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Spa Cover Factory Tour

February 20th, 2014 by

spa-cover-factory-tourI’m mighty proud of our spa and hot tub covers, and there’s many reasons why we make the best spa covers, and now you can witness the quality construction for yourself.

Below is a nice video with Jerry, one of the owners of Hot Tub Works, taking you on a tour of our state of the art spa cover manufacturing facility. Below that, is the complete transcript of the video.

I hope you enjoy the tour ~

- Jack

 

Hi, welcome to our state of the art spa cover manufacturing facility. My name is Jerry and I’m going to take you on a tour of the facility today. This factory can produce over 1000 spa covers per week, and uses the latest technology and has decades of hard earned experience to make quality spa covers.

I’m going to start with the process of how we receive orders. Now we’re standing in customer service, and literally hundreds of calls come in to this room per day, from people looking for help with their hot tub.

We make it really easy for you to order a new cover, you can order a new spa cover online, you can call us, or you can even fax it to us. No matter how you do it, we try to make it easy, and we’re all experts here at getting you a perfect cover every time. Once the order comes in, it goes to Production Management – let’s take a look at that process and then we’ll go into manufacturing.

hot-tub-works-factory-tourProduction Control takes every order that comes in and produces what’s known as a CAD file, which is basically an automated drawing which is fed to the manufacturing floor. That produces a perfect cover every time, specific to your order.

We use absolutely the best marine grade vinyl on our hot tub covers. This vinyl is 30 oz weight, it’s made for outdoor use. It has UV and mildew inhibitors built in. As you can see, we have a lot of vinyl here in our facility – we offer 10 different colors, all of them on our website for your choice.

Our sewing team has the latest equipment that they use to sew every cover by hand. They have decades of experience, and there are 27 points of reinforcement sewn into every cover.

This big block of foam that you see here, that looks kind of like a giant piece of tofu, is actually EPS foam. EPS stands for Expanded PolyStyrene. Now, EPS foam is often used in floating docks and buoys, and it’s also an excellent insulator product, and it’s what we use for the inside core of the hot tub cover.

We offer three different densities of foam, 1 lb. density, 1.5 lb. density and 2.0 lb. density. And basically what that means is, as the weight changes, the foam gets harder – the insulation value goes up and the cover gets stronger.

The big block of foam you just saw then gets cut down into sheets. This particular piece of foam is made for our Ultra Cover, where it’s 6 inches thick on this side, 4 inches on the other side. Each piece of foam is actually cut, specific to your order.

After the foam is cut into a taper, it is then cut into the shape of your hot tub cover. This machine here is fed the same CAD file that the sewing room is using to sew your cover. The foam is being cut with a red wire, cutting through the foam, creating the perfect shape to meet up with the vinyl skin that has been sewn. After the foam is cut to it’s final shape, a steel reinforcement channel is placed into the foam to add strength to the product. At this point it’s ready for final assembly, so let’s head over to that department.

One of the last stages and a very important one is where we vapor seal the foam. We use a 6 mil plastic to wrap the foam with, and it’s vacuumed down and heat sealed, so moisture can’t get to the foam core. You can even order a double wrap, which is two layers, to give you a longer lasting spa cover.

Now the final step of inserting the foam into the vinyl skin. It’s zipped up, and then final quality control inspections are done, making sure every measurement is accurate and correct. Then it’s wrapped into a protective plastic and placed in a box ready for shipment.

We’re now standing in distribution, and as you can see, I’ve got hundreds of covers around me. This is the last place we touch them before they get shipped out to you. They come in here to get direct and efficient shipment to your home.

We appreciate you watching the video, hopefully it’s answered some questions, and we appreciate your time and consideration of our spa and hot tub covers.

 

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