Focus 2012 Mid-Valley Made

Focus 2012

MID-VALLEY MADE A new look at some of the great stuff manufactured right here in Linn and Benton counties Friday, March 23, 2012

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Tec Labs hypes its employees, innovation

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Organic corn pops up across nation

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Corvallis fiberglass leads the industry

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Burst’s Chocolates keeps things sweet

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At full steam Hull-Oakes mill still processes trees the old-fashioned way

FOCUS 2012: THE STORY CONTINUES You’re looking at our annual Focus special section, published early each spring to call attention to a particular topic.

A year ago we concentrated on a number of mid-valley enterprises that produce something and sell it, partly locally and partly out of the area, supporting and strengthening the local economy.

We realized that there were plenty more entrepreneurs and companies in that category than we had room to cover last year, so here we are again, carrying out our theme, “MidValley Made,” for the second year in a row.

The section covers the great variety and diversity of industrial expertise and entrepreneurial craftsmanship among your neighbors here in the mid-valley. Some of them are well known and others you may be hearing about for the first time. They all reflect, in their different ways, the varied skills and knowledge among the people of this part of Oregon.

As always, this section is a cooperative venture of the staffs at our sister newspapers, the Albany Democrat-Herald, Corvallis Gazette-Times and Lebanon Express.

We are grateful to the advertisers who supported this project and whose messages you find in this section.

2 A chance endeavor Family carries on with lottery dispenser business started

by Albany entrepreneur

8 Stylish coops Sweet Home man makes high-end chicken pens

Hasso Hering Editor, Albany D-H

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Western Pulp focuses on sustainability

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Wah Chang aims for the stars with metal alloys

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Nursery’s local roots go deep

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Celtic tradition meets innovation

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FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

David Patton | Mid-Valley Newspapers

Calvin Tigner, one of the owners of Take-A-Ticket, shows the newest lottery ticket displays while holding the first prototype, which was made of cardboard.

Just the

ticket

Seth Tigner uses a CNC machine to cut out plastic parts.

A chance Scratch-it purchase in 1985 led an Albany man to start a dispenser business, which is still run by the family

BY CATHY INGALLS Builder Cal Tigner was returning home to Albany from a job in Eugene in June 1985 when he stopped at a store in Harrisburg to get a soda.

He saw a stack of $1 lottery tickets in the cash register drawer so he decided to try his luck and buy a few.

Tickets were still a novelty because Oregon had just introduced its first Scratch-it game in April of that year.

“He wouldn’t have bought them if he hadn’t seen them,” said Calvin Tigner, 66, son of the founder of Take-ATicket, an Albany company that makes clearplastic lottery dispensers.“He came home and that night made a cardboard prototype for a dispenser.

He made his second one out of acrylic.”

Cal didn’t have a background in plastics but he was always inventing something, Calvin said about his father, who died in 2008.That first dispenser has undergone a number of incarnations since Cal started Take-A-Ticket in November 1985.

Later that year, the company sold a few dispensers to the Oregon Lottery Commission and then on Valentine’s Day 1986, the state put in an order for a thousand.

Now the familyowned company housed in a building at 130 Montgomery St. N.E sells dispensers internationally, but primarily to stores and lottery offices throughout the United States.

Written on a whiteboard hanging on a wall

Susan Holloway builds trays for in-counter dispensers.

in the company’s office is a list of the orders that soon will be on their way to cities in New York,Washington, Colorado, Kansas,Texas, Missouri, Kentucky,Virginia and Florida.

The company, which employs an average of 19 people, is one of two firms in the United States making the dispensers, Calvin said.

“It would be hard for someone else to get into the industry right now because our customers know us pretty well,” he said.“We make our contacts through lottery trade shows and people approach us asking if we can make something.”

One reason the company is doing well is because it sends orders out as quickly as possible, said Don Tigner, 61, Calvin’s brother.

“Customers don’t like to wait,” he said.“We’ll hire temps to get an order out on time,” adding the company has many repeat customers.

The company’s two latest creations are lottery ticket display units.

Examples sit on a counter in the office of the industrial-looking building that was once a chicken processing plant. In one room, a few feathers from those

days remain stuck to the ceiling.

The new cases come in two different heights and have motorized units that turn the display tickets every six seconds, with LED lights shining down.Tickets that are for sale are kept elsewhere.

Zach Tigner, 36, grandson of the founder, is now chief designer at TAT. He’s expanding the line into brochure and

Zach Tigner, left, and Charles Pointer work in the glass shop.

gift card holders.

Seth Tigner, 29, Zach’s brother and Don’s son, also works at the plant.

When Calvin was asked about the company’s yearly bottom line, he laughed and said,“we’ll still be here in March.”

All of the production and shipping is done at the Montgomery location, where there is a cutting room, a place where plastic is bent to shape and a shipping and packaging area. The company’s warehouse is across the street.

Employees devise much of the equipment used at the plant.That way,TAT gets specifically what it needs and at a lower price, Don said.

The family points with pride to the fact that 95 percent of the company’s plastic waste is transported to Portland

and Vancouver for recycling.

When asked why someone would want to work at Take-A-Ticket, Calvin came up with several reasons: It’s an easy environment, the pay is good, the bosses are nice, there’s a good medical and dental plan and employees can take part in a 401K plan.

And employees get to begin work early each morning so they can have most of the afternoon off.

When Calvin’s not at work, he helps his wife on her goat farm, and Don takes family members on trips to the desert.

Zach and Seth also operate a new company called BYO, which stands for Build Your Own. The brothers make plastic trolling fishing flashers.

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

BLADE

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From a slab of steel and chunk of elk bone, Cochran roughs out the shape of the knife and handle, then sharpens the blade and attaches the grip, finally polishing the honed steel to a mirror-like finish, and pairing it with a leather sheath.

RUNNER Sweet Home man crafts specialty knives for outdoorsmen, intended to last a lifetime and be passed on to future generations

BY ALEX PAUL Foy Cochran handcrafts hunting and fishing knives so beautiful they could be hung on the wall like works of art.

But Cochran, 75, says his knives are made to be used and then passed on to future generations of outdoorsmen.

Born in Oklahoma but a Sweet Home resident for most of his life, Cochran has always been good with his hands and built his first knife as a youngster.

“As a kid, I loved to fish and hunt,” Cochran said.“I learned to build boats and made a few knives, but it wasn’t until I was about 40 that I saw a nice knife and realized I could make that.”

Cochran was working for Willamette Industries at the time, a career that would span 33 years until his retirement in 1993.

He slowly built up a small workshop in his backyard — the same workshop he uses today — including constructing much of the equipment he still relies upon. He and his wife, Martha, live on the family home near the South Santiam River.

“I knew what type of knife I wanted to build from the start, but it took about three years to perfect the design,” Cochran said.“I wanted a high-quality, edge-holding knife that hunters can rely on. I put a lot of time into getting the quality I wanted.”

Cochran crafts numerous sizes and styles of knives, including long, thin-bladed fishing filet knives, but his trademark knife is one that can be “palmed” with the user’s forefinger extended over the spine of the blade to its tip. It’s made to skin deer and elk.

