PolyFlex 鈥� Part of聽Nefab Group is expanding its plastics packaging manufacturing and processing operations with a new 137,000-square-foot facility in McMinniville, TN. The facility is designed to enhance thermoforming and extrusion capabilities, supporting increased production efficiency, in-house material processing, and sustainability efforts.
The expansion aims to strengthen聽Nefab鈥檚 heavy-gauge thermoforming capabilities聽provide cost-effective plastic packaging solutions for聽industrial and automotive applications. The investment is part of a broader effort to improve production capacity while integrating聽closed-loop recycling initiatives聽that support a more sustainable supply chains.
The McMinnville facility will focus on聽heavy-gauge thermoforming, featuring:
- An expanded rotary line聽to increase production capacity
- New heavy- and thin-gauge roll stock extrusion capabilities
- Cost savings of approximately 15% on sheet production, increasing competitiveness in the thermoforming market
“The McMinnville facility represents a strategic investment in high-performance thermoforming and sustainable plastics manufacturing,”聽said聽Patric Vestlund, EVP Americas at Nefab Group.聽“By integrating advanced extrusion, thermoforming, and recycling capabilities, we are expanding our ability to deliver high-quality, cost-effective solutions while supporting circular economy initiatives.”
Additionally, Nefab will consolidate its Morrison Thermoforming operation into the new McMinnville site, with full readiness expected by year-end. The installation of new extruders, scheduled to be operational by December 2025, will further expand capacity and reinforce in-house material production.
A key component of the expansion is the facility鈥檚聽role as a recycling hub for heavy-gauge thermoformed trays. The site will be equipped with a聽new grinder to support closed-loop recycling, allowing customers to return plastic trays at the end of their lifecycle through聽Nefab鈥檚 take-back program. These materials will be reprocessed and聽re-extruded into new plastic sheets, reducing waste and promoting a more sustainable lifecycle for plastic packaging.
“This expansion is not only about increasing our manufacturing capacity but also about strengthening our commitment to sustainability,”聽said聽Darrell Tiedeman, Vice President of Plastics Solutions Americas at Nefab.聽“By integrating recycling directly into our operations, we can help customers reduce their environmental impact while improving material efficiency.”