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Hey, it’s Fay from the Grill Dads [Applause] and guess what? I’m in Cambridge City, Indiana today at RTA Outdoor Living, their manufacturing facility. RTA is the only place that you can get an outdoor
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kitchen that you can install in one day. RTA is the modern alternative to contractor-built outdoor kitchen. I mean, look, we all know the deal. You get an initial quote and you end up paying a lot more than that first quote was. And by the way, and it takes a lot longer to do it, but not with RTA. RTA’s
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promise to their customers is beautiful, modern, customized outdoor kitchens. And it’s all delivered in an efficient timeline that doesn’t change halfway through. They produce every single part of the kitchen right here in Cambridge
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City, Indiana. And what’s more, they ship it directly to you. So come with me and let’s put RTA’s promise to its customers to the test. [Music]
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Hi, Amanda. Look at all this. >> I love those big Midwest hugs, man. The best. >> Well, thanks, Amanda. I’m actually really excited to be here. Uh, you know,
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as a as a guy who’s been on the Food Network, had a bunch of shows. We’re regulars on the Today Show. I’m in front of camera a lot, but I don’t get to see the back end of stuff very often. which is kind of exciting to see where the the entire brainchild like all the manufacturing is done basically here.
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99% of everything >> is done here. >> Yep. And >> and you’re going to show me the whole thing. >> You get to see it all. >> Well, what are we waiting for? >> Let’s do it. >> Cool. Can I get a sandwich on the way out, though? I’m kind of hungry actually. >> Yeah, let’s do it. So, this is the very first step of the outdoor kitchen
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process. Someone puts in their order and then the order goes into production. This step of production is called casting. So this is where the concrete is mixed. This is where it’s poured into the molds um customized for your
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kitchen. So if you want a grill, your grill cutout is placed and poured right around that. >> So let me ask you this question because from my understanding a lot of outdoor kitchens are brick or stone. So explain to me why you guys are using concrete.
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>> So our concrete mix is very strong. Um, a normal concrete uh sidewalk or driveway is 4,000 PSI, which seems like a lot, right? But our concrete mix is very strong and dense and it’s 17,000.
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So, this allows it to last way way I mean very long time plus also up to like more than 100 years. >> Really? >> Yeah. >> Wow. I uh >> Do you think you’ll be around to see that? >> Absolutely. 100% I’m going to be around
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for [Laughter] You know, I’ve been around outdoor kitchen builds before and a lot of times you’re using stoner brick, you’re building frames, you’ve got all sorts of pieces of metal. There’s there’s obviously, you know, a kind of base
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level you’ve got to put in. So, you got to be able to screw everything in there. I haven’t really seen anything like that from RTA. So, what’s the deal? >> Yeah. So, ours are single monolithic panels. They just screw together. And a lot of times when they uh contractors
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use the multiple layers, um sometimes the weather just does not sit well with all those different layers. They may, you know, expand. Uh >> those are all the vulnerable points basically in ah got it. So unlike So RTA is not an onion.
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>> We’re not peeling all these different No. No. Okay. >> We’re more of an apple. >> Sturdy apple. >> Sturdy apple. >> Yes. So one of the things that we say RTA is more layers more problems. So the less layers, the less issues that you have. You just go with one and you’re
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done. >> So more layers, more problems. We don’t have that. >> Say it again. >> More layers, more problems. >> Less layers, less problems. >> The whole inside of your kitchen can be utilized. Whether it’s storage space, whether it’s wiring your grill up, uh
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your propane, putting your beer fridge in, your karator. >> All right. So less layers, more stuff. >> Yes. more opportunity to cook out and bring your family together. So, this is the batch plant. This is where we mix our
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concrete. Um, so it’s mixed and then dropped down. Um, and then the grout hog is what we take to each table and pour into the molds uh for each panel of the kitchen. >> And these are the molds. >> So, these are the molds. These are all
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different uh panels that can be made. Um, and some look like stack stone, some look like um bricks. So, this is the batch plant room. Okay. >> This is where uh the computer system we
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use to run the batch plant, which mixes our concrete mix 1,000 lbs at a time. >> Wow. Okay. That’s a lot. >> Yes. So, not only does our concrete mix go in, but then this is where we add fiber. This is where we add the pigment to make the color of your
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>> custom colors, whatever you want. Got it. >> Yep. And then the water. So water is just mixed with all of that which then creates our our concrete mix. >> Amazing. And you’re telling me with one click of a button here, >> I’m mixing 1,000 lbs. >> Yep.
