Dragon Cement and Concrete Completes $50 Million Modernization of Thomaston Plant

Dragon Cement and Concrete announced today it has completed a $50 million modernization of its cement plant in Thomaston, the first major expansion of New England's only cement plant since 1971. The modernization included a $10 million dollar upgrade of Dragon’s distribution system including the acquisition of new railcars and construction of new storage capacity.

Dragon President Joseph Koch said the modernization changes the plant to a more environmentally efficient process while increasing fuel economy and production capabilities. The expansion also allows Dragon to maintain or increase employment levels at the plant for the next 20 to 30 years.

The modernization, which involved a major overhaul and rebuilding of the plant, began in the spring of 2003. As a result of the modernization, which changed the cement-making process from a wet, slurry-type process to a dry, state-of-the-art process, the company will be able to save energy and reduce fuel consumption for each ton of cement made. The change will also reduce the process time of the kiln and at the same time increase production by over 30 percent, said Koch, who is also a former chairman of the Maine State Chamber Board.

"Rebuilding the plant is the beginning of a new era for Dragon," said Koch. “This investment in state-of-the-art technology and equipment will not only provide continued employment at the plant but also increase our exports from Maine, enabling us to continue to grow at a steady pace,” said Koch.

"Dragon's modernization project is an investment in Maine by a long-time and stable Maine company - it's also an important economic contribution to the mid-coast region and to the state as a whole,” said Gov. John Baldacci. “We are glad to see a company looking into and building the future in our great state."

"Dragon's $50 million modernization is a boost to the mid-coast region as well as a significant investment in Maine," said Dana Connors, president of the Maine Chamber of Commerce. "The business community recognizes Joe Koch for his leadership of this important company, New England's only cement manufacturer, and applauds him for his confidence in Maine’s future."

With the modernization, the Dragon plant can produce over 700,000 tons of cement on the same amount of fuel currently used to produce 500,000 tons. “This increased efficiency results in a positive environmental benefit because while our production increases, our air emissions will not," said Dragon’s Environmental Manager, Ann Thayer. “We also made substantial upgrades to dust collection equipment and incorporated low NOx technologies to minimize our emissions.”

Dragon Products is one of Maine’s leaders in recycling industrial materials to replace virgin feedstocks and has received numerous state environmental and safety awards over the years, including a Governor’s Award for its dust reduction program in 1998 and for waste recycling in 2002.

In addition, Dragon has invested millions of dollars over the past 10 years into environmental equipment and programs. In 1996, the company made a $1 million investment to recycle cement kiln dust back into the process through a very successful system known as the “dust scoops”. As a result, new material added to the pile has actually been reduced by 98 percent from pre-dust scoop days. Cement kiln dust is a by-product of cement manufacturing. Prior to the installation of the dust scoops the material was treated with water and stockpiled. “The success of the dust scoops solved a major solid waste problem for the company and allowed the focus to shift to reuse opportunities for the material,” Thayer said.

Headquartered in Portland, Dragon operates the only cement manufacturing facility in New England in Thomaston and is the largest supplier of ready-mix concrete in Maine. The company employs more than 225 full-time employees statewide. The cement is supplied to most ready-mix companies in the state, and others throughout New England by barge through Coastal Cement terminals in Newington, N.H. and Boston.

The modernization was aimed at upgrading equipment at the Thomaston plant that ranged in age from 30 to 70 years and hampered Dragon's effort to compete in the marketplace.

"This modernization is a solid plan to keep the plant viable in a competitive market," Koch said, pointing to increased competition from Canada caused by the favorable exchange rate. "It will be good for the community and good for our employees at the plant, who are the key to the Dragon team."

The most important improvement is the change over in cement production, Koch added. Formerly, the company utilized a wet-kiln process. Conversion to a dry process will provide dramatic savings in terms of energy by shortening kiln time from 150 minutes to 45 minutes and reducing fuel consumption by one third, Koch said.

In 1995, Dragon expanded into the southern New England market with the addition of a multi-model marine and rail terminal and shipping operation. The increased production from the plant will be sent out by rail and barge thus reducing emissions from transportation of the product to market. “Dragon’s commitment to alternative forms of transportation takes over 10,000 truck trips off the road per year,” said Thayer.