PolyFlex Opens Thermoforming and Recycling Hub in Tennessee
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| Image: Nefab |
PolyFlex – Part of Nefab Group is expanding its plastics packaging manufacturing and processing operations with a new 137,000-square-foot facility in McMinniville, 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 provide cost-effective plastic packaging solutions for industrial and automotive applications.
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
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’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.
