PolyFlex to expand thermoforming operation in Tennessee

PolyFlex, part of the Sweden-based Nefab Group, is expanding its plastic packaging manufacturing and processing operations with a new 137,000-square-foot facility in McMinnville, Tennessee.

According to Nefab, the facility is designed to enhance PolyFlex’s thermoforming and extrusion capabilities, support increased production efficiency, in-house material processing and sustainability efforts.

Nefab says the aim of the expansion is to strengthen its heavy-gauge thermoforming capabilities and provide cost-effective plastic packaging solutions for industrial and automotive applications. The $8.3 million investment is part of a broader effort to improve production capacity while integrating closed-loop recycling initiatives in support of more sustainable supply chains.

Nefab says the McMinnville facility will focus on heavy-gauge thermoforming and include an expanded rotary line to increase production capacity; new heavy- and thin-gauge roll stock extrusion capabilities; and a cost savings of approximately 15 percent on sheet production.

“The McMinnville facility represents a strategic investment in high-performance thermoforming and sustainable manufacturing,” says Patric Vestlund, executive vice president Americas at Nefab. “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 thermoforming operation in Morrison, Tennessee, into the new McMinnville site, and expects the new facility to be operational by year-end. New extruders are being installed and are scheduled to be operational by December.

Nefab says a key component to the facility’s expansion is its role as a “recycling hub” for heavy-gauge thermoformed trays. The company says the site will be equipped with a new grinder to support recycling, allowing customers to return plastic trays at the end of their life cycle through Nefab’s takeback program. The materials will be reprocessed and extruded into new plastic sheets.

“This expansion is not only about increasing our manufacturing capacity but also about strengthening our commitment to sustainability,” says Darrell Tiedeman, vice president of Plastics Solutions Americas at Nefab. “By integrating recycling directly into our operations, we can help customers reduce their environmental impact while improving material efficiency.”

A Tennessee Department of Economic & Community Development news release claims the PolyFlex expansion will create 58 new jobs. Upon the completion of the expansion, PolyFlex will employ 85 people across Warren County.

“What happens in rural Tennessee matters to all Tennesseans, and I’m grateful to PolyFlex for their additional investment in Warren County,” Gov. Bill Lee says. “These nearly 60 new jobs will bring greater opportunity to Tennesseans across this region, and I look forward to seeing the continued success that follows today’s announcement.”