Res 123-2021 Amending Budget for WFEDC to Include Expenditure to Falls Metal Fabrication, LLC 10/19/2021 Resolution No. 123-2021
Resolution approving the programs and expenditures of the Wichita
Falls Economic Development Corporation (WFEDC) and amending
the budget to include up to $16,000 for Falls Metal Fabrication, LLC,
to assist in the expansion of their existing business in Wichita Falls
WHEREAS, Texas Local Gov't. Code §501.073(a) provides "The corporation's
authorizing unit will approve all programs and expenditures of a corporation and annually
review any financial statements of the corporation"; and,
WHEREAS, on October 14, 2021, the WFEDC approved the Project listed below
and as stated in its agenda.
NOW, THEREFORE, BE IT RESOLVED BY THE CITY COUNCIL OF THE CITY
OF WICHITA FALLS, TEXAS, THAT:
1. The Wichita Falls Economic Development Corporation's approval and funding
of the following programs and expenditures as described below and in said corporation's
agenda, are approved:
Falls Metal Fabrication Project:
• A total of up to $16,000 to be used for the expansion of the existing
business in Wichita Falls.
2. The current fiscal year budget of the WFEDC is amended to provide for the
aforementioned expenditures and changes thereto.
PASSED AND APPROVED this the 19th day of October, 2021.
/V‘"k` lel' I"-"-'
MAYOR
ATTEST:
City Clerk
WICHITA FALLS ECONOMIC DEVELOPMENT CORPORATION
PROJECT SUMMARY
October 14,2021
ITEM/SUBJECT: Falls Metal Fabrication
INITIATED BY: ideaWF—Scott Manley and Jeannie Hilbers
ATTACHED: Business Plan
COMMENTARY:
Falls Metal Fabrication,LLC—Owners Johnny McClane&Lee Birk
Falls Metal Fabrication is a custom metal fabrication shop established in 2018 in Wichita
Falls. Although a newer company, it is operated by experienced metal fabricators. Their
specialties include custom HVAC duct work and fittings.custom roof flashings, rain caps,and
metal trim. They provide service for contractors,homeowners,and farm and ranch as well as
carry a wide variety of metals such as galvanized,paint grip,stainless steel,and copper_
The company is expanding their business to manufacture vent free fireplaces. As the owner of
the Ember Shop,Johnny is very familiar with fireplaces;last year he saw an opportunity for
expansion,as two manufacturers had recently gone out of business. Adding the vent free
fireplace to their production will greatly improve cash flow,taking them from a negative cash
flow to a positive one. The cash flow generated from the fireplaces will allow them to retain
their existing employees and add four new employees. They plan to add two employees in
January 2022 and two additional employees in September 2022.
The company has been brought to you as a winner in the ideaW F business plan competition_ A
more detailed project description and the business plan the company submitted for the
competition is included in this packet.
RECOMMENDAT ION:
I recommend the I".DC:agree to a cash-for-jobs incentive of$4,000 per job up to 4 new hires,for
a maximum commitment of S16,000.
SAMPLE MOTION: To provide a cash-for-jobs incentive to Falls Metal Fabrication for
$4,000 per job up to 4 new jobs.
Respectfully submitted,
Henry Florsheim,
Wichita Falls Chamber of Commerce
4
Falls Metal Fabrication, LLC
3411 McN/el Ave. #201
Wichita Falls,TX 76308
(940)723-5578 office
(940)723-5612 fax
www.fallsmet Ifabrtcatlon.co.m
Executive Summary:
Falls Metal Fabrication, LLC., a 50/50 Partnership, was started by Johnny
McClane and Lee Birk n January of 2018. The business was formerly owned by
Autumn Air Heating and Air Conditioning and was called Gage Metal. After the
death of the owner of Autumn Air, the family sold Gage Metal to McClane and
Birk. it was decided to move the business to a better location and change the
name since many of the HVAC Contractors n the area did not use Gage because it
was owned by a competitor. It is an "old school" custom sheet metal shop.
The current machinery is functional, it's the same manually controlled equipment
that has been used 'rr sheet metal fabrication for over 40 years. Our Manager/
Head Fabricator, Freddy Ozuna, has over 40 years experience beginning with M
& M Mfg., and his apprentice, Mason Baker, has been with Falls Metal since
February of 2019. We can find a way to make those difficult duct or flashing
jobs easier because we've already experienced the fabrication needed for your
job.