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>> Yep. >> That’s impressive. >> It is wild. And that’s what allows us to make so many kitchens in one day. >> It’s like batch crazy. >> Yeah. You ain’t batching. Once the concrete is mixed, it’s headed to the U molds. So that’s where I’m going to show
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you next, the layout casting department. >> All right, let’s go check it So, this is the CNC room. Um, this is where we prep kitchens, um, and get the cutouts ready for each of the openings and the panels. >> Got those where the appliances go, what you’re saying, the grills, the sinks, and all the >> Yep. That’s what I have right here. So,
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we use the CNC machine to cut out um, each individual um, cutout is what we call them, but it’s the, you know, the placement in the kitchen of where each appliance goes. >> Okay. So, you’re using I can see the computer behind me. You’re using digital
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program to basically completely customize to precision measurements. >> Correct. Yep. So like right here, this is a sink cutout, but when this countertop was poured, a piece of styrofoam that was cut on the CNC was sat in here and poured around.
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So like this would be for a single burner in your countertop. It would go >> That’s awesome. So this is the casting room. This is where each uh kitchen is made in the
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very beginning. So after the customer has uh put in their order and have chosen their profile out of all the different profiles that we have, they’ve chosen what appliances they want in their kitchen and have approved their
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blueprints. Then we get the order and start right here. >> Got it. So this is like basically where everything starts. This is the after it leaves my office, it goes right here where it goes. >> Gotcha. All right. And it’s funny, I look at all the molds here. It seems like you have a lot of varieties of
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people to choose from. >> We can meet anybody’s needs and wants for what uh patio they’re trying to design. So, if they like um brown, then we have different options of brown or if they like a more modern look, then we can uh they can do that profile as well.
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>> Awesome. So, how many people work in this part of the plant? And how long does this process take? >> So, there’s probably around 10 employees in this casting department. This process takes 3 days. What we pour today, we’ll
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pull tomorrow and then it will cure for 24 hours and then the process starts all over again. >> So, it just keeps going and going and going, >> keeps going and going and going. [Music]
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Okay, great. What’s next? >> Processing. Let’s head there. That’s what makes it pretty. So, this is the processing department. This is stage two of the kitchen going out the door. >> Okay. So, what happens here then?
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>> So, this is where the panels come after curing for 24 hours. Each of the cutouts is cleaned up so that the appliances slide right in. And then even countertops are sealed and ready to go to the creating department. >> So this is after the pour. This is the
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pool, the cure, and this is the processing. >> This is the processing. >> I remembered that. >> Yes. >> So Amanda, am I right in saying this is kind of where RTA’s advantage is really cuz it’s the human aspect that’s brought in. So I see a lot of these panels now
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there there’s cutouts in them. We know the CNC does that with the styrofoam. >> Yes. >> But then what is all this? I see these molds here that they’re putting in here. >> Sure. So when the panels are made in the casting department, we place the the
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styrofoam that was cut with the CNC machine in the in the mold. >> So then we pour the concrete mix around. >> Well, after that the concrete, you know, slides under. Yep. So then in the processing department that is where we
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hand grind each opening so that the appliances can slide in and out. >> So you’re telling me a human being is taking this for example this is a cutout right here. >> Yep. This is a door >> and taking this making sure it fits and if it doesn’t So this is like pure human quality control.
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>> Yes. Yep. So, we use each uh cutout for um the appliances and the they stick it in, make sure it fits, and then they know that it’s good to go um for the customers. >> Okay. So, that that to me is really important because honestly, a lot of
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companies it’s all automated this and that and yeah, it’s great for efficiency and all of that speed, >> but you still need the human aspect to check the work, right? >> Yes. Yep. We know that it should be perfect when it goes out to slide your appliance right in.