“I want my knives to be extremely sharp and stay sharp,” Cochran said.“I don’t want a hunter to get an elk down an hour before dark and have to worry about sharpening his knife before he gets it quartered out and hung up.”

Cochran says one knife can do all of the work except quartering out the animals.

He uses only the finest stainless steel,

David Patton | Mid-Valley Newspapers

Foy Cochran shapes a blade using his custom-made grinder.

working the quarterinch thick blanks down until they are sharp enough to shave with.

Knife handles are made of elk shin bone that Cochran dyes a multitude of colors.

“Oregon State fans want orange and black, and Duck fans want green,” Cochran said.

The bones are immersed in dyes for anywhere from a few hours to overnight, Cochran said.

“I use bone because it will last forever,” Cochran said.“They’ve dug up bones that are thousands of years old.”

Elk hunting friends keep him supplied with elk legs, Cochran said.

Although he builds knives on order, he keeps a supply of several designs on hand for people who don’t want to wait six months for one to be built.

Cochran said he spends a few months in the winter turning steel blanks into rough knife blades and attending area shows to take orders.

Then, after orders are received, he begins finetuning the blanks into knives with mirror-like blades. He slips leather covers over his thumbs and forefingers, and

smoke flies as the heavy grit belts chew away layer after layer of steel.

Every so often, Cochran dips the blade into a coffee can filled with water to cool it down.

The work can take from a couple hours to an entire day, depending on the style of knife.

In addition to hours of grinding — on machines Cochran handbuilt — the steel is also heat-treated.

“It takes about three hours to get it warmed up to about 1,900 degrees, and I hold it there for about 15 minutes,” Cochran said.“Then I let it air temper.”

After that, Cochran polishes the steel until it shines with a reflective finish.

Although most of his customers come from the Pacific Northwest, Cochran’s knives are used in virtually every corner of the United States and as far away as Africa.

“We just had a guy from Germany drop by,” Cochran said.“He was visiting White’s Electronics and heard about us. He took home a couple knives.”

Cochran said he likes to do most of his knife building in the winter

Cochran keeps a stash of finished knives on hand for customers who don’t want to wait several months for one to be built.

Cochran’s signature knife, made to skin elk and deer, can be “palmed” with the forefinger extended along the spine to the tip of the blade.

months, allowing him to go fishing in the summer. He says his grandson, Zach, 23, has picked up the trade and “can build a very nice knife.”

Cochran’s knives always attract numerous bidders during local civic events such as the annual Boys & Girls Club auction.

“What we’re now seeing is that guys who have my knives are buying them for their sons or grandsons and putting them away in a safe until the kids grow up,” Cochran said.

Prices range from about $155 for a fishing filet knife to $200 for his trademark hunting knife or $1,200 for a pair of Damascus steel knives.

Cochran said he continues to learn things about knife building, but his basic premise has not changed.

“It’s not about speed, it’s about quality,” Cochran said.

He also continues to add new designs to his lineup of offerings.

“Usually, late at night, when things get quiet, that’s when I dig out my notebook and start sketching,” Cochran said.

Cochran said he gladly works with customers who have an idea for a knife but don’t know how to translate that onto paper.

Every knife comes with a handmade leather sheath.

Cochran builds from 60 to 100 knives per

year and every one of them is guaranteed for life. He has made mistakes but said he has never had to throw a knife away because he ruined it.

Plus, he will hand sharpen every knife,

free of charge.

“My knives are truly lifetime knives,” Cochran said.“If you take care of them, you will never wear them out.”

For more information, call Cochran at 541-3675277.

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FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

5

Fired up future FOR THE

Driven by steam and tradition, Hull-Oakes still mills logs the old-fashioned way

BY BENNETT HALL

years old,” Nathan Nystrom said.

To find them, he turns to salvage sales, tribal forAt the tender age of est managers and private 25, Nathan Nystrom is a timberland owners. He good deal younger than also buys oversize logs most of the other log from timber sales desbuyers he bids against tined for mills that can’t for saw timber. take large-diameter trees.

And his wood science And once inside the and technology degree mill, the logs are from Oregon State Uniprocessed the old-fashversity doesn’t always ioned way. Instead of regive him the answers he lying on optical scanneeds. ners and computerized “The stuff you learn presets to optimize the in school,” he admits, cutting of each log, saw “doesn’t necessarily operators make those apply.” judgments as they Despite his youth, work, sizing boards to however, he’s not with- match order tickets out experience.The from customers. great-grandson of Hull“There are no comOakes Lumber Co. puters or scanners anyfounder Ralph Hull, he’s where in the mill,” the been working in the younger Nystrom said. family enterprise since “Every decision in here his teens. is made between the And his father, who ears.” took over the mill in the But there’s an even small town of Dawson, bigger anachronism in tucked into the Coast the mill, one that sets it Range foothills of south apart from all the rest: Benton County, in 1998, the boiler room. Hullwants him to learn every Oakes is the last steamaspect of the business. powered commercial “He’s the next genera- sawmill in America. tion,” Todd Nystrom “Nobody runs on said.“We’re going to try steam anymore,”Todd and keep Nystrom this place noted.“No‘There are going.” body in their no computers The Hullright mind, or scanners Oakes mill anyway.” anywhere in has been The mill’s going for 75 the mill. Every massive boilyears now, decision in here ers are more and it’s is made between than a cenchanged retury old, and the ears.’ markably litreplacement tle in that parts can be NATHAN NYSTROM time. costly and While hard to find. other sawmills have reBut they produce plenty tooled to handle small-di- of steam to run the ameter logs in the postmain carriage that spotted owl era, Hullmoves logs through the Oakes still mills the big mill and to drive the ones, turning out masheadrig and edger that sive timbers up to 80 or saw timber into boards.

100 feet long for bridge And mill operations supports, railroad trestles produce plenty of fuel and crane mats, used as a to keep them running. working platform for Wood scraps from the heavy equipment in road saws go right into the construction. firebox. Nor do the leftWith severe restricovers go to waste. Shavtions on cutting oldings are sold to make growth trees on federal wood pellets and partiforests, finding big logs cleboard, while chips to feed the mill’s 54-foot get shipped to pulp and bandsaw is a major chal- paper mills. lenge.

Of course, the mill uses electricity as well, “Our ideal is old, and Hull-Oakes recently large-diameter secondinvested about $200,000 growth logs, up to 100

LEFT: A panoramic photo compilation shows the pond at Hull-Oakes Lumber in Dawson.

BELOW LEFT: Nathan Nystrom looks into the fire box, where temperatures can top 2,000 degrees.

BELOW: Rob Shannon pulls scraps away from boards as they pass through the edger.

ABOVE: A Wagner log unloader drops three logs into the pond, where they will stay until they are brought into the mill.

LEFT: Hull-Oakes log buyer Nathan Nystrom stands next to a load of wood destined for the lumber mill. He tries to buy “old, large-diameter second-growth logs,” and turns to salvage sales, tribal forest managers and private timberland owners.

with help from the Energy Trust of Oregon to make it more efficient.

