From miter doors and dovetail drawers, to mantels and wainscot panels, the DePere, WI-based Valley Custom Door does it all.

The component manufacturer shares the 180,000-square-foot plant with sister company Valley Cabinet, a full-service manufacturer of custom cabinetry for the kitchen and bath. Also at the location are the corporation’s semi-custom Seville Cabinetry line and postformed countertop division, Counterform LLC.

"We’re unique in our diversification, but are so intertwined," said Steve Mashl, plant manager. "We share materials, finishing and even the employees."

Founded by Jim and Mary Jane Stoller, the company has more than four decades of experience in manufacturing for the cabinet industry. In addition to its other products, Valley Custom Door offers more than 250 door styles, including 15 standard wood species and more than 90 standard finishes, from which to choose. Specialty finishes are also available.

The company uses just-in-time manufacturing to produce approximately 3,000 doors per week. Valley Custom Door uses high-tech machines, including a recently purchased Balestrini for miter door construction, to ensure strict dimensions during the machining process. In addition to the immediate savings in time and quality control, Mashl said, the company realized a return on investment for the machine of approximately one year.

In addition to the Balestrini miter door machine, other equipment integral to the production of the cabinet components are: Progressive Systems rip and crosscut lines, a Holzma panel saw, Stiles/Weeke routers, a DMG/Celaschi tenoners, a Doucet clamping system, Wadkin moulder, and Costa, Opti-Sand, Timesavers and Fladder sanding systems. Cabinet Vision software is also used at the facility. The company runs two shifts in the door, dovetail drawer and finish areas, and one shift for the cabinet and countertop lines.

According to Mashl, Valley Custom Door is committed to reducing its carbon footprint. For example, the company has installed variable speed air compressors and conducts an annual air-leak study to ensure it is not wasting energy. Also, wood waste is sold to a local company for fuel.

The company has three showrooms in Wisconsin: DePere, Sturgeon Bay and Fox Valley.

Watch a video to see how the miter doors are machined.

For more information, visit www.valleycustomdoor.com

More WCMA Plant Tours

Oshkosh Door, Oshkosh, WI

Elipticon Wood Products, Little Chute, WI

Oshkosh Design, Winneconne, WI

Wolf River Lumber, New London, WI

Valley Custom Door, DePere, WI

DeLeers Millwork, Green Bay, WI

J. Pechauer Custom Cues, Green Bay, WI

Wisconsin Log Homes, Green Bay, WI

Video tour of the plants

Main story

The next WCMA Fall Conference & Plant Tour Event will take place Oct. 3-5, 2010, in Williamsport, PA. Contact the WCMA at wcma@woodcomponents.org, or visit www.woodcomponents.org

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