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All right. So, this is where we do the panels. Right back here is the countertops. I want to go show you those. Okay. >> This is where our countertops are processed and uh sealed to get ready to be created. A lot of different countertops are done. You can do brown,
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you can do gray, you can do white, but one of the most common is the chiseled edge. So, it’s not thin, it’s not a clean smooth edge, but it gives you a little bit of that rustic texture. Kind of looks stone like, you know, and that’s still concrete. >> Yep. concrete. So now that we are done
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with the processing department, this is where it is beautiful. It’s ready to ship. So now we are headed to the creating department because each panel is uh loaded to head to the customer. >> All right. After you >> this way,
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>> I heard a rumor that you guys you weren’t fine with just the regular creating solutions that are probably out there. You have to make your own pallets and your own crates because of >> Yeah. So we make everything from the ground up. Uh we make our pallets and we
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build the crate around each of the of your each kitchen unit that we send. So >> So you’re not just packing the stuff, you’re building the crates that it goes into. >> We are building the crates. We know that these are shipping across the whole United States. >> They are going on multiple trucks
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through LTL shipments. We have to meet the specs for those, especially being a liftgate delivery at a residential home. Oh, for sure. um they have to be able to be lowered on a lift gate and dropped off at each of the customers houses. >> So, something I noticed too, and maybe
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it’s just my high intellect in this business, but I see a number one, a number two, a number. Are you telling me that you guys have figured out like my steps to actually uncrate? Cuz I got to tell you, major problem I have is when I get shipped something, I don’t even know how to open the box. >> Yes, correct. And it’s not even
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following directions because as long as you know how to count, you should know how to uncrate the the kitchen. Uh, one thing that we do pride ourselves on in building our crates and our pallets is we buy everything locally. So, everything that you uh, receive when it
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comes to material, your lumber, everything is bought locally. >> Okay. These guys just keep getting better and better. Humans, quality control, really nice people, present company included, you know. And now you’re telling me that you locally source the stuff to make your crates and
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your pallets. >> Yes. >> All right. Goody t shoes. I love it. So after this uh your panels are in the crate, everything is screwed together and it’s very structurally sound. It is not going anywhere. So we have an open
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air crate, but this is only the it’s almost finished. >> Wait, you’re about to show me the finished? >> But I’m going to show you the finished product. So, this is the cover that we cover the crates in, which helps waterproof the kitchen and the crate
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while it’s shipping. >> Wow, that’s awesome. So, even if like it happens to rain when the truck arrives and all of that, you’re like, it’s okay. Yep, >> we thought of everything. Guys, think of everything. >> So, we are done with your kitchen.
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>> Okay, it’s going to be shipped. Oh, there’s more. There’s always more here. >> Yes. So, every cutout that you have in your kitchen >> I know. I know. Gets an appliance. >> Gets an appliance. So, >> the next step is pulling those appliances, gathering it, getting ready
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to ship with your kitchen. So, we’re going to head that way. >> All right. Remember when I told you at the very beginning that everything that you get for your outdoor kitchen can arrive in one day. And one of the key components of that is the fact that they ship out all the appliances and they go
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in the exact same truck to be delivered on the same day. Unlike contractors, I mean, look, your tops could be coming a different day. Your appliances come next Thursday and you’re sitting there like, I don’t know when anything’s going to get here and I’m starving. So, that’s a key differentiator with RTA.
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>> Yes. Yep. So, we get our Coyote appliances in bulk. So, we have plenty to choose from, but also have them ready to uh palletize and send on your way. >> Yep. Got a few appliances here. >> Yep. Just a couple. >> One of the things I can’t stand is, you
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know, even if the contractor’s good, a lot of times they want to pass the buck and say, “No, no, no. You got to call them, have nothing to do with it. Yeah. So, you’re telling me I can just make one phone call to RTA and they’ll say, “No problem, Mr. Fay.” >> Yep. >> Take care of it. >> They’ve got your back.
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>> To sum all this up, easy reminder. This is the onestop shop for all your awesome custom outdoor kitchen designs, builds, and guess what? You have the fun of installing it yourself. Man, >> let’s get your kitchen on the road, and
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I’ll show you the last step. >> Great. >> of your kitchen. So, this is the shipping department. We’ve already created your kitchen. We have pulled your appliances and put them on a pallet. So, we are ready to load
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them in a truck and it’s going to be on your way. You have seen the entire phases of making your kitchen. So, we’re going to head back to the office and I can show you a couple more things. >> Great. Do you guys you guys have snacks in there? >> We do. >> I’ve been through the whole tour. Uh
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I’ve been able to see every single aspect of this business. These lovely people opened up their house to me and said, “Here’s the plumbing, here’s the electrical, here’s the stuff.” And what’s really cool is they said everything that they’re making for their outdoor kitchens, these beautiful custom outdoor kitchens, is made right here in
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Cambridge City in Indiana. The technology, the honesty, and the people factor is one of the coolest things that I’ve seen here with open arms. They said, “Fay, this is this I want you to meet this person, etc.” And it’s been really cool um to be able to do that.
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When I started this process, I wanted to see if RTA’s promise to their customers was actually true. Truth is, they’ve definitely held up their end of the bargain. Every aspect of everything that I’ve been shown is so incredible that’s assembled here. 99% of everything that’s
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put into these outdoor kitchens is manufactured right here in Cambridge City. So, they’ve done all the work. So, by the time that your outdoor kitchen gets to you, they basically done everything. All you have to do is unpack
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it, read the instructions, and put it together. And by sundown, or even way sooner, you’re cooking. [Music]
