuable asset to our team,“ Pipedream Chairman and CEO Nick Orlandino said. "Senior Vice President of Operations Pete Ledeboer has an extensive background in manufacturing for mainstream companies like Mattel, Kransco and El Dorado Stone, and he’s helped develop and implement large-scale manufacturing processes that will help us make the highest quality products at the best prices.”
Ledeboer is enthusiastic about the new facility.
“I have been involved for twenty-plus years with slowly moving manufacturing from the United States to either Mexico, China, Indonesia, or the next low labor market on the horizon due to labor costs,” Ledeboer said. “My goal, starting with the Basix area, is to remove as much non-value added cost to our product lines, using lean manufacturing principles, so that as many of our current and future products can possibly be made in the U.S.A. in a high-quality, efficient manner. Every time that we are successful at this strategy, it will help Pipedream achieve timely new product introductions, quicker reaction to market, less complex supply chain management, and ultimately, higher customer satisfaction.”
In addition to new collections like Real Cock, Pipedream also is able to offer private label manufacturing for custom orders. The addition of the new processes, systems and equipment can make Pipedream "the largest manufacturer of rubber and TPR in America," a spokesperson said.
The facility will produce Pipedream's new Real Cock collection, with more than 50 pieces offering "the most realistic PVC dildos ever created in America." The Real Cock collection offers 18 distinctive styles available in three colors: flesh, brown, and black. Each piece has been handcrafted and detailed to offer a lifelike beginner’s dildo, made with phthalate-free, latex-free, hypoallergenic PVC rubber. Real Cock is offered as an affordable alternative to Pipedream's more realistic higher-priced Real Feel Fanta Flesh collections.
“We’ve taken the most affordable material on the market and transformed it beyond what most people imagine when they think of PVC,” Pipedream VP of Development Rob Phaneuf said. “Though both collections are made with PVC, the Basix range features the traditional transparent look that’s associated with jelly toys; the Real Cock collection looks and feels like a completely different range. From better molds to even better manufacturing to extremely detailed decorating, the entire manufacturing process has made Real Cock the best beginners PVC range on the market.”
Every Real Cock dildo features a suction cup base for wall attachment and harness compatibility. Sizes range from 6 to 12 inches long, with and without balls, and include double dongs and anal plugs. "The variety of shapes, sizes, and styles truly ensures satisfaction for everyone," Phaneuf said.
The products of the Real Cock collection are shipped to retailers in uniform clear clamshell packages, and are supported by Pipedream's marketing department, offering custom planograms, physical and digital catalogs, art, videos, branded signage, and hands-on training by request to meet distributors' and retailers' needs for effective merchandising, both in-store and online.
“With the flood of cheap, non-compliant Chinese imports in the market today, Pipedream has built the ultimate facility to bring manufacturing back to America,“ Orlandino said. "By doing so, we can offer better quality, compliant, body-safe products in large volume at competitive prices, and we can do it faster and more efficiently than any other manufacturer. Pipedream is known for 95 percent fill rates on our entire product line, and this new facility will help us maintain this standard.”
For more information, visit PipedreamProducts.com.
