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  Nypro, Inc., Page 42Nypro, Inc.
43 Harvard Street, Worcester, MA 01609


Clinton, Massachusetts
Total Square Feet: 102,475
Construction Period: Oct 2002 to Feb 2004 

GENERAL CONTRACTOR: Cutler Associates, Inc. - 43 Harvard Street, Worcester, MA 01609
STRUCTURAL ENGINEER: Kimball Chase - Pease International Tradeport, 29 New Hampshire, Avenue, #4, Portsmouth, NH 03801
ELECTRICAL ENGINEER: Interstate Electrical Services - 70 Treble Cove Road, N. Billerica, MA 01862
MECHANICAL ENGINEER: Shifman Design Associates - 141 Cross Street, Stoughton, MA 02072
COST ESTIMATOR: Cutler Associates, Inc. - 43 Harvard Street, Worcester, MA 01609

The state-of-the-art 2-story addition for Nypro, Inc., in Clinton, Massachusetts, was designed and built by Cutler Associates to be architecturally compliant to the nationally historic brick mill to which it connects. The new advanced technology center addition provides manufacturing space for Nypro Mold. The addition also provides a second floor 25,400-square-foot class-100,000 (ISO Class 8) clean room, office and engineering space and conference rooms.

Cutler's architects designed the exterior of the new building to compliment the existing, century-old, brick industrial revolution architecture of the existing structure. Design elements such as arched windows, a tower element, and extended overhang soffit detailing continue the architectural style of the existing mill building. A mezzanine on the interior provides views of the manufacturing process through an open walkway. Large windows bring in an abundance of natural light into offices and conference rooms and the fenestration in the West elevation was designed to reflect the two-story manufacturing area.

Steeply sloping grades, up to 20-feet in areas, impacted the site design. Cutler architects created an on-grade entrance to the mezzanine office level that gradually slopes down to the original level. The mezzanine along the North and East sides of the building helps to structurally support the retaining wall needed to support the elevated grade. Cutler used a geo-textile fabric to eliminate the need for a retaining wall against the existing 100-year-old building, and although the building connects to the existing facility, it can operate as a stand-alone entity.

The new facility is connected to the existing structure with a series of enclosed ramps and walkways. To keep the existing trucking configuration open during construction, Cutler architects and engineers worked with extreme care within the tight site parameters, high water table and high site elevation.

An elevated external loading platform and a 10- x 10-foot overhead door gives Nypro Mold the ability to move large equipment components into the second floor clean room. At the ground level a 12- x 12-foot overhead door allows fully assembled equipment to be moved into the first floor manufacturing and moldmaking areas. Housed in the mold-making area are five bridge cranes having two to-four ton capacity.

Nypro, Inc. is an $800 million business that operates 29 plastic molding facilities and nine mold-making shops in 12 countries. As one of Nypro's largest operating units, the Clinton facility combines the latest technology in injection molding, robotics, secondary operations, assembly and innovative plant design.

Cutler Associates services clients in the corporate/industrial, scholastic and assisted living and housing markets from its locations in Worcester, Mass., Allentown, Pa., and Tampa, Fla.

DIV 04: Masonry: Woburn Concrete Products.
DIV 06: Architectural Woodwork: Melton Classics.
DIV 08: Entrances & Storefronts: Kawneer; Glass: Solar Seal.
DIV 09: Carpet: Inter face Carpet Tile; VCT: Tarkett; Vinyl Base, Rubber Tile; Rubber Stair Treads: Johnsonite.

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