Minnesota-based Alexandria Industries was one of the winners at last weekend's Indy 500 at Indianapolis Motor Speedway.
The component manufacturer used its aluminum extrusion prowess to build the world's longest Hot Wheels track: Four one-mile-long lanes arranged side-by-side in a giant oval for a pre-race competition sponsored by toymaker Mattel.
About 30 Alexandria Industries employees, guests of the company, watched 12-year-old Christopher Bienusa from company hometown Alexandria win the race with his toy hot rod among four contestants. Bienusa made it to the Indy 500 through a Mattel online competition.
Alexandria Industries used nearly 5,000 pounds of aluminum to make the track through an extrusion process of heating a billet — or log — of aluminum and pushing it through a die, creating the track shape. To make the precision curved sections, team members enclosed the track in a form-fitting plastic mold and "stretch formed" the extrusion around the form to keep its track shape while bending.
"This project brought out the kid in our entire team," said Tom Schabel, CEO of privately held Alexandria Industries.
The company, which serves customers in the medical equipment, boating and snowmobile industries, took market share during and after the recession, which sidelined many competitors, Schabel said in an interview last week.
"We are a 'quick response manufacturer,' " Schabel said. "We focus on reducing lead times to improve quality, reduce cost and eliminate non-value-added waste. We have been doing that for a long time and it really allowed us to gain market share as we came out of the recession."
Sales rose 18 percent last year to $85 million. Alexandria, which added 74 employees in 2012 for a total of 525 at plants in Minnesota, Texas and Indiana, should top $100 million in sales this year.