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TOTO's $224M Manufacturing Facility in Georgia: A New Era in Luxury Toilets

In a significant move to bolster its manufacturing capabilities in the Americas, TOTO, the world's foremost plumbing manufacturer, officially launched a cutting-edge manufacturing plant in Morrow, Georgia. The newly constructed facility, which represents a whopping $224 million investment, is poised to expand TOTO's luxury toilet production capacity by an impressive 150%. This strategic development not only aims to enhance the delivery efficiency for the brand's high-end one-piece toilets but also affirms the company's dedication to sustainability and local manufacturing.

A Leap Towards Enhanced Production

TOTO has been at the forefront of bathroom innovation since its inception, and this new facility marks the latest chapter in its growth story in the United States. The Morrow plant spans a substantial 363,393 square feet and is designed to house the latest in manufacturing technology. It is expected to yield an additional 300,000 toilets annually, significantly contributing to the company’s regional supply chain and ensuring a more agile response to the burgeoning market demands.

Taro Muroi, the CEO of TOTO USA, emphasized the importance of this new facility in a recent statement: “This is more than a factory opening—it's the next chapter in our U.S. manufacturing story.” Since launching operations in America in 1991, TOTO has built a legacy combining innovative manufacturing techniques, local craftsmanship, and sustainability, thus elevating the premium experience associated with its products.

The advantages of local production are manifold, especially when it comes to surmounting the logistics hurdles that have historically impacted delivery times. With luxury toilets primarily sourced from TOTO's Asian plants, customers faced significant wait times. The establishment of the Morrow factory offsets these challenges and enhances the overall efficiency of the supply chain.

Cutting-Edge Technology and Robotics

At the new facility, advanced technology plays a pivotal role in streamlining production. Key innovations include:

• - Tank Bonding Robot: A groundbreaking automation tool that accurately aligns and bonds tank fittings to bowl structures, enhancing both quality and throughput.
• - Automation Fleet: Comprising thirty-four specialized robots, this fleet manages various processes from molding to finishing, maintaining TOTO's commitment to artisanal craftsmanship while improving operational efficiency.
• - Automated Guided Vehicles (AGVs): Six AGVs facilitate the transportation of materials between different stages of production, minimizing physical strain on workers.
• - High-Pressure Casting Equipment: This advanced machinery expands the types and sizes of products that can be manufactured, ensuring TOTO can meet diverse consumer demands with adaptability.

Moreover, each product will have unique heat-resistant QR codes, providing real-time quality tracking and facilitating data analysis to refine the manufacturing procedures over time.

Committed to Sustainability

TOTO fundamentally believes that innovation goes hand in hand with responsibility to the planet. The Morrow facility was constructed with sustainability as a guiding principle. By implementing energy-efficient practices and reducing shipping distances, TOTO aims to lower its carbon footprint while optimizing resource consumption. Some of the initiatives include:

• - Integrating water-saving technologies throughout operations to ensure responsible usage.
• - Employing systems that cut CO2 emissions substantially, with plans for advanced kilns that promise a 23% reduction compared to older models.

These efforts align seamlessly with TOTO's WILL2030 sustainability mission, contributing significantly to various United Nations Sustainable Development Goals (SDGs).

An Ongoing Commitment to America

TOTO's journey in the Americas began in 1989, and over three decades, it has earned a reputation as a reliable manufacturer dedicated to quality. The additional capacity from the Morrow facility positions TOTO to meet growing consumer demand seamlessly, reaffirming its status as an industry leader with a firm grasp on luxury bathroom innovation.

As reported for the fiscal year 2024, TOTO USA achieved remarkable sales of $464 million, reflecting consumer interest in premium bathroom products. Despite housing market slowdowns, the expansion promises enhanced service delivery and innovation, reinforcing TOTO's commitment to the environment, quality, and community-building.

Taro Muroi encapsulated TOTO's vision perfectly: “This expansion cements our leadership in luxury bathroom innovation while creating a more agile, resilient manufacturing network.” With these advancements, TOTO plans to enhance customer satisfaction, promote employee welfare, and positively impact environmental sustainability—all while honoring decades-long relationships built on trust and collaboration across the Americas.