PolyFlex—part of Nefab Group—is expanding its plastics packaging manufacturing and processing operations with a new 137,000-square-foot facility in McMinnville, Tennessee. 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 Nefab’s heavy-gauge thermoforming capabilities and provide cost-effective plastic packaging solutions for industrial and automotive applications. The investment is part of a broader effort to improve production capacity while integrating closed-loop recycling initiatives that support supply chains that are more sustainable.

Building a Heavy-Gauge Thermoforming Hub

The McMinnville facility will focus on heavy-gauge thermoforming, featuring:

• An expanded rotary line 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," said Patric Vestlund, EVP Americas at Nefab Group. "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.

Commitment to Sustainability: Closed-Loop Recycling

A key component of the expansion is the facility’s role as a recycling hub for heavy-gauge thermoformed trays. The site will be equipped with a new grinder to support closed-loop recycling, allowing customers to return plastic trays at the end of their lifecycle through Nefab’s take-back program. These materials will be reprocessed and 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," said 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."

Strategic Growth Through Facility Investments and Acquisitions

The McMinnville expansion is part of Nefab’s ongoing investment in sustainable plastic packaging manufacturing, which includes strategic facility expansions across the United States and Mexico. Recent acquisitions have further enhanced Nefab’s ability to offer integrated, high-performance plastic packaging solutions while expanding its North American production footprint.