For decades, plastics followed a predictable path from production to landfill. Today, forward-thinking companies are charting a different course – one where circularity guides the process. By designing products for durability, repairability and recyclability, businesses are keeping materials in use longer and reducing waste.

In this feature article in Sustainable Packaging News, Hoffer Plastics senior product manager John Strubulis highlights four ways flexible packaging can strengthen a circular economy. This includes critical considerations for choosing the right cap and spout. These components may be small, but they have a big impact on a package’s recyclability. From material alignment to performance requirements, Strubulis shows how innovation in fitment design is helping brands close the loop and keep valuable resources in circulation.

Discover how Hoffer is developing solutions that support circularity while maintaining the performance, safety and convenience consumers expect.

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British Plastics & Rubber sat down with Hoffer Plastics Vice President of Quality Excellence, Jim Stoffel, to discuss how the company is redefining sustainability in manufacturing. As an organization, we’ve grown in our commitment to be an environmental steward over our 72-year history. Our early focus on environmental initiatives like recycling has today grown into a full-scale commitment to environmental responsibility. From cutting carbon emissions with energy-efficient equipment, to innovative lightweighting designs that use less plastic, to using post-consumer recycled (PCR) in projects, we’re constantly assessing ways to be a responsible corporation.

But the journey doesn’t stop there. We’re pushing further with zero landfill initiatives, water conservation efforts, and partnerships that enhance our sustainability. With plans for solar power, electric forklifts, and a dedicated Environmental and Sustainability specialist, the company is driving toward a future of lower emissions and long-term sustainability. Read more about how Hoffer is making a real impact.

Read more from British Plastics & Rubber.

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Plastics Technology sat down with members of the Hoffer Plastics team to learn more about the company’s ongoing investment in automation and the benefits to customers. Automation project manager Adam VanMeter explored our integration of autonomous mobile robots (AMRs) and cobots, which together support part inspection, filling, palletizing and transporting boxes.

Since installation, automation has saved more than 55,000 hours of manual labor for the team. The AMRs also protect employees from lifting between 1.5 and 2.0 million pounds annually.

Read this article to see how our ongoing reinvestments in the business create new opportunities for our team while ensuring consistent quality for our customers.

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The company’s success is attributed to its high-volume, high production capability, which involves manufacturing a diverse range of plastic parts from automotive components to consumer goods. Key to their achievements is a strong emphasis on relationships—internally among the three co-CEOs and employees, and externally with suppliers and customers. Hoffer Plastics maintains a 99.4% on-time delivery rate, excels in transparent internal communication and integrates technology solutions, including advanced robotics and automated systems.

Additionally, the company’s unique “plants within plants” structure and commitment to continuous improvement and employee involvement further distinguish it as a leader in manufacturing excellence.

Read more about the award from IndustryWeek and uncover why Hoffer Plastics was recognized as the best of the best.

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Food Industry Executive shared insights into Hoffer Plastics’ commitment to creating a thriving workplace culture with perspectives from Hoffer Plastics team members Jeff Klabunde, Vice President of Operations and Shari Nelson, Director of Human Resources.

By prioritizing training, professional growth and embracing new technologies, companies like Hoffer Plastics foster a skilled, motivated workforce that drives innovation and long-term retention. Furthermore, companies that commit to sustainable practices enhance brand reputation, attract talent and strengthen employee morale.

As the manufacturing landscape continues to evolve, one truth remains constant: a thriving workplace culture is the cornerstone of success.

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Recognizing operational excellence, customer focus and ongoing employee engagement

SOUTH ELGIN, Ill. (September 3, 2024) – Today, Hoffer Plastics, a leading provider of custom injection molding solutions, joins the ranks of manufacturing’s top leaders as an IndustryWeek Best Plants Award winner. This recognition is a celebration of Hoffer Plastics’ dedication to fostering a culture of continuous improvement and operational excellence across all levels of its manufacturing organization.

The IndustryWeek Best Plants Awards program encourages manufacturing companies to adopt world-class practices, technologies and improvement strategies, increase customer satisfaction, and offer rewarding work environments for employees. The rigorous application process includes an in-depth questionnaire that gathers in-depth performance data and insights through a mix of essay and multiple-choice questions. The questionnaire covers 11 topics including performance measurement, quality achievements, supplier partnership, environment and safety programs, and more. Submissions are reviewed by a panel of IndustryWeek editors and outside experts. Hoffer Plastics was one of two North American manufacturers to be recognized as a 2024 award winner alongside HindlePower in Easton, Pennsylvania.

IndustryWeek Editor-in-Chief Robert Schoenberger visited the Hoffer Plastics facility as part of the judging process. “Finding the right balance between productivity and flexibility is tough enough for most companies, but to do so while maintaining a constant focus on developing people and supporting its community made Hoffer Plastics really stand out in this year’s competition. The company’s long-standing, yet extremely innovative, plants-within-a-plant structure enables Hoffer to react quickly to customer needs and ensure that managers will hear the voices of their employees. The facility really exemplifies what it means to be an IndustryWeek Best Plant.”

