Toto, one of the world’s leading plumbing manufacturers with over $5.34 billion in annual sales, has opened a $224 million state-of-the-art manufacturing facility in Morrow, Georgia.
The new facility marks a major investment in the company’s Americas growth strategy, enabling faster delivery of strategic high-end one-piece toilets to meet surging market demand.
To achieve this, Toto is shifting more production from Asia-based Toto Group plants to North America, strengthening its regional supply chain, enhancing manufacturing resilience, and advancing its long-term sustainability goals.
Taro Muroi, CEO of Toto USA, says: “This is more than a factory opening – it’s the next chapter in our US manufacturing story.
“Since we began production here in 1991, we’ve united Toto’s manufacturing expertise, innovative technology, local craftsmanship, and commitment to sustainability to deliver premium products made in America.”
Muroi emphasizes: “This new facility builds on that legacy and strengthens the deep, enduring bonds of trust, collaboration, and shared vision with our employees, partners, customers, and communities across the Americas.”
Expansion meets surging Americas demand
With the new facility online, Toto’s production capacity in the Americas rises to approximately one million units annually across its Morrow, Lakewood, and Mexico plants. The new building in Morrow alone adds production capacity of approximately 300,000 units per year.
Luxury one-piece toilets are a strategic product for the Americas market. Previously sourced primarily from Toto Global Group plants in Asia, they often faced extended lead times.
Localized production now ensures timely delivery, strengthens Toto’s North American supply chain, and supports the company’s growth strategy across the Americas.
In June 2023, Toto broke ground on the new facility on the site of its original Morrow plant. Construction concluded in November 2024, and production will begin in the fall of 2025.
The expansion adds about 161,500 square feet (15,000 sq m) of advanced manufacturing space, bringing the new three-story facility to over 363,393 square feet (33,800 sq m) and sustaining 420 local jobs.
Robotics, AGVs, and high-pressure casting anchor innovation
The new Morrow facility showcases next-generation manufacturing technology designed to advance quality, precision, and operational efficiency:
- Tank bonding robot – A first for any Toto Group plant, this robot – jointly developed with an equipment manufacturer – precisely positions and bonds tanks to bowls for one-piece toilets, boosting quality and productivity.
- Automation fleet – Thirty-four advanced robots streamline processes from molding to finishing while maintaining local artisanal craftsmanship.
- Automated guided vehicles (AGVs) – Six self-driving vehicles carry three toilets each between molding, drying, glazing, and firing over approximately 44 yards (40 meters), enhancing efficiency, and reducing worker strain.
- High-pressure casting equipment – Overcomes previous production limitations by enabling the manufacture of larger, more complex designs, expanding the range of premium products made in the Americas.
- Heat-resistant QR codes – Durable 2D codes applied to each product enable real-time tracking, quality control, and big-data analysis to optimize manufacturing processes.
- Planned new kilns (2027) – Two convection-heated kilns with advanced insulation and digital temperature control will improve energy efficiency and cut CO2 emissions by approximately 23 percent compared to current kilns. Planned for installation in 2027, these new kilns’ design will accommodate taller products, improve firing consistency, and reduce energy loss associated with older kiln technology.
Sustainability in design, manufacturing, and logistics
The new facility was built with sustainability at its core, aligning with Toto Will2030 – Toto’s global strategy centered on “cleanliness, comfort, and health, the environment, and connections with people”.
Sustainability initiatives include:
- Energy-efficient manufacturing systems embedded throughout production.
- Localized production that reduces shipping distances and lowers transportation-related carbon emissions.
- Water-conserving technologies integrated into operations.
Planned new kilns that will cut CO2 emissions by approximately 23% compared to current models through advanced insulation, convection heating, and precise electronic temperature control.
These measures support Toto’s mission to contribute to the United Nations Sustainable Development Goals (SDGs) and maintain its leadership in sustainable innovation.
A 36-year commitment to the Americas
Toto began operations in the Americas in 1989 in California and has grown steadily through the bonds built with customers, strategic partners, and local communities. In 1991, the company launched US-based manufacturing in Lakewood, Georgia, and in 1996 opened its first major manufacturing facility in Morrow.
Now, 36 years later, Toto continues to strengthen its brand in the Americas. Featuring advanced automation, precision robotics, and sustainable systems, the expanded Morrow facility increases capacity, enhances Toto’s US manufacturing footprint, and reaffirms its deep commitment to the Americas market.
This investment builds on years of steady growth and positions the company to meet growing demand for premium bathroom products across the Americas.
Strengthening regional market leadership
For fiscal year 2024, Toto USA recorded sales of $464 million, underscoring strong demand for its premium bathroom products, despite a slowdown in the US housing market.
The company is a key growth driver for the Toto Global Group. Like its award-winning Washlet bidet seats, Toto’s premium one-piece toilets combine luxury design, high performance, superior water conservation, and exceptional cleanliness and comfort.
Muroi says: “This expansion cements our leadership in luxury bathroom innovation while creating a more agile, resilient manufacturing network.
“It builds on our strong market momentum, allowing us to serve customers better, support employees with safer, more efficient technology, and contribute meaningfully to the sustainability of our planet – all while honoring the deep bonds we’ve built through decades of trust, collaboration, and shared purpose with the people and communities throughout the Americas.”
