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The story of the Nomacorc factory in rural Zebulon, N.C., epitomizes how U.S. manufacturing is using a mix of brains and automation to counter forces squeezing it from all sides.ZEBULON, N.C.—In a nondescript factory in this small, wooded town, 10 giant machines worked around the clock last year to churn out 1.4 billion plastic corks, enough to circle the earth 1.33 times if laid end-to-end.

Unknown to most American wine drinkers, the plant's owner, Nomacorc LLC, has quietly revolutionized the 400-year-old wine-cork industry. Since the 1600s, wine has been bottled almost exclusively with natural cork, a porous material that literally grows on trees in Portugal, Spain and other Mediterranean lands.

But over the past 10 years, an estimated 20% of the bottle stopper market has been replaced by a new technology—plastic corks that cost between 2 and 20 cents apiece. More than one in 10 full-sized wine bottles sold worldwide now come with a Nomacorc plug, while another 9% or so come from other plastic cork makers. Screw caps took another 11% of the market.

To read the full, original article click on this link: Seeking Closure: Plastic Stoppers Crack 400-Year-Old Natural Cork Monopoly - WSJ.com

Author: TIMOTHY AEPPEL