Hoffer Plastics consistently delivers unparalleled quality through continuous improvement initiatives that drive new investments in supplier relationships, technology, automation and people. These investments lead the Company to uplevel its operational excellence across engineering, tooling, injection molding and value-added assembly to accelerate customer satisfaction. A notable area of focus is the Company’s on-time delivery rates, with an unmatched 99.45% on-time delivery to customer request date. The Company achieves this success through strong relationships with suppliers, investments in its quality management system and agile teams that easily adjust to customer needs.

“We are truly humbled to receive IndustryWeek’s 2024 Best Plants Award,” said Co-CEO Charlotte Hoffer Canning on behalf of the Hoffer Plastics’ third-generation leadership team. “This recognition is a profound reflection of our collective commitment to customer satisfaction, financial stability and focus on finding new ways to drive productivity while also lessening our environmental impact. It’s a testament to what we can achieve together when we embrace new technologies that allow individuals to learn and grow in new, exciting and fulfilling ways. We take immense pride in this achievement and are excited by the opportunities that lie ahead for all of us.”

For 71 years, Hoffer Plastics has continuously evolved its manufacturing operations, setting new benchmarks for quality and productivity within its 365,000-square-foot facility. With more than 350 employees within focused factories that house 112 high-performance injection molding presses, Hoffer Plastics caters to a diverse range of industries including packaging, medical, consumer industrial, automotive and appliance with custom and proprietary products.

To learn more about Hoffer Plastics, visit hofferplastics.com.

About Hoffer Plastics

Founded in 1953 by Robert “Bob” and Helen Hoffer, Hoffer Plastics is celebrating its 71-year anniversary with an ongoing commitment to driving customer, employee and industry success. A full-service contract manufacturing partner, Hoffer produces more than three billion plastic parts annually with a consistent 99% on-time delivery record. The company serves customers in markets that include flexible packaging, medical, automotive, consumer, industrial and appliances. Located in South Elgin, Illinois, Hoffer employs more than 350 individuals within its 365,000-square-foot facility located on 24 acres. The company has pioneered numerous product innovations, including the company’s proprietary Lok family of products. For more information, visit www.hofferplastics.com.

About The IndustryWeek Best Plants Award Competition

Established in 1990, the IndustryWeek Best Plants Awards program annually recognizes plants, located in North America, that are on the leading edge of efforts to increase competitiveness, enhance customer satisfaction and create stimulating and rewarding work environments. Its further goal is to encourage other manufacturing managers and work teams to emulate the honorees by adopting world-class practices, technologies, and improvement strategies. For additional information, visit www.industryweek.com.

About IndustryWeek

IndustryWeek lives and breathes transformational manufacturing. Decision-makers and disruptors turn to IW for the news, trends, strategies and best practices that help companies leverage talent and technology to achieve revolutionary leadership practices, business models, production systems, and products. Visit www.industryweek.com for more information.

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Hoffer Plastics, a leading provider of custom injection molding solutions, is pleased to announce two significant achievements. The recognitions showcase a dual commitment to driving higher quality and greater productivity for customers, while strengthening the community through educational opportunities and engagements that provide pathways to a brighter future.

Named one of IndustryWeek’s 2024 Best Plants Award finalists, Hoffer Plastics is one of just five facilities from across the U.S. to make the cut. The prestigious award honors North American manufacturers who are leading efforts to increase competitiveness and customer satisfaction through reduced lead times and accelerated quality. It also recognizes those who are committed to creating stimulating and rewarding work environments for employees. The winning finalist will be announced later this summer.

Hoffer Plastics has also been awarded the 2024 Illinois Manufacturing Association’s Community Impact award for its exemplary leadership in serving its local community. Through the Hoffer Foundation, the company nurtures longstanding partnerships with local educational institutions, nonprofits and organizations. These partnerships include robust apprenticeship programs and leadership development opportunities that open new career opportunities while promoting the value of manufacturing careers throughout the region. This award also celebrates Hoffer Plastics’ commitment to sustainability, including the continued elimination of carbon dioxide emissions totaling 3,005 metric tons since 2019, the diversion of 250,000 pounds of plastic materials from landfills each year, and the ongoing monitoring of its own sustainability initiatives through meaningful, tangible metrics and goals.

“We are deeply touched by both of these recognitions,” said Co-CEOs Charlote Hoffer Canning on behalf of the Hoffer Plastics executive team. “Being a finalist for IndustryWeek’s 2024 Best Plants Award is humbling. But it’s a testament to the difference you can make when all your employees work together to leverage new technologies and innovate new solutions that prioritize customer satisfaction, performance and a cleaner, healthier environment.”

