Nefab Expands Thermoforming and Recycling in Tennessee to Advance Sustainable Packaging

Nefab Group, through its PolyFlex division, has opened a 137,000-square-foot facility in McMinnville, Tennessee, according to company announcements. The expansion is designed to boost thermoforming and extrusion operations while integrating closed-loop recycling, with the aim of delivering more efficient and sustainable plastic packaging solutions.

It is reported that the facility will focus on heavy-gauge thermoforming, a process increasingly important for industrial and automotive packaging. The new site includes an expanded rotary line, enhanced extrusion capabilities for both heavy- and thin-gauge roll stock, and is expected to reduce sheet production costs by about 15%, thereby improving competitiveness in the thermoforming market. Patric Vestlund, EVP Americas at Nefab Group, noted that “the McMinnville facility represents a strategic investment in high-performance thermoforming and sustainable plastics manufacturing.”

According to Nefab, the company will also consolidate its Morrison Thermoforming operation into the McMinnville site, with full readiness anticipated by the end of this year. New extruders are scheduled to come online by December 2025, further increasing capacity and strengthening in-house material production.

The facility will additionally serve as a recycling hub for heavy-gauge thermoformed trays, Nefab noted. A new grinder has been installed to enable closed-loop recycling, allowing customers to return plastic trays at the end of their lifecycle. These materials will be reprocessed and re-extruded into new sheets, reducing waste and supporting a circular economy. Darrell Tiedeman, Vice President of Plastics Solutions Americas at Nefab, said, “By integrating recycling directly into our operations, we can help customers reduce their environmental impact while improving material efficiency.”

Industry sources point out that demand for sustainable packaging continues to grow as companies respond to regulatory pressures and customer expectations for environmentally responsible solutions. Closed-loop systems and heavy-gauge thermoforming advances are viewed as key tools in reducing waste and building more resilient supply chains. Observers note that Nefab’s investment in Tennessee strengthens its North American footprint and underscores its commitment to combining production efficiency with sustainability.

According to company information, the McMinnville expansion is part of Nefab’s broader investment program, which also includes facility growth across the United States and Mexico, alongside recent acquisitions aimed at expanding integrated packaging capabilities. With this latest move, the company is positioning itself as a stronger player in the industrial and automotive packaging markets while reinforcing its environmental commitments.

Source: Nefab Group