Our specialty is industrial, commercial, and residential duct work but we also
build custom duct fittings, roof flashings. raincaps, and even counter tops. We
have a large selection of duct work and duct system components. For the
professional HVAC Contractor or the Do-It-Yourself, we can build any duct system
to specifications. We can ship or deliver locally to the job-site. We have just
developed a website that has the ability to sell and ship parts. Our shop h open to
the public Monday- Friday, 8:00-5:00, and we also have a Facebook page.
We have a wide variety of metals and machinery to match custom sheet metal
needs. We can make projects out of galvanized, bonderized (paint grip).
aluminum, stainless steel, and copper. No job is too small or too big. Jobs are
priced to customers on an hourly rate plus weight/square footage of material
used.
We have invested a lot out of pocket expenses the last three years to purchase
the business, equipment, moving the entire shop, advertise, payroll, insurance,
and materials. Our present need is to add two machines that would greatly
benefit our customers, and modernize our capabilities. This is machinery that 's
needed to take this company to the next level by increasing the speed of
processing the material for each job and lowering our cost on materials because
we will be able to buy metal 'rr rolls.
5
The first machine is an Advance Cutting System Auto-Fold I-Fold 516 offered by
Advanced Cutting Systems (description sheet attached). Adding this equipment
would enable Ls to buy our raw materials in rolls. Rolls of metal are a better
price, easier to store, and less waste of material. The price of the machine includes
software, installation, support, and training. Not included n the price 's shipping
from Alabama and tax. This machine is priced at $89,900.
The second machine is a 5 x 70 Plasma Cutting System. This computerized
precision controlled plasma cutter would immediately benefit our operation by
reducing time and material needed for each project, which will also streamline
and increase profit of our manufacturing process. The price includes software,
support, installation, and training. This machine 's priced at $32,000.
The plan we have for Falls Metal in the next two years s to add the ability to
manufacture Vent Free Gas fireplace units. Once we are in production of this
initial unit. we have plans to add other models that are in high demand. These
two machines are a perfect fit in that they will decrease the time required to
produce the fireplaces and the time required for the custom fabrication that we
now offer. The McClane family has been involved in the sale of pre-fab fireplaces
since 1971 (The Ember Shop, Wichita Falls, TX.) and are very familiar with the
popularity of vent-free fireplaces used n new home construction and remodeling
in this region of the country. With the addition of this machinery we would
need to add A least another 5-6 employees within two years to produce and ship
these fireplaces. We have relationships with dealers in eight Midwest states who
sell and install these units. We also have relationships with two distributors in
the DFW area that have a dealer network that sell these units. We can either sell
dealer direct or sell to the distributors.
We are currently in contract with Underwriters Laboratory to test and approve
our prototype. The UL test fee s $7,800 which we are paying and will take
approximately 7-8 weeks. Having UL test our fireplace meets insurance
requirements and provides our customers the benefit of having a third party verify
the safety of the fireplace. We are also in the process of publishing an Owner's
Manual for each unit.
Market:
The Hearth Patio Barbecue Association has published the "Consumer Behavior
Research 2020 State of the Hearth Industry" report. Manufactured fireplaces 's
currently a two billion dollar industry, and growing, with half being gas fireplaces
and the rest being wood-burning or electric. Three in five North American
homes have a hearth appliance. Half vent out the roof, one third vent
horizontal, and the remaining 17% do not require venting, (vent-free). Currently
there are 7-800,000 units produced annually and our plan is to tap into the
demand for the vent-free fireplace segment of this industry. Our projections are
6
to produce approximately 1,200 units the first year which would be a minimal
percentage (1.2%) of the market. Ease of use and ease of maintenance are the
two highest rated benefits of a gas appliance.
The Vent Free fireplace 's an insulated housing for vent-free gas logs. They
are mostly purchased by contractors for use in new construction and remodeling.
The vent-free system has gained in popularity as the public has become aware of
the benefits and safety of the product. Falls Metal Fabrication believes we can
tap into a portion of the market by marketing our units to distributors in our
region of the country. These distributors employ in-house sales reps that market
all their hearth and patio products. There are three distributors in Texas and one
in Oklahoma that serve 14 midwest states. One distributor has several locations
throughout the US and serves over 30 states.
Competition:
A major manufacturer in Georgia, Vangaurd/FMI. closed in 2020 (they were
an old company that made a lot of other products and had been involved in
mergers in recent years). Another manufacturer in Alabama, IHP/Superior/Astria,
discontinued a small segment of their vent free units that there is still demand for.