The headrig and edger have been set up to run on electric power if the

boiler needs to be shut down, and Nathan Nystrom estimates the whole mill could be converted to electric power for another

Carriage rider Michael Oakes and Jesse James guide a log along a sawblade to create a variety of sizes of boards.

$200,000 or so. But he’s in no hurry to make that change.

“If it’s not broke, don’t fix it,” Nystrom said with a shrug.

“I wouldn’t say we’re opposed to change, but we’re pretty conservative with our decisionmaking, which is why we’re still here.”

Clifton McGillvary sorts boards into piles based on size.

PHOTOS BY JESSE SKOUBO ❖ MID-VALLEY NEWSPAPERS

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FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

7

David Patton | Mid-Valley Newspapers

Greg and Shawna Hopla show the production area for the wooden axes, swords and shields at their World Tournament Of Champions: Knights of the Realm complex in Brownsville.

A battle ax to grind At Brownsville’s World Tournament of Champions: Knights of the Realm, Medieval props and costumes are the order of the day

BY JENNIFER MOODY

Ruben Valdez, left, and Sammi MacMillan do finish work on wooden versions of a two-handed blade.

swords that tended to splinter and break. In the early 1990s, a brother who worked Let’s say you need a cosat Oremet in Albany sent tume for the next RenaisHopla a piece of titanium. sance fair. Or you’re looking “You won’t break this,” Hopla for a one-of-a-kind gift. Or remembers him saying. perhaps there’s just someHopla figured out a way to thing about a double-edged cut a sword shape from the battle ax that speaks to your metal and brought it to the soul. arena to test against a fellow Greg Hopla wants you to knight. A fountain of sparks quest no further than his burst from the crossed Brownsville-based company, blades.“It was like the Fourth World Tournament Of Chamof July,” Hopla said.“Everypions: Knights of the Realm. body’s like,‘Oh my God!’” Hopla, 53, supplies After that, everyone wanted weapons, costumes and a titanium blade, Hopla said. props for Universal Studios, He did some research, confor the Las Vegas hotel and The business makes an assortment of titanium swords, which don’t break like steel nected with Wah Chang in Alcasino Excalibur, and for his swords do and produce an impressive show of sparks during fights. bany and started a business own traveling jousting show, sword once while watching a in blue, in the Jim Carrey making them for sale at the a regular attraction at the making axes, maces, daggers, tournament at Medieval show. movie “The Cable Guy.” Linn County Fair. pirate swords, anything a cusTimes. Hopla can make you He’d set up a generator in Hopla, who took his own tomer might want.

His workshops are piled your own version, and the the back of his pickup truck, company solo about a year high with swords, customFrom that start came recostume to go with it. and a half ago, taught himself order a truckload of pine and quests for the other accoumade weaponry and chain set to work in the parking lot trements: costumes, armor, many of the skills he still mail, both real and a lighter, In fact, if you are familiar with a router, a jigsaw and a more comfortable fabric ver- with Medieval Times, it’s pos- uses today. presentation shields and table saw. sion that looks like the real sible you’ve seen Hopla himHe grew up watching his other props.

“I’d make everything up thing. Currently, his crews are self. He worked for the com- grandfather make and repair It was a little overwhelmworking on several twopany, which performs dinner farm tools in his Brownsville and I’d sell it out in two ing for a while, Hopla said.At handed blades similar to days,” he recalled. shows and jousting tournashop. In his early years with one point he had 12 employbat’leths, the weapons faments in mock castles Medieval Times, he saw a deAt the time, Hopla and his ees and would run back-tovored by Klingons on “Star around the country and in mand for child-sized versions colleagues on the tournaback shifts at his Brownsville Trek.”

Canada, for more than 20 of the performers’ swords ment field worked with shop. He’d sell 10,000 Maybe you saw a cool years. That’s him, the jouster and shields and set about heavy, unbalanced steel weapons a month, and that was to just one customer.

Then he and Medieval Times ended their business partnership, he said, and work is now down to when and where he wants to take it. In between tours, he still makes swords-and-sorcery weapons, but he’s branched out to include metal art and children’s toys for his newest venture, a pioneer-themed restaurant called the Kirk’s Ferry Trading Post.

He’s still available for custom work, too. Orders can be made via email at swordsandshields@hotmail.com, or see his website at http://tournament-of-champions.com/ Wooden axes, left, and swords, above, wait to be finished. kirksferry.php.

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FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

Custom coops prove popular What started as an effort to house his own chickens has turned into a side business for Sweet Home man

BY ALEX PAUL Tristan Nichols never set out to own The Chicken Coop Store.

All he wanted to do was raise a few chickens for fresh eggs and teach his three young sons about responsibility.

Four years later, Nichols, 32, now builds dozens of custom-designed chicken coops annually and is shipping them throughout the Pacific Northwest and as far away as Texas.

“I wanted to give the boys something to do and to see what it takes to keep something alive,” the 1998 Sweet Home High School graduate said.“I built our first chicken coop and our friends couldn’t believe how nice it was.”

Nichols said a friend bet him a barbecue dinner that he couldn’t sell the coop in three weeks.

“I advertised it on the David Patton | Mid-Valley Newspapers Internet and it sold Tristan Nichols of Sweet Home lets his chickens out of his custom-made coop. quickly,” Nichols said.“I roof and working shut- made to last.” kept the ad online and ters. the next thing you The floors are solid Nichols gets know, I was getting a It houses rooster two-by-six planks and help loading up ton of orders.”

Duke and hens Big Bird, the siding is sevena finished The Sweet Home man Marshmallow, Midnight, eighths-inch cedar, comchicken coop for Darkness, Big Red and monly found in highworks for the city of delivery, which Multi. quality fences. is included with Lebanon wastewater the price of the treatment plant and The Nichols boys — Galvanized metal or coop within a started building the Gavin, 10, Brady, 7, and clear plastic is used for reasonable Bode, 4 — can gather coops in his garage on the roofing. distance of the eggs and feed the nights and weekends.

“I like the clear plastic Sweet Home. chickens He because it allows more He can ship without soon outlight into the coops and orders greater having to the chickens will congrew the distances, and get into garage tinue laying in the winsaid he sent the nestand built ter if they have enough one coop to ing porTexas for $300. a small light,” Nichols said. tion of the “Some of our coops backyard building. shop. come with flower They boxes.”

“I crecan pour ated my Nichols can create a feed down coop to fit any yard, own dea plastic sign and ranging from a 3-by-4tube into foot model that retails just the feeder for $450 to a 5-by-8 started and colgoing coop that costs $895 or lect eggs with the new large coop that ‘I had one fall off from bethat,” retails for $1,500. Prices my trailer on I-84, hind the Nichols include delivery within nesting and all I had to said.“The a reasonable distance of area. only thing replace was some Sweet Home. was my trimming. These things Nichols “We can also ship said qual- them anywhere in the wife, Aliare made to last.’ ity sepacia, said country,” Nichols said. rates his the coops TRISTAN NICHOLS “We shipped one to chicken had to be Texas and it only cost coops cute and about $300.” look nice in someone’s from others on the marNichols said he has ket. yard.” improved the quality of “I had one fall off my the coops over time.

