Contributing to these sales is the production and distribution of a unique polyethylene float, which is filled at the company’s “foam plant” in Fergus Falls. Prior to the startup of the foam plant, more than 5,000 floats were filled in Iowa in 1987. ShoreMaster president Dennis Tuel estimates that 10,000 floats will be filled for ShoreMaster’s use in 1988. In addition, approximately 7,500 floats will be filled for other companies. By filling the floats in their Fergus Falls plant, ShoreMaster was able to reduce transportation costs significantly and realize a profit in their first month of operation.

Otter Tail Power Company’s very competitive Controlled Service Interruptible Rate and Rebate Plan were important factors in ShoreMaster’s decision to install an electric boiler in their foam plant. ShoreMaster’s 105 kw electric boiler is intrinsic to the first and third stages of their foam plant production system.

During the first stage, a polystyrene bead, similar in appearance to sugar or bale salt, is preexpanded by live steam. The beads are then moved along by air blowers to large mesh bags where the beads are allowed to give up the gas of expansion and reach equilibrium. This is the second stage of production. In the third stage the float is filled with the preexpanded beads, and a probe supplying live steam is inserted into holes located on the top side of the float. This live steam at 2 PSI and 330 degrees is injected into the float for approximately three minutes, assuring proper expansion of the beads. The floats are then allowed to cool and plastic caps are glued in place to seal the filler holes.

Another major reason for selecting an electric boiler was the safety factor – no open flame. The electric boiler is also CLEAN, QUIET, DEPENDABLE and COMPACT. EASE OF INSTALLATION was assured since NO FUEL STORAGE, AIR DUCTING OR AUXILIARY PIPING ARE REQUIRED. In addition, DESIRABLE OPERATING CHARACTERISTICS INCLUDE FAST RESPONSE TIME, FINE-TUNABLE OUTPUT, MINIMAL OPERATOR SUPERVISION AND SIMPLE OPERATION. Chuck Hanson, Supervisor, Industrial Services, at Otter Tail Power Company, worked with ShoreMaster’s management in various aspects of the project,

such as SIZING, SPACING, COORDINATING INSTALLATION AND ASSISTING WITH PROCESS INTERPHASE.

With the addition of more manpower and equipment, they are now filling approximately 80 floats per day and are able to keep pace with the demand for product.

Gary’s main function is to monitor the raw chemical used in the float for cost and efficiency and to determine which particular chemical will best meet their particular needs.