IHP is the leading manufacturer of vent-free fireplaces in America. Then there is
American Hearth/Empire Comfort Systems located in Belleville, IL.. Vent-free
fireplaces are also offered on numerous online sites. There are several fireplace
manufacturers that produce wood-burning and vented gas fireplaces: we are only
going to concentrate on the vent-free fireplaces at this time. There are not any
fireplace manufacturers in this region of the United States.
Location:
Our current location 's in a good, high traffic area that k convenient for our
customers. But its also higher rent than we need to be paying at this time. We
are only using about 70% of the building because the rests built as offices and a
reception area that does not fit our needs. The overhead doors are 10' wide
making it difficult to transport sheet metal of 10' and 12' lengths. The Landlord
for this property does not want is to make any modifications nor 's he willing to.
We signed a 60 month lease that expires January of 2023.
Our growth over the last three years has created this space problem. We do
not have the room at this location to add any more machinery. Once this
production is in full swing, we are going to need more space due to the area
required for the new machinery and a loading dock. We are currently shopping
for a larger facility to purchase or lease preferably in the downtown area. Most
of the HVAC supply houses are downtown which would make a good fit for us to
be in the same area.
7
Management:
Our day to day operations are shared by McClane and Birk. All our
QuickBooks and billing 's performed by Shantel McCoy since 2019. The CPA
firm we use Gant. McGee, and Baber. Our business checking is with American
National Bank. Our current equipments on a lease with American National
Leasing and the lease will be completed ii February 2023. Shop operations.
inventory management, and custom orders are performed by Freddy Ozuna.
Fabrication of orders is performed by Freddy Ozuna and Mason Baker.
The new equipment will allow u; to retain our existing employees, increase
existing employees' wages. and add four new employees. We believe that once
Mason has been trained on the operation of the new equipment. we will be able
to increase his wages and add two apprentices in January and another 2 in
September. Our annual payroll is about $68.000. increasing Mason's salary and
adding the two apprentices in January and another two in September would add
another $97.760, bringing the total payroll to $165.760. Cash flow projections
for 2022 include the addition of 2 employees in January and 2 additional
employees n September.
Once we have the UL approval we will begin producing and marketing our
fireplaces. Initial plans to produce a minimum of 24 units per week within two
months, with a profit of $150.00 per unit. Popularity and demand for the
vent-free fireplaces is expected to increase. requiring Falls Metal Fabrication, LLC.
to increase production, thus also increasing profit. The increase in production and
profit will enable us to add even more jobs in the future.
8
Falls Metal Fabrication,LLC
2020 cash Flow
all Et. Lk kla &a lk1 filig SZG v.,. a... Mil
Inc
Rental rneome 87S 875 875 875 875 870 875 875 437 7,432
Sales 8,559 9,341 14177 1407 12,183 14,831 13,547 14711 24,783 10631 20,548 13336 164312
Tonal Income 9,434 10,716 11,052 15,532 13p68 15,701 14422 11,586 25225 10,631 20,548 13,636 171,741