The family’s most recent coop is a dandy. It’s trailer on I-84, and all I “I figured out how to had to replace was 8-by-10 feet and inmake cleaner angle cuts some trimming,” Nichols cludes a small tack and to make tighter said.“These things are room, a clear plastic measurements,” Nichols said.“I still enjoy it. It’s fun and it’s also nice to see how much people enjoy them.”

Recently, Melea Kellogg and her mother, Pattie Bean, visited Nichols’ home to talk about having a coop built.

“We have a couple old coops and we want a big coop,” Kellogg said.

“We have 16 hens and two roosters.”

Nichols has also added school bus shelters to his woodworking lineup.

“They’re made so the opening faces the house and parents can watch their kids while they wait for the bus,” Nichols said.

They sell for about $400.

For more information, call Nichols at 541-223-2900, email tristan@thechickencoopstore.com, or visit Nichols’ family chicken coop features a tack www.thechickencooproom on the back side to allow easy access store.com. to feeding, watering and gathering eggs.

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

Making green by going green

The new wine bottle dividers cushion bottles from both sides, reducing the number needed per box of six bottles.

Equipment upgrade opens new markets for Western Pulp’s sustainable products

BY BENNETT HALL Founded in 1954 on a business model that turns recycled materials into products that are either recyclable, compostable or biodegradable,Western Pulp Products came early to the sustainability party.

Now the company is using Oregon energy efficiency incentives to shrink its environmental footprint still further while modernizing production and rolling out two promising new product lines.

At its south Corvallis factory,Western Pulp takes old newspapers, wax paper and cardboard box trimmings, mixes them with water to form a slurry and vacuum-forms them into new products such as flower pots, floral containers, protective packaging inserts and plantable nursery containers.

The newly formed products are placed on a conveyer belt for a trip through a drying oven. It’s a high-volume process, but it has some drawbacks: It consumes a lot of electricity, some parts can warp during drying, and the vacuumforming equipment leaves a rough finish on one side of the product.

Amanda Cowan | Mid-Valley Newspapers

Bryon Schreiber, training and technical supervisor, handles the controls of a thermoforming production line at Western Pulp Products in Corvallis.

Last year, with help from the state’s business energy tax credit program,Western Pulp purchased a new thermoforming production line that accepts interchangeable molds for a variety of products.

rough surfaces.

“The finished part is so much more refined and detailed,” said Bryon Schreiber, the firm’s technical and training supervisor.“It’s a huge leap forward for us.”

Rick Hurley,Western It’s somewhat slower Pulp’s vice president for technology, said the than the old process, but it uses one-third less thermoforming equipment opens a world of electric power. It also new possibilities for the uses heated, high-pressure molds for forming company. and curing, resulting in “The parts are smooth thin-walled but strong on both sides, so what fiber products with no you’re able to do is

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replicate the functionality of a plastic part without the historical compromises of molded fiber parts,” Hurley said.

The first two products coming off the new line take full advantage of that fact.

One is a case pack divider for wine bottles.

Dubbed Vintner’s Choice, the divider slips between the top and bottom layers of a sixbottle laydown container, holding the bottles in place and cush-

ioning both layers.

Most laydown dividers now on the market support the bottles from one side only, meaning two are required for each case of six.Western Pulp’s alternative requires half as many parts and makes for compact storage.

That added value, Hurley says, can be a powerful selling point.

“At Western Pulp Products, we’re always trying to figure out sustainable competitive advantages

— building better mousetraps,” he said.

The other new product is a small greenhouse container for vegetable starts. Marketed under the name PaperWorks, these pots nest tightly yet come apart easily, like the ubiquitous black plastic pot, but are far more environmentally friendly.

“This is the first recycled paper, biodegradable, compostable greenhouse container that replicates the handling characteristics of a black plastic pot,” he said.

“It’s a game-changer for us.”

While Western Pulp has no plans to discontinue its old product lines, Hurley believes the thermoforming production equipment will continue to open doors into new market spaces.

The key is to make a sustainable product that performs like plastic at a comparable price point.The fact that it’s eco-friendly just sweetens the deal.

“We always have to compete on price.What we’ve found historically is that green is good when it costs the same or less,” Hurley said.

“We feel great about this, and what’s neat today is that our customers feel good about it too.We have the sustainability wind at our back.”

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FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

An eye to the sky

Hafnium, an extremely heavy material used in turbines, blades, discs and rotors, is one of many alloys produced at ATI Wah Chang in Millersburg.

ATI Wah Chang’s metal alloys have many uses in the aerospace industry

BY STEVE LATHROP At ATI Wah Chang, researchers have always had an eye on the sky.

The company, which became ATI Wah Chang in 1996 following a merger, has become a major player in the aerospace industry.

“We are one of the top two in the world in producing high-purity levels of metals for use in the air industry,” said Carl Shawber, aerospace manager of business development for the Millersburg company.

“We play a big role, especially when the industry is gearing up like it is now.”

Shawber, who has been with Wah Chang for more than 10 years, said hafnium, titanium and zirconium alloys are all used and they all bring something to the table.

Hafnium is used in turbines, blades, discs and rotors. It is added in the production of nickelbased “super alloys,” which provide great strength and high resistance to temperatures.

Titanium alloys, some of which include zirconium to add strength and temperature resistance, are used in most critical components of aircraft.The lightweight metal has become more prominent as Boeing

Mark Ylen | Mid-Valley Newspapers

Carl Shawber talks about a display at ATI Wah Chang showing products the company makes for the aerospace industry.

has altered the design of its fuselages.

“Boeing is going away from the aluminum and doing more with composites,” Shawber said.“It is using more titanium for rivets, screws and fasteners to attach metals to the composites.”

Wah Chang material is prominent in the current and next generation aircraft, according to Jim Denham, public affairs coordinator, who has been with the company for 32 years. The

‘We are constantly trying to develop new applications to make metals more fabricable and do more with it.’

JIM DENHAM, ATI WAH CHANG

new Boeing 787 and the Airbus A380 are customers.

Titanium comprises nearly 14 percent of the total airframe of the 787. Denham said the titanium content is several hundred thousand pounds, more than twice what had been used in the past.

One of the newer brands is ATI425, an alloy sheet that has better forming capabilities.

It retains its strength and can be cold-rolled and formed into sheet products that are used in tubing and hydraulics.

“We are constantly trying to develop new

applications to make metals more fabricable and do more with it,” Denham said.

Denham said Wah Chang researchers continue to work to bring the next generation titanium alloys to product.

The company is looking at different chemistry in developing properties.

“We want to know how it might be furnaced and fabricated on our existing equipment,” Denham said.

He said ATI425, for ex-

ample, was more than 15 years in development.

The company is also in the position of utilizing various other facilities that make up ATI. That includes not only ATI Operations (formerly Oremet) in Albany, but other manufacturers around the country.

The Millersburg company, which opened in 1956 on more than 100 acres, was among the first to produce exotic metals that are refractive and reactive and have diverse applications.

The properties are what make the metals vital to aerospace, including the U.S. space program.Wah Chang materials like the niobium C-103 alloy are used in thrusters and rocket nozzles.

