Thermoformer PolyFlex, which is part of the Sweden-based Nefab Group, has revealed plans to expand its plastics packaging manufacturing operations with a new 137,000 sq ft facility in McMinnville, Tennessee.
The plant is intended to increase heavy gauge thermoforming and extrusion capacity, improve in-house material production and support recycling initiatives. Nefab produces industrial and automotive plastics packaging and has been expanding its manufacturing footprint in North America.
The McMinnville site will become a hub for heavy gauge thermoforming, adding an expanded rotary line and new roll stock extrusion equipment for both heavy and thin gauge materials. According to the company, this is expected to reduce sheet production costs by around 15 per cent.
Patric Vestlund, executive vice-president for the Americas at Nefab Group, said: “The McMinnville facility represents a strategic investment in high-performance thermoforming and sustainable plastics manufacturing.
“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.”
Consolidating operations
Nefab will consolidate its existing thermoforming operation in Morrison, Tennessee, into the McMinnville site, with full readiness expected by the end of the year. Additional extruders are scheduled to be operational by December 2025.
The facility will also act as a recycling centre for heavy gauge thermoformed trays. A new grinder will enable a closed-loop system in which customers can return plastics trays at the end of their life for reprocessing into new sheets. This is aimed at reducing waste and dependence on raw materials.
Darrell Tiedeman, vice-president of Plastics Solutions Americas at Nefab, said: ”This expansion is not only about increasing our manufacturing capacity but also about strengthening our commitment to sustainability.
“By integrating recycling directly into our operations, we can help customers reduce their environmental impact while improving material efficiency.”
The McMinnville investment is part of Nefab’s wider programme to expand plastics packaging production capacity and recycling initiatives in the US and Mexico, alongside recent acquisitions to strengthen its North American manufacturing network.