Cost of Good Sold 3,28 373 2,161 4,376 5,911 3,623 7,1177 4,055 3,074 3,975 2658 8,793 026
Gross Raft 6,146 10,344 8,872 10,66E 7,,47 12,078 12,490 7531 22152 6,657 17,690 5,043 126,716
E<pensrs
Ruounting 159 197 250 140 150 - 200 200 1C0 - 1,340
Credit Card Fees 235 133 90 129 73 172 PF 193 128 159 121 1,676
Insurance 1,218 1,213
Interest Expense 2,354 2,354
IoonntoryTax 154 45 218
Latin Care 37 A
Lease Payment lexistingl 775 775 775 775 77S 775 775 775 77S 775 775 775 9,300
ORIce Supplies 412 230 642
Payroll Tax Expense 441 437 428 414 9127 333 395 494 401 5E12 401 546 5365
Payroll 14a4e Expense 5,155 5,146 5,311 5,186 6,452 5156 5,166 6,457 5,246 6557 5,246 7,140 68,228
Rent 2,500 2,500 2,500 2,500 2,500 2500 2,500 2,500 2900 2,507 2500 2,500 30,000
Repairs Maintenance 72 ND 200 1,319 261 2I2 1,44Z 45 334 4,174
Tax.Property 1,153 1,153
Telephone 200 250 150 260 150 150 1,160
441f1l41 597 616 571 379 464 3E0 169 646 507 552 286 797 6,231
Total Expenses 9,731 10,862 9,868 10,407 11528 12.672 11,170 11412 11,490 11509 9,617 14,781 133,665
Cash Row 13,5641 (5381 199E1 249 14,381) 1.406 1,X10 13,890) 10,662 14,8521 8,073 (4,734) $ 06,3491
9
Falk Metal Fabrication,LLC
2021 cash Flovr
lan FED M5r 4g Mav LB I Total
Income:
Sales 6,922 10,380 24,461 22,740 7,805 11,967 10,822 14,231 105,327
Total Income 6,922 10,380 24,461 22,740 7,805 11,967 10,822 14,231 109,327
Cost of Good Sold 818 3,209 4,584 7,812 2,687 2,982 4,366 1,815 28,273
Gross Profit 6,104 7,170 19,877 14,928 5,117 8,985 6,456 12,416 81,054
Expenses:
Accounting 250 250 300 800
Advertising 416
Credit Card Fees 476 138 124 114 306 127 185 237 1,707
Insurance 1,213 27 1,240
Interest Expense -
I nventory Tax -
Lawn Care -
Lease Payment(existing) 775 775 775 775 775 775 775 775 6,200
Office Supplies 181 122 50 320 673
Payroll Tax Expense 449 445 423 518 434 391 487 434 3,581
Payroll Wage Expense 5,246 5,200 5,211 6,557 5,581 5,108 6,362 5,633 44,898
Rent 2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,500 20,000
Repairs&Maintenance 165 1,616 1,781
Tax-Property -
Telephone 150 350 150 300 150 175 1,275
utilities 744 688 526 753 320 510 433 430 4,404
Total Expenses 10,505 10,959 11,733 11,340 10,316 9,961 11,658 10,504 86,975
Cash Flow {4,401) (3,788) 8,143 3,588 {S,199) (975) (5,201) 1,912 (5,921)
iu
Fab....Fbrldlm,LIE
1122 cash Row Pr sles lorrs slth Flre Bar
all 5.111 9111 11[L /M1 2.1'1 00 .13611 I41HL
,Vast Fran 36361013 Produwd 5 31 24 55 115 12 LW 171 , 141 DM 2,80
54mles
s91... 10,944 10,904 10,994 10,941 16,916 115,416 16,416 16,416 16,416 16,416 10,944 10,534 16.4150
Vast lea Fi.plr.s 1,950 9,960 5,361 97,440 41,1360 46,833 46,810 45,1100 56,160 56,160 56,150 56160 4611000
Dash ha
• _..........1� .._....-1_...._ .... 45 1.65 .......65,215
1, � T2,5 72' �.
Total lrsvalae 3Pl 20,114 3W 6 265 Z15 71,216 16 ]6 76 67,1t14 67,104 150
Coat of Gods Sold 2.955 2,955 2,M5 2..75 40152 4,432 4,492 4,492 4,492 4,432 Z955 2955 44,323
Cost of Goads Soar.Rh/places 1.310 5,760 5,760 23000 27,950 29960 26,9010 291,331 391560 31563 54560 545E0 2119$0:10
Taal Cast 0 Goods 998 4,155 4715 4715 25,995 92,632 33,232 93,292 95232 35992 34932 37,515 37,515 33,323
COGS% 32,0 4915 996 54% 52% 53% 47% 594 516 554 5666 55%
Gres Pre,from.e17er saves 7,959 7,9133 7,919 7,33 11,931 11,561 11,981 11,9151 11,951 11,931 7,98 7,503 119,837
Grins Prof it-Firlplaw, 795 3,500 9/310 144W 17M _4a 18000 _ .78 0.1 2 B00 21400 z;aao 21,11.6.0 1&4005
