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 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 a more sustainable supply chains.
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 percent 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.
Published December 2025