Wah Chang’s products come in many forms and sizes, including ingots, wire, extrusions, bars, tubes, foil, sponge and powder.

Denham said 928 employees work in 80 buildings in Millersburg and another 930 are employed at the ATI Operations plant in Albany.

“Aerospace is a major and growing part of our business portfolio,” Denham said.“It’s a part of Wah Chang that we want to expand with the market.”

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

11

Business grows from kernel of an idea Corvallis woman’s kitchen is home base to an organic kettle corn brand sold across the nation

BY EMILY GILLESPIE An industrial-size popcorn machine sits behind a kitchen counter, and boxes and packaging material are strewn across the dining room table.

Although it’s a small operation run out of a northwest Corvallis home, Grow Your Family Healthy has a large scope.

Amber Humphrey and her two employees make, package and distribute organic kettle corn to more than 100 stores across the nation.

“It’s fun but it’s overwhelming,” Humphrey said.

She uses only natural, gluten-free ingredients to make two flavors of the healthy snack; caramel, made with coconut sugar, and sweet-n-salty, made with celtic sea salt and agave sugar. She cooks the organic “mushroom”-style popcorn kernels with rice bran oil and then flavors them with the sugars.

The group then packages, labels and self-distributes the product, shipping to states as far away as Florida.

“Anything from animals is acidifying to the body,” Humphrey said.“That’s where disease happens.”

After years of bad eating habits, Humphrey was diagnosed with rheumatoid arthritis when she was in her 40s. She threw herself into research and learned what she was eating was negatively affecting her health.

Now 51, Humphrey is a vegan and a nutritional consultant. She hopes to show people that healthy snack options can come in the form of a tasty treat.

Andy Cripe | Mid-Valley Newspapers

Amber Humphrey holds packages of sweet-n-salty and caramel kettle corn in her Corvallis kitchen.

She said she has fielded calls from mothers thanking her for making a snack their kids like to eat and is still good for their growing bodies.

Humphrey started Grow Your Family Healthy in 2007 by making a non-dairy frozen product called Heaven Sent that she sold to local stores beginning in February 2008.

The ice cream-like product gained popularity, but “It bled us out financially,” Humphrey said mismanageshe said. ment by brand managers and But the kettle corn, which marketing companies led her she introduced in late 2010, to stop producing it. It is still is holding its own. in some local stores, but only until sometime this summer.

Offering samples at gro-

entrepreneur and getting creative with her recipes.

“I smell up the whole neighborhood. It’s like Candy Land,” she said.“We always smell like maple bars. It’s our family’s perfume.”

AMBER HUMPHREY And built into the company’s business model is the Ariel Mitchell, 21, opportunity for fundraisers works on a batch for good causes. of the sweet-nHumphrey said she will sell salty variety. bags of kettle corn to individcery stores is cheaper since uals or groups at cost and the product doesn’t have to allow the profit to go toward be frozen or served to shop- fundraising. pers. It also costs less to “If it’s for a good cause, we transport and store. would love to be able to supHumphrey enjoys being an port them,” she said.

‘We always smell like maple bars.

It’s our family’s perfume.’

12

FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

Turning sand into glass ...

Ron Reher, manager of materials and distribution for Evanite Fiber Corporation, stands among fiberglass material ready for shipment.

... fiberglass, that is, and it’s what Evanite has been doing since 1979 at its Corvallis plant

BY RAJU WOODWARD

cotton candy. However, it looks like regular cotton — white and soft.

Here’s the process, in a One of the world’s leadnutshell, for creating ing manufacturers of micro glass fibers. fiberglass is right here in the mid-valley.

Sand is combined with sodium carbonate and Evanite Fiberglass Corporation has been turning several other common raw minerals into product mineral modifiers. Using large furnaces, the minersince 1979 at its plant in als are melted. Discs are south Corvallis. used to spin the molten Its output is used in electric clean rooms, med- matter and elongate the fibers. ical facilities and automotive applications.

“It varies because of various factors, but typically Filtration and energy the process management ‘We want to help takes about are two of the main uses of the world become 12 hours,” Evanite fibera cleaner place.’ Reher said. glass.

Screens are KEN ECKROTH, “We like to used to colDIRECTOR OF FIBERGLASS lect the say we help OPERATIONS make clean air fibers, which and energy,” then are said Ken Eckroth, director formed into bales. Evanite of fiberglass operations. ships fiberglass in 50- and 200-pound bales.

Making micro glass fibers involves some com“An important thing is plexities, but for the most the diameter of the prodpart it’s a pretty straightuct,” Eckroth said. “We forward process. have controls in place to make sure we get what “It involves heating we want.” something and then spinning to make a product,” Eckroth said that Evansaid Ron Reher, manager ite is one of a handful of of materials and distribucompanies throughout tion at Evanite.“It’s kind the United States, Europe of like you do with sugar and Asia that manufacto make cotton candy.” tures fiberglass.

Interestingly enough, “A lot of our product fiberglass usually turns goes to Europe and Asia,” out soft and fluffy like Eckroth said.“So other

countries are helping support our company, and in turn, our local economy.”

And Evanite officials are excited about the potential for the company to expand its presence and sell more of its product overseas, especially when it comes to green cars.

Eckroth said there’s a push in Europe to reduce greenhouse emissions.As a result, there’s a demand for more micro-hybrid cars, which use glass batteries instead of traditional plastic ones.

Micro-hybrid vehicles use start-stop systems, in which regenerative braking technology helps stop combustion engines when the vehicles stop and then restart them when drivers accelerate again.The process prevents vehicles from idling and is designed to reduce emissions.

Evanite employs about 150 people and has added more in

Amanda Cowan | Mid-Valley Newspapers

recent years despite the sluggish economy.

“We feel like we are in a position of stable growth, especially because of the potential with the micro-hybrid cars,” Eckroth said.“We want to help the world become a cleaner place with our product.”

Illustration by Don Boucher | Mid-Valley Newspapers

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

Getting an edge on radio control flying

RealFlight 6, the radio control flight simulator made by Knife Edge, has a variety of aircraft and airfields to choose from.

Corvallis software company’s RealFlight simulator helps enthusiasts prevent costly crashes

BY RAJU WOODWARD The concept behind Corvallis-based Knife Edge Software is simple.

Radio control airplanes and helicopters are expensive.They range in price from $100 to $20,000, so crashing these aircraft can be painful on the wallet.

However, Knife Edge’s RealFlight simulator aims to reduce the odds of crashing radio control aircraft.

How real are the simulations? Users can enter data to create airplanes or helicopters that look and fly like their radio control ones.

“It saves money and time,” said James Bourke, owner of Knife Edge Software.“Radio control flying takes a lot of training.You don’t want to destroy your plane the first time out.You want to be able to fly it well and enjoy it.”

The first version of the RealFlight simulator was developed in 1995 and came out about two years later.

Knife Edge released RealFlight 6 last year and is currently working on RealFlight 6.5.

Andy Cripe | Mid-Valley Newspapers

James Bourke owns Knife Edge Software, which makes flight simulation programs for radio control aircraft.

