Archives for October 2012


Sheboygan, WI – Custom injection molder Polyfab Corporation was preparing for the demise of their largest customer (36% of sales) in the food service industry with production ending in 2012. Polyfab Corporation responded aggressively to identify a plan and strategy to overcome the expected loss in business.

Fortunately for Polyfab, their website presence worked to their benefit when a new prospect learned of Polyfab online. Now their new customer represents more business than what will be lost in business from the food service customer of Polyfab. Their new customer is a leader in the manufacturing of critical safety components. “Polyfab responded to the specific requests of the customer”, said President Rick Gill. “Internal process controls were critical to the customer applications”.

Polyfab utilizes cavity pressure controls with Kissler and Master Molder training through RJG. The program requires critical pressure tests, Polyfab’s ability to mold tight tolerance production as well as monitor the molding process within stringent parameters was essential to the new business. Although the arrival of the first molds took place in May 2012, all applications from the new program will be in full production with Polyfab within one year.

A commitment to manufacturing excellence, the new awarded business has resulted in the addition of six new employees to the Polyfab team as well as new injection molding presses. Polyfab recently purchased a new Kraus Maffei (140 ton) and four Toshiba (ranging in size from 110 to 390 ton) presses and the necessary auxiliary equipment to not only support the new program, but as a commitment to replace aged presses greater than 10 years old. Capital investments in the quality lab included the purchase of a new Aberlink Metrology Coordinate Measuring Machine (CMM). All the Quality Techs at Polyfab are able to write programs for the CMM.

Polyfab currently has 76 employees at its 44,000 square foot facility in Sheboygan, WI.