[music playing] from the hot arid desertsof arizona, nevada, and new mexico to the cool, moistsea coast of california, dunn-edwards paints areformulated specifically for the climate of the southwestto protect and beautify a wide variety ofarchitectural surfaces. since its founding 85years ago, dunn-edwards has provided more than 450million gallons of paint
to the region, enough to covermore than 6,000 square miles of surface area. but why do so manyprofessionals choose to paint their most importantprojects and their own homes with dunn-edwards paints? because they knowfrom experience it's the highestquality paint available. in 1925, two youngwallpaper salesmen, frank buddy dunnand charles smith,
formed the dunn-smith company. and by 1927, it evolved intothe consolidated wallpaper corporation of los angeles,selling wallpaper and paint. by 1937, paint sales beganto exceed wallpaper sales. and the company openedits own paint factory consisting of two usedstone mills, an agitator, a cooking kettle,later, some rotor mills. its crew consisted of oneman who made the paint and cooked the varnish.
the next year, arthur c. edwardsbought into the business, becoming half owner. sales immediately improved. and a businessphilosophy was born-- make the finest line ofpaint, and give the best service at fair prices. it's a philosophy thatendures to this day. throughout the 1950s, hundredsof thousands of new homes were built across californiaand the southwest.
many of them werepainted with the brand the professional paintersrecognized as the best available-- dunn-edwards. the following decadesaw dunn-edwards continue to expand. [cameras snapping] today, with more than 100stores across the southwest, dunn-edwards remains theforemost manufacturer and supplier of premiumarchitectural and industrial
coatings in the region. with landmarks such as staplescenter arena, caesar's palace, the walt disney concerthall, and many other renowned structures all entrustingtheir beauty to dunn-edwards, we understand theimportance of continuing our legacy of producing the veryhighest quality paint possible. towards that goal, in 2009,dunn-edwards began work on a new state-of-the-artproduction and distribution center in phoenix, arizona.
the new facility includesa manufacturing plant, product development, andquality control laboratories, a distribution center,store, and office space. totaling over335,000 square feet, it has a capacity to produce30 million gallons of paint annually and can employ upto 150 full time workers. for 85 years, dunn-edwardshas prided itself on providing world classservice and great paint. and we continue tostrive towards that.
here we'll be able toexpand our capacity and improve our efficiency. this new facility in phoenixrepresents the next chapter in the story of dunn-edwards. at the heart of the new facilityis the state-of-the-art paint manufacturing plant thatproduces the finest paint formulations in the world. the process begins with thedelivery of raw materials that include resins andvarious paint additives.
storage capacity of morethan 400,000 gallons is used to store over 250unique ingredients that are used in dunn-edwardsdiversified paint lines. many of the liquid rawmaterials are stored in a 60 tank fishbowl system. each fishbowl, which is a275-gallon mini bulk tank stores a different additive. the weight of eachtank is precisely measured using afloor scale which
allows for accuratedelivery of small amounts of these ingredientsto a batch of paint. one method of dryraw material addition is through ouradvanced slurry system which convertssolid raw materials into liquid slurry that can bepumped throughout the plant. this system allows solids tobe mixed 30% more efficiently. and dunn-edwards is theonly us paint manufacturer were to use thisslurry technology.
dry raw materialsthat are not processed using the slurrysystem are processed using high speed dispersers. weight controlledthrough load cells, these stainless steel tanksprovide high speed mixing to achieve specifications. the speed and heightof the mixing blades are automaticallycontrolled and tailored for specific formulations.
these high speeddispersion tanks use an integrateddust capture function so that 100% of thepigment is used in product and there are noparticle emissions. this makes good senseboth economically and environmentally. in the final mixing steps,the end process materials and remaining ingredientsare mixed in let down tanks. these tanks gently agitateup to 12,000 gallons of paint
at a time to the finalproduct specifications before the fillingprocess begins. to design the processcontrol system in this plant improves the accuracyand efficiency of paint manufacturing. there over 1,600automated valves that are used to the materialsthroughout the system. every tank sits on its ownload cell which can precisely weigh the amount ofraw material that
goes into every batch of paint. this automation ultimatelysaves us time, reduces waste, and helps us create ahigher quality product. after the painthas been produced, the job of packagingand shipping begins. dunn-edwards automatedfilling lines can package over100,000 gallons per day. it starts with the de-palletizerwhich automatically sorts empty cans frompallets and places them
on a conveyor to be filled. as cas speed down the conveyors,they're labeled and filled. the automated fillersdispense paint into the cans based onspecific formula weights to ensure accurate fill levels,cleaner fills, and lower product waist. one line alone iscapable of filling 44 one-galloncontainers per minute. lids are placed on the cans,ensuring proper placement
and seal. gallon cans are baled. each and every can is identifiedfor manufacturing, quality control, and tracking purposes. the processes and technologyused in this paint plant are unsurpassed inthe paint industry. this allows us tocreate a quality paint that's consistent canafter can, batch after batch. product is bundledin four-pack gallons
and nine-pack quarts of paint. using a strong lightweightrecyclable polyethylene film, the bundler reduces packagingcost by more than 50% and eliminates the wasteand energy costs associated with cardboard boxes and trays. as product completesits journey, the palletizer stacks bundlesof one-gallon and quart cans onto pallets. the pallet wrapper wrapsthe pallets with film.
it uses a pre-stretchedcarriage that allows the film to be stretchedup to 300% for optimal use and cost savings. this saves the equivalentof approximately 60 miles of unstretched film per year. larger five-gallon containersgo through much the same process as the gallon and quart cans. one step that is differentis the palletizing of the five-gallon buckets.
here, a robotic arm actuallylifts and stacks the buckets. it's capable apologizing upto 60 five-gallon buckets per minute. the robot offers a safer,quieter, and more energy efficient alternative totraditional palletizing technology. this plant can be describedas an ultra-low discharge facility, meaning wastegeneration is minimized. in addition, the entiredesign and construction
followed leed guidelines andhas achieved leed certification. this is all in keepingwith dunn-edwards greener by design philosophy of beingas eco-efficient as possible. from the company's first paintfactory in the 1930s to its industry-leading practices todevelop environmentally safer formulations, dunn-edwardscontinues to set new standards of quality with the openingof this state-of-the-art eco-efficient paint factory thatwill pave the way into this new century.
dunn-edwards was founded onstrict standards of excellence backed by stringentquality control, testing, and eco-efficient principlesto assure the finest and safest paint products possible. our highly precisecomputer-controlled manufacturing process resultsin the best formulated, most reliable paint andcoatings in the industry: can after can,batch after batch. no wonder dunn-edwards paintis the number one choice
of painting anddesign professionals. in fact, morepainting professionals paint their own homewith dunn-edwards than any other paint. we could think of nobetter endorsement. dunn-edwards-- thenumber one choice of painting professionals.