Bourke said the company now tries to release a new product every year, whether it’s a new simulator or an upgrade.

The goal is to make each version a little more realistic and visu-

ally appealing than the last; RealFlight 6 features local airfields.

So how does each version of RealFlight come together?

Knife Edge buys radio control airplanes and helicopters, usually a

mix of both popular and nontraditional models.

Employees fly the aircraft and record information, including the weight of the aircraft, how they fly and the sound they make while

taking off and in the air.

“The fun part is crashing them,” Bourke said.

“We want those to be as realistic as possible too.”

Photographs are taken of each aircraft and uploaded onto computers,

‘The youngest person I’ve heard using our software was 3 years old.

He’s really good. I admit he’s better than me.’

JAMES BOURKE, OWNER OF KNIFE EDGE SOFTWARE

13

where they are rendered into 3D form.

Artists then work on images to get them ready for the simulator.

The final step is the programming. A team of 12 employees works on the development of the simulator software.

“Radio control planes can do things like hover in the air,” Bourke said.“They have the power to do that.

So it adds a really fun element.”

And having fun is one of the biggest draws of RealFlight.

Bourke, who operates radio control aircraft himself, estimates he has spent at least 1,000 hours honing his skills using the simulator.

The latest version of the simulator costs $200 and includes a transmitter controller.

He said in a lot of cases, fathers who are radio control operators buy the software for their children, who often become very good operators themselves.

“The youngest person I’ve heard using our software was 3 years old,” Bourke said.“He’s really good. I admit he’s better than me.”

14

FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

Lebanon chocolatier carries on tradition

74 years OF confections

Victorian Chocolate Co. owner Kelly Reetz still relies on what he learned from former Burst’s owner Ralph Bateman, and also likes to create new treats

Community involvement has helped Burst’s Chocolates remain a stable source of sweets in downtown Corvallis

BY AUDREY GOMEZ

BY EMILY GILLESPIE

make the handcrafted confections Magee bought from other stores that closed.

For the past 74 years, Magee said that aside Burst’s Chocolates has ocfrom quality, another reacupied part of the storeson Burst’s has survived for front of the Vance Taylor 74 years is its connection Building, 353 S.W. Madison to the community.

Ave. in Corvallis.

For example, right now The heavy door opens Burst’s staff is preparing to the smell of chocolate, solid chocolate bunnies and the sight of a wooden and eggs with names case full of confections written on them in and colorful candies in chocolate. glass jars.

“We’re part of people’s “We’ve been here for a traditions,” he said. long time,” owner Patrick Marti Staprans-Barlow of Magee said. And the reason you’ll know what he Corvallis said every year for is simple:“We have a really means. good product.”

Magee said his business is Christmas she buys 10 to Taste an Irish cream truf- one of just a handful of lo- 15 boxes for her friends and family. fle, a toasted coconut stick cally owned chocolate “Nothing says caring like said.“It puts people in a or one of the chocolatestores left in Oregon — a good mood.” dipped orange slices and a box of chocolates,” she lot of the equipment to Staprans-Barlow said ABOVE: she’s been a customer at Martz Burst’s for more than 15 fills up a years. mold with “I can’t say enough nice chocolate things about Burst’s canwhile dies and Patrick, his wonbringing a derful creative chocolates chocolate and everything he does in bunny the community,” she said. to life.

“He hand makes his chocolates and does it all downRIGHT: stairs. It’s like an ‘I Love Burst’s manager Lucy’ episode.”

Erin Rainey assists a customer.

15

Amanda Cowan | Mid-Valley Newspapers

Chocolatier Kyle Martz prepares Easter bunnies at Burst’s Chocolates.

Christmas,Valentine’s sions, such as a stethoDay and Easter are all big scope for hospital-related holidays for the chocolate events. shop. Right now, the staff is working hard on chocolates for the Easter rush.

“We’re making thousands and thousands of bunnies — and we’re just getting started,” Magee said.

Burst’s also participates in fundraisers and makes donations to various organizations. It even has special molds for unique occa-

‘We’re making thousands and thousands of bunnies — and we’re just getting started.’

PATRICK MAGEE, OWNER OF BURST’S CHOCOLATES

The creativity and community connection are what keep Magee going.

“At the end of the day, I like to have made something,” he said.

Assistant chocolatier Chris Lockhart works on a batch of bunnies.

Burst’s staff are preparing solid Easter bunnies and eggs engraved with people’s names, one of the many personal touches that keep the business connected to the community.

It’s been more than 20 years since Kelly Reetz learned how to hand-make chocolate candy.

Reetz’ shop,Victorian Chocolate Co., features traditional confections as well as those of his own invention.

He has been making chocolate in Lebanon since 1988.

Reetz learned his craft from Ralph Bateman, former owner of Burst’s Chocolates in Corvallis. “(Bateman) helped mentor me and get my business under me,” Reetz said.“He would be 102 years old this year.”

Bateman passed on some practical advice as well.

“Ralph always told me no matter how many times you make a batch, always keep your formula book out,” Reetz said.

“I know from experience he was right.”

Reetz said one of the first things Bateman taught him how to make was oldfashioned cream-centered chocolates.

For new ideas, Reetz reads a lot of cookbooks. He has a long list of ideas he

Reetz hand-dips a fudge-centered heart in chocolate.

Audrey Gomez | Mid-Valley Newspapers

Kelly Reetz weighs a freshly made chocolate at his Victorian Chocolate Co. in Lebanon.

wants to try.

“I’ve always got plenty of people wanting to test it out,” Reetz said.

He sold his creations wholesale before opening his storefront on Grove Street in 2005.

One of the benefits Reetz sees in having a shop, rather than just making candy for wholesale, is customer feedback.

“You put (the chocolates) out and see what the reaction is,” Reetz said.“It’s nice to see what (customers) think about it.”

Reetz’ rocky road chocolates are a customer favorite. A root beer float candy is his latest creation.

Victorian Chocolate is at 959 Grove St. in Lebanon. It is open from 12:30 to 5:30 p.m.Wednesday through Friday.

16

FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

Garland Nursery grows into the future Family-owned garden store grows 40% of its annuals and perennials

BY GAIL COLE Garland Nursery’s seeds date to 1937, when the William and Corlie Schmidt family started a filbert root stock business.

But the modern Garland truly bloomed beginning in the 1950s when the Schmidts’ daughter, Oregon State University horticulture professor Garland Schmidt Powell — who’s also the business’ namesake — began growing garden plants in a small greenhouse to sell.

Today, Garland Nursery is one of the state’s largest plant and gardening suppliers outside of Portland.

Located between Corvallis and Albany at 5470 N.E. Highway 20, Garland boasts six acres of retail space and Amanda Cowan | Mid-Valley Newspapers three acres of growing area.

Garland Nursery is now owned by the founders’ grandchildren, siblings Lee, Brenda and Erica Powell.

The acreage allows Garcialize in plants,” said coshrubs as in previous years, land to grow 40 percent of owner Lee Powell. but the popularity of farmthe annuals and perennials it ers markets and home garFor example, Garland will sells, a high ratio for retail offer 30 different varieties of dening is fueling demand for nurseries. native vegetation and heirdaylilies later in the spring.

