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20 SEPTEMBER 2018 n NATIONAL HARDWOOD MAGAZINE
Monroe, WA–Canyon Creek Cabinet Compa-ny, based here, is a leading manufacturer of affordable frameless and framed-style
cabinetry, as well as closet-storage options. Its manu-facturing operation combines state-of-the-art, precision automated equipment and old world handmade crafts-manship to produce high-quality cabinets.
Founded in 1981 as Cascade Cabinet Company, Canyon Creek was renamed in 1995. Two years later, it moved to its current 285,000-square-foot facility where 400 employees work. Key personnel include Robert Foote, president and CEO; Mark Kovich, executive vice president; Ron Larson, vice president of finance; and Pat Foltz, vice president of operations.
Canyon Creek buys approximately 700,000 board feet of lumber from sawmills and distributors annually. Maple, Cherry, Hickory, Red Oak, Beech and Alder are purchased in Select and Better, No. 1 and No. 2 Common, Superior and Cabinet grades. The company also buys Walnut, Rift White Oak, Sapele and vertical grain fir in Select and Better grade.
By Kathy Brooks
“Maple is our number one choice in wood species due to its uniform characteristics,” said Kovich. “Because of that uniformity and consistency, Maple also is the species of choice for our painted options. Beech is popular as a sus-tainable option and because of its beautiful grain patterns with some color variation.”
Canyon Creek has four product lines: the semi-custom lines, Cornerstone and Millenia, let homeowners personal-ize everything from a cabinet’s shape and size to the color and material of the doors and drawer fronts. Katana, the value line, offers a wide selection of door styles and fin-ishes without the custom options. Canyon Creek Closets Plus features storage options for closets, pantries and mud rooms.
Once an order is received, materials are purchased and the cabinet doors, boxes and accessories are constructed, using mostly Biesse saws and routers, and SawStop table saws. They are then sanded with Kündig and Costa equip-ment, followed by finishing with Sames Kremlin equipment.
Canyon Creek uses a sophisticated pivoted tray conveyor finishing system called the “Pater Noster” to finish miscel-
Canyon Creek Cabinet Company of Monroe, WA, manufactures a range of cabinetry from Hardwood species. They include this Cor-nerstone semi-custom line.
AT CANYON CREEK CABINET COMPANY,
SEPTEMBER 2018 n NATIONAL HARDWOOD MAGAZINE 21 Please turn to page 48
laneous cabinet accessories. Made in Italy, it was the first such machinery in the United States, and the world’s largest at 190 feet long and 14 feet wide. The Pater Noster consists of 140 trays attached to a chain that serpentines around a series of gears; the large trays allow for most of the acces-sory parts for a given job to be kitted and finished together.
“Bringing this level of automation to an area that had been very manual and labor intensive has greatly improved processing efficiency, overall color quality and consistency from job to job,” said Kovich.
All production takes place in a humidity-controlled, dust-free environment. Products are packaged by PackSize ma-chinery to reduce the amount of cardboard inventory and scrap generated, then delivered to the customer either by one of Canyon Creek’s trucks or an LTL carrier.
AUTOMATION AND SUSTAINABILITY INTERSECT
Robert Foote is president and CEO of Canyon Creek.
The company operates from a 285,000-square-foot facility, includ-ing warehouses for raw material storage.
400 employees work at Canyon Creek’s facility in Monroe.
48 SEPTEMBER 2018 n NATIONAL HARDWOOD MAGAZINE
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Canyon Creek has long been a leader in energy and materials conservation, and the sustainable management of waste materials, even converting its own waste into resources for other businesses to use. The company has a dust collection system with an air-recovery feature that allows warm air to be ducted back into the building to provide heat during the winter. This system also provides a healthier, safer environment for employees.
Canyon Creek partners with the local power company on many projects. In 2017, it worked with the Snohomish County Public Utility District to retrofit the company’s old, less-efficient lighting system with LED technology, both inside and out. The lighting upgrades have resulted in an overall 56 percent decrease in annual energy usage for lighting.
In addition, Canyon Creek replaced all finish fluid pumps and guns with an air-assisted sys-tem, which reduced compressed air requirements by 30 percent. The company also replaced three 100HP air compressors with one 200HP air com-
pressor and dryer, thereby reducing power usage by 11 percent, and replaced high bay industrial mercury lighting with fluorescent lighting to reduce energy consumption.
For its conservation efforts, Canyon Creek has twice re-
CANYON CREEK Continued from page 21
Bringing this level of automation to an area that had
been very manual and labor intensive has greatly improved processing efficiency, overall
color quality and consistency from
job to job.
–Mark Kovich,
Executive Vice President,
Canyon Creek
Cabinet Company
SEPTEMBER 2018 NATIONAL HARDWOOD MAGAZINE 49
NORTHERN & APPALACHIAN HARDWOODS
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A line of storage shelving and cabinetry called Closets Plus is also manufactured by Canyon Creek.
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1-2 H Template_Layout 1 8/7/13 4:01 PM Page 1Katana is the company’s value line, offering a wide selection of door styles and finishes.
Once finished, cabinets are packaged by a PackSize ma-chine to reduce the amount of space that packing materi-als can take up.
ceived the Washington State Governor’s Award for Sustainable Practices, as well as Seattle Business magazine’s Washington Green 50 Manufacturing and Community Impact Awards.
The company’s philanthropy includes the donation of cabi-netry for community housing projects. Assorted Hardwood and plywood cut-offs are given to a local retirement community, where residents make toys that are donated to local charities. Canyon Creek also donates wood pieces to the carpentry pro-
CANYON CREEK Continued from page 48
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Canyon Creek’s Millenia line is another of its semi-custom offerings, allowing for personaliza-tion of cabinet shapes, sizes, colors and materials.
To learn more, visit www.canyoncreek.com.
gram at the Washington State Reformatory – Monroe Cor-rectional Complex, which in-mates use to build doghous-es, toy chests and desks that are donated to charities.
Association memberships include the Kitchen Cabinet Manufacturers Association, National Kitchen & Bath As-sociation, Impact Washing-ton, Master Builders Associa-tion of King and Snohomish Counties, MBA – Built Green, and the Association of Wash-ington Business. n