Taal 5144.7r16 7739 11,993 11,589 22;389 3,294 29,994 29,994 29,534 31,.581 33581 29,599 29,589 79,037
Expense
Accounting 190 190 30 142 130 - 206 200 160 1140
1590t Ca•sr Fees. 137 197 137 137 35 35 2E5 255 15 205 1.47 137 2..052
I narana 119 1,253
1n.renta6Tas 154 fb 213
117.'Care 20 33
L.r.Pay-ne6 Ira sling) T5 775 T5 T5 775 775 75 775 715 715 775 775 9,330
lease Pasene,1 1ne1•2 1950 1,950 1,950 7951 1.950 1.950 1950 1,950 1950 1.950 1,950 1,950 23,400
1ffcc 5u=91,.8 412 ID 542
Parrol Tas Ex73753 411 497 428 464 507 393 954 558 451 577 461 625 5,.75
51,m318309 Esperse 5,155 5,146 5,911 5,186 6,452 5,166 5,941 7,426 6033 7,541 5,033 0211 79600
Gen 2,950 2,560 2,500 2,500 2,500 2502 2,507 2,500 2,500 2,600 2,500 2500 90,000
Gel'ars&Marra.ance 9 323 730 1,319 372 792 1442 f6 330 4,174
Tar.Pr4pr±7 59133 3J0110
Te'eshcoe 193 191 193 193 181 150 135 150 150 150 193 193 1310
Uhirte.s 594 546 521 919 464 33 4E 616 ii.SOT 552 25 797 5,91
roar El.Ile99e4 11,30 13113 11,972 11354 13,050 11934 15,534 14513 14179 14,745 17,392 15,545 157,756
Cash Flory RA91 115291 [333] 10,056 19720 17,0E0 14,150 15,471 19561 1933 17,193 14,044 9 197,081
Payroll-N51/Wages. 5,7E0 97E0 5,760 5140 5,750 5160 9,763 5,760 11503 11.520 11,514 11,330 92,160
.lMs..rages re included in Cos!cf Goads Mid-Fir.placas
lmaary.add 21cbs[44 funds r..-..wd duly 70221
S.pl.m6 so add 2j r6s(44 funds r.oawd F.6rury 2323)
11
Fads M.3:I Fabcr adm,LLC
2023 rash Flax Prgerborm xith Pre Boa
Vent free Replacer Pooduced 197 197 150 197 150 150 150 LLY 155 150 150 750 195.0
Interne:
910E 12033 12036 12038 121188 13035 18,1138 13C68 1330 19058 15058 120 12,E 1813576
Verrt Leffi Frepaces 53,5C0 5Br0] 5$9351 53501 59501 53500 58,503 59 59,5071 59,S0J 53507 53501 702,011
cast fvJrbs(44 &WO - - - - 430
Toot tnocrne 73538 73,533 711538 70598 75,933 73553 73558 76558 76558 76,558 717538 7059 930976
Cost of Goods Sdd 3,E0 330 3,30 3,250 4,876 4876 4,876 4,876 4,376 4676 3250 3150 43756
Cat of Goods Sdd-Fireplaces 36,000 36,001 36,030 36,000 36,011 33007 36,001 36,000 36x01:0 33013 34000 36,031 432003
Tod Lost of Goods Sdd 39,290 39150 33290 33,250 43876 44876 44376 44876 44876 40676 33250 304250 43617.
COGS% 53% 5016 5656 9563 5316 5316 53% 5316 5316 &716 5876 5916
Gras Pr.*Yom*tier sales 37E3 8.788 9,799 3,736 13122 13182 13132 13,182 13132 13182 378E 378E 739320
Gross Profit-Fireplaces M.SCO 22,503 22500 2Z500 _22,500 22503 22503 ".2,500 22,00 72973 7y500 22503 273007
Tors Gras Profit 31203 31,288 31,233 •...31,268 35,932 39332 35,62 33682 39682 33602 31,238 312E8 401,831
Expenses.
Accounting 150 150 150 193 150 - 200 Zb 10] - 1,397
Credit Card Fees 150 157 150 150 226 223 276 226 226 226 150 150 Z257
Insurance 3203 1,303
I nunnery Tax 154 F 218
Lana are 37 ai
Lease Papne t[revs} 1,660 1,497 1,350 1950 1,950 1,37 1950 1,930 1950 1,950 1,560 1,950 25400
OM.yuppies 412 230 642
Payroll Tar F perne 5C0 503 92 476 563 M8 454 56 961 577 961 628 4169
Fa nil 93e EWerce 5933 5916 51f6 5,954 7,420 5941 5911 12426 6,033 7,591 6,oaa 3211 73962
Rest 25C4 05173 2500 2500 2500 2,503 2.500 2500 2501 12507 2,5W Z503 336:00
Repass&Melirtenatre 22 no 2C0 1,319 221 522 1,442 6 334 4,174
T.-P.merty 3000 3003
Teephone 150 150 150 150 150 150 150 150 150 150 150 150 1423
Inililie: 594 CM 571 379 464 300 929 695 507 552 236 797 6231.
Total E9)915e3 31,760 13195 12072 12,432 13,743 12994 15079 19753 13139 13691 11630 13791 1936117
rani Flow 19,508 13,093 19,216 13,356 21933 22698 20,603 21,921 22213 21,691 19,658 16501 6 942904
12