And when Garland does loom varieties of foodGarland’s ability to grow buy plants from wholesalers, producing plants. much of its it stays as local as Early spring is spent own product possible, using ‘There isn’t a preparing for the busy also allows it to growers such as specific plant months of April, May and adapt to trends Linn County’s Peowe specialize in June, when help from the and fluctuations ria Gardens. multigenerational family — we specialize in demand withThe mix of comes in plenty handy. out waiting for homegrown plants in plants.’ stock from Lee Powell shares ownerand purchased LEE POWELL, wholesale grow- ship of Garland with sisters goods allows GarCO-OWNER ers.

Brenda and Erica Powell, and land to provide a huge variety of “We’re able to his own daughters often help out at the nursery when they Brenda Powell browses through the selection of product, making it the choice make those decisions Northwest plants. have time. for both seasoned and novice quickly,” Powell said. gardeners.

In addition, Lee, Brenda and and his wife, Sandra — are when they can, though as New construction is “There isn’t a specific plant down, so the business hasn’t Erica Powell’s parents — Gar- often found straightening Lee Powell explained, we specialize in — we speland’s son, Donald Powell, plant displays and assisting “they’re officially retired.” sold as many trees and

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

Tall in the saddle Former manufacturer has switched to making repairs at his leather business, which opened in 1971

BY EMILY MENTZER

there was my name in red you feel good.” them, riding in rodeos or ropmarker, and 1957,” Wendell ing.

For some of those older said.“That was my saddle as a saddles, it doesn’t have to be Wendell designs all the Wendell Branton hasn’t usable, just clean. Often peo- trees — the wooden part of built a saddle in 10 years but boy.”

Marci’s childhood saddle ple will use a 100-year-old the saddle, covered in stays plenty busy making realso has come back for repair saddle as a decoration more leather, that makes up the pairs. to their shop. than for a horse ride. seat. He orders them from a “We’ll replace or repair tree maker in Oklahoma after Wendell will fix or replace “It’s a hobby and it’s fun anything for the Western measuring both the horse whatever needs to be done when you work on one sadhorse, from the blanket he to renovate a saddle, no mat- dle,”Wendell said.“When you and the rider. wears in the stall to ropes, ter how old. do 100 a year, it’s a job. But Both need to be considered halters, bridles and saddles,” Branton said.

“Someone brought in her it’s not a job you dread com- when fitting a saddle,Wening to.” dell said.

He and his wife, Marci, have mother’s saddle,” said Marci, 63.“It was from the Wendell has always made “We can fit it exactly to a run their saddle and leather early ’20s. It had been a his living in the world of horse,” he said.“We want it to shop outside of Lebanon wedding present from her horses, whether it was train- fit him, but we want it to fit since 1971.They work on dad to her mom. It makes ing the animals, shoeing other horses, also.” about 100 saddles a year.

“We make a living,” Wendell said.

Wendell, 67, was introduced to saddlery as a young man when he began spending time with L.W. DeWitt, a saddle maker and roper.

“I didn’t care about the saddle making, but he could rope,” Wendell said.

Wendell was 20 at the time and more interested in having fun than making a living, he said. But he made himself useful between roping lessons by tearing saddles apart for DeWitt.

“I didn’t know I was learning a trade,” he said.“I didn’t realize I was learning something that would earn me a living. I learned by accident.”

Through the years, he has seen saddles come back through his shop many times, including some he had a personal connection to.

Matt DeBow | Mid-Valley Newspapers “I had a saddle come in, Wendell Branton sews two parts of a saddle together, using a heavy-duty machine and lifted the rear jockey, and that can push through several inches of leather.

FRIDAY, MARCH 23, 2012

17

Branton works on a saddle in his home-based repair shop near Lebanon.

“Fit the horse first, then you can do whatever you want for the rider,” Marci added.

Wendell has designed trophy saddles for horse associations, including the Oregon Quarter Horse Association.

Wendell has all the tools to build an entire saddle by hand but prefers to use a custom saddle maker.

“Unless you are one of the great saddle makers, you can’t compete with the big companies,” he said.“While I’m cutting one saddle out, they’re cutting 10.”

Some cheaper saddles are created on an assembly line.

“It’ll be a good saddle when it’s finished, but the guy who built it start to finish has a little more pride in it, so it’ll be better,”Wendell said.

One look around his shop can give an idea of the economy,Wendell said.

“When the economy is good, they’re buying new saddles,” he said.“When it’s not, they’re repairing them.”

In between saddle maintenance and design,Wendell spends time creating other leather items — including chaps, purses, book covers and halters — in a variety of designs and leathers. Some of the more exotic leathers he’s used include ostrich, elephant and sting ray.

“If we don’t have it, or can’t build it, we can get it,” he said.

18

FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

In tune with the times

Gandara offers a lifetime warranty on his carbon fiber instruments.

Corvallis man uses carbon fiber bodies to craft bagpipes, flutes and didgeridoos that maintain a traditional sound but don’t warp from humidity or temperature

BY GAIL COLE Like so many entrepreneurs, Rob Gandara’s venture into wind instrument fabrication came out of necessity.

While traveling in early 2006, a piece on his Spanishstyle bagpipe broke. He’d already had the part temporarily fixed by an instrument repairman years ago, so rather than taking it back to the shop, Gandara constructed a makeshift part with carbon fiber to tide him over until he could return it to Spain for a permanent fix.

Gandara discovered how carbon fiber, not traditional blackwood, can create a durable, resonating instrument body that won’t warp due to temperature or humidity while still providing a full, consistent sound.Thus, Carbony Celtic Winds was born.

Gandara has since teamed up with Hood River’s Real Carbon to manufacture the thin sheets of the carbonfiber material, but the rest of the work — from the product design to the creation of the instrument bodies to the construction of the instruments — is done in his Corvallis home.

In addition to bagpipes, he uses the carbon-fiber material to make flutes, collapsible Australian didgeridoos, Scottish Great Highland and Spanish bagpipes and chanters, and Irish flutes, his best-selling item.

Though locally made, his sales are split between website orders — he ships instruments all over the U.S. and

Andy Cripe | Mid-Valley Newspapers

Rob Gandara plays one of his carbon fiber Irish flutes, the most popular item he makes through Carbony Celtic Winds.

throughout the world — and at Celtic and Irish-themed conferences and festivals. He typically visits two conferences each month.

Earlier this month, he attended the North Texas Irish Festival in Dallas and the Sonora Celtic Faire in California, and he plans to attend a bagpipe festival in France later this year.

‘When someone picks up this instrument and they play it, it will naturally play in tune.’

ROB GANDARA, CARBONY CELTIC WINDS

“I’m not technically Irish, but they allow me to come and bring these instruments with me,” Gandara said.

The products have a lifetime warranty, thanks to the

quality of the materials and the numerous mathematical calculations Gandara uses during construction.

“I’m a geek,” he joked.

While the instruments are

developed with highly technical precision, Gandara, who has an engineering background and plays in the Corvallis Celtic band Ordinance, aims for an authentic sound.

“My goal is to keep the way they’re played as traditional as possible,” he said.“When someone picks up this instrument and they play it, it will naturally play in tune.”

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

FRIDAY, MARCH 23, 2012

19

An itch that’s well worth scratching Albany’s Tec Laboratories Inc., makers of Tecnu and LiceFreee, puts its employees first, striving for a ‘Disney-like culture’

BY CATHY INGALLS

love to work with other great people,” Smith said.

President and CEO The philosophy is paySteve Smith’s philosoing off. phy for operating Tec Laboratories in Albany is Tec Labs has appeared “take care of the horses in Oregon Business first.” magazine’s list of 100 best companies to work Nurtured and caredfor 12 of the last 15 for employees are inspired and motivated to years, most recently in “work until their heart’s the March issue. He said content,” he said of the Tec Labs’ persistent apmotto that governs the pearance on the list is a helpful recruiting tool. family-owned business And he can see exactly located for the past 11 how the company years at 7100 Tec Labs stacks up against other Way S.W., across from Linn-Benton Community employers, which is a useful management deCollege. vice.

The company develThe dreaming, develops and sells over-theoping, creating, warecounter products that housing and shipping kill head lice and Production team member Jack Rowe prepares a tank for formulating cleanse poison oak and all goes on in a 50,000Smith, a chemical en- poison oak in students. poison ivy oil from the square-foot building that Avenue in Albany where sits on nine acres.The Smith’s father, Robert, Bell Telephone employgineer, believed every skin. Its latest developstructure was designed developed Tecnu, the American home would ees also used it in the ment is an antibioticso that it could be exproduct that helps have a bomb shelter, so field. free wound care gel. panded to 200,000 avoid the rash caused he set out to develop The company later The three are availby poison oak and ivy.

Tecnu, which he said moved to the former able in almost 100 per- square feet.

The sleek, modern He finalized the product would remove radioac- Borden’s Creamery on cent of the drug stores building is a long way in early 1961 during the tive fallout dust from around the United Water Avenue.“We’ve from the garage on First Cold War. the skin.

States, Smith said. been in Albany so long because it’s such a busiLuckily, Steve Smith He believes a successness-friendly city,” Steve said the product never ful business is also about said. had to be tested.

But it “growing employees in a found a new life when Disney-like culture.Walt Next the company deSteve’s mother, Evelyn, Disney is my hero. He veloped LiceFreee, a used it after cleaning worked with creative product line that comout a patch of poison and innovative people bats head lice, and now oak. She never develand we’re using a busion the market is a gel oped a rash. ness model that supfor minor wound care ports that.”

— Tecnu First Aid Gel Robert Smith made Tecnu available to Ore- — that is substantially A creative environmore effective than othgon State University’s ment is important beDepartment of Forestry, ers in killing antibioticcause it “attracts the resulting in a precipiresistant staphylocochighest quality of peoQuality control chemists Kevin Collin and Nikki Frum work in the Albany lab. tous drop in cases of cus, he said. ple and great people

David Patton | Mid-Valley Newspapers

at Tec Laboratories.

Smith said the product is being used in prisons with great success and was sent to Haiti after the 2010 earthquake.

Steve’s brother,Vernon, also is on the Tec Lab team and serves as vice president of operations.The company employs 28 full-time workers and has a “flex force,” bringing the total to 30.

Smith said he isn’t all business, all the time.

To relax, he runs marathons, is a private pilot, plays golf, is a pianist and he loves to cook.

“And I’m a perpetual learner,” he said.

20

FRIDAY, MARCH 23, 2012

ALBANY DEMOCRAT-HERALD, CORVALLIS (OR) GAZETTE-TIMES

Harnessing their animal instincts ters for the llamas on items) and the mailing cific to llamas and their the ranch. Her job inlist (400 people) and set smaller, fluffier cousins, volved traveling to the alpacas.Today, the to work. horse shows, leaving litA regular horse halter company carries a wide tle time to keep up with won’t work on a llama. variety of halters, along with blankets, driving friend had llamas and demand for her halters, The nose bone in a

BY JENNIFER MOODY Apersuaded so Chlarson’s friend sugharnesses and packs, llama’s face doesn’t her to pick gested she buy out the reach all the way to the veterinary supplies, care Their packs have trav- up a few as well. She fig- neighbor’s business. nostrils, which means a and grooming products, ured they had the room eled to the top of and books and videos halter that tightens on Again, Chlarson figand it couldn’t hurt to Mount Whitney.Their the soft spot can cut off on training, packing and try breeding them. ured it couldn’t hurt. harnesses have draped spinning fiber.

Her husband made sad- the animal’s breathing.

Another friend had a the fiberglass reindeer dles and they had an inAs the business develPeople with other in the Macy’s Thanksgiv- neighbor who worked dustrial-strength sewing oped, Chlarson found for central Oregon kinds of livestock started ing Parade.Their cusrancher Dick Patterson machine. So she bought herself creating more contacting Chlarson tomers have included and had developed hal- the product line (all 12 and more products spe- with requests. Could she Kim Novak, Dennis Weaver and NFL Hall of Famer Jim Otto.

Not bad for a business that started in a garage.

Quality Llama Products of Lebanon, now in its 33rd year, is the oldest and largest manufacturer and supplier of tack and supplies for llamas, alpacas and other pack animals in the country, and the only one on the West Coast.

With more than 2,000 products, its mail-order catalog is nearly half an inch thick — and 80 percent of the products are manufactured right in Lebanon.

Co-owners Nancy Chlarson, 64, and her daughter, Cindy Lewis, 31, say they never would have dreamed this business if they hadn’t lived it, but they wouldn’t want it any other way.

“It’s been quite a David Patton | Mid-Valley Newspapers ride,” Chlarson said.

Quality Llama Products co-owners Nancy Chlarson and daughter Cindy Lewis pose with a In 1979, Chlarson was custom-made pack, a row of harnesses and a stuffed llama made with real llama hair by a living on a farm in Bend. grateful customer.

Quality Llama Products in Lebanon adapts its line of tack as new ideas come in

Leroy Garret sews a llama feed bag.

make a driving harness for a goat? What about a donkey? A camel?

“They just see a need, you know: ‘I need a halter for my cow, too,’” Chlarson said.“So we work with them to design it.”

Chlarson’s company has made collars for chimpanzees at a speech research center in Florida, a harness for a classroom’s pet iguana and the packs for the llamas in the movie “Star Trek: Insurrection.”

The business now has some 44,000 customers worldwide.

Technically, the company is now three businesses: Quality Llama Products, which is the retail outlet; Alternate Livestock Supply, which is the manufacturing division and international arm; and Gateway Imprints, which daughter Lewis developed to meet a marketing demand for smaller-scale printing and design.

Gateway can do large print runs, too, Lewis said, but it caters to people looking to print just a couple T-shirts or posters without committing to a minimum order.

For 33 years, Chlarson said, that’s the way the business has gone: See a need, fill it. She anticipates that will continue.

“Whatever the market says to do, we’ll do,” she said.