According to Co-CEO Gretchen Hoffer-Farb who oversees the Hoffer Foundation, “The Community Impact Award reaffirms our profound commitment to live the core values of Family, Integrity, Service and Trust that have been fundamental to Hoffer Plastics’ success since our inception in 1953. We are grateful to be part of the South Elgin community, and in return believe in the importance of being a good neighbor. To do so, we continue to grow our sustainable business practices while donating our resources to enrich the lives of others in the area.”

To learn more about Hoffer Plastics, visit hofferplastics.com.

 

About Hoffer Plastics

Founded in 1953 by Robert “Bob” and Helen Hoffer, Hoffer Plastics is celebrating its 71-year anniversary with an ongoing commitment to driving customer, employee and industry success. A full-service contract manufacturing partner, Hoffer produces more than three billion plastic parts annually with a consistent 99% on-time delivery record. The company serves customers in markets that include flexible packaging, medical, automotive, consumer, industrial and appliances. Located in South Elgin, Illinois, Hoffer employs more than 350 individuals within its 365,000-square-foot facility located on 24 acres. The company has pioneered numerous product innovations, including the company’s proprietary Lok family of products. For more information, visit www.hofferplastics.com.

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Vote for Hoffer Plastics for Illinois Manufacturers’ Association’s Makers Madness: The Coolest Thing Made in Illinois! Our P-15 Tamper Evident Cap and Spout, used by Big Easy Blends, boasts a 46% reduction in plastic compared to similar products on the market today. Plus, it’s engineered to seamlessly integrate with today’s recyclable materials.

Join us in championing forward-thinking products! Vote up to five times per day.

Vote Now

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Back in 1953, Robert Hoffer started out with a powerful idea: Putting the needs of customers, employees and the community first would drive a successful business. It’s a seemingly simple concept that has led Hoffer Plastics through 70 years of business.

Today, into our third generation of family leadership, the course that Bob and Helen set for Hoffer Plastics remains at the heart of our success. As we conclude our 70th anniversary year, we’d like to celebrate some of the many innovations and ideas that have and continue to drive our company forward.

Generation One: Entrepreneurial Spirit

This company, of course, wouldn’t be here without the entrepreneurial courage of Robert Hoffer and his wife, Helen. We remain steadfast in our visionary values on which they built Hoffer Plastics – Family, Integrity, Service and Trust.

 Robert continually maintained an eye on the future, taking many bold steps to set standards for taking care of customers and the community.

• Adapting the Focused Factory Model: Seeing that large factories sometimes can lose sight of innovative opportunities, Robert implemented a Focused Factory model at the Hoffer Plastics facility in South Elgin. This organized individual plants and teams around customers, markets and technical expertise for greater accountability.
• Prioritizing Education: Robert had a passion for education – specifically around manufacturing. That’s why the company established the first U.S. Department of Labor-recognized injection molding apprenticeship in partnership with Elgin Community College in 1979 (a program that continues today).
• Bettering the Community: Rooted in a commitment to giving back that’s been at our core from the beginning, Hoffer Plastics continues to ignite a brighter future for our community and our company through the Hoffer Foundation (established 1966).
• (Co)Generating New Ideas: Always thinking about new, innovative ways of serving customers and the community, Robert, together with his sons, established an on-site co-generation facility that would both ensure continuous power to the plant in the event of an outage and allow Hoffer Plastics to assist in relieving the local power grid, if necessary.

 Robert Hoffer accomplished many milestones in more than 40 years as CEO of Hoffer Plastics. In doing so, he laid a solid foundation for ongoing excellence as the business transitioned into its next phase under the leadership of the next generation.

Generation Two: Operational Advancement

With Robert setting a course for innovation, the next generation of Hoffer leadership sought to scale operations to meet rapidly rising demand. Together, William and his brother Robert Jr. instilled a focus on operational excellence that built upon the foundation laid by G1.

• Improving Processes: Under G2’s leadership, Hoffer Plastics embarked on its Lean manufacturing journey to enhance efficiency, reduce waste and keep pace with customer expectations and demands.
• Advancing Technologies: G2 made important investments in the latest advanced manufacturing technologies to benefit customer programs. From equipment re-investment to the addition of new technologies like 3D printing and robotics, William recognized Hoffer Plastics’ ability to guide customers through the adoption of new technologies and processes.
• Expanding Capabilities: William led the team to expand its capabilities beyond injection molding, adding assembly and post-molding secondary operations expertise to its wheelhouse. Focused on adaptability, we were able to do more for our customers, streamlining production while meeting diverse customer requirements.
• Centralizing Sustainability: For William, ensuring Hoffer Plastics focused on sustainability was a non-negotiable. He supported and led employees in creating our facility-wide recycling program. Today, that program enables us to divert 350,000 lbs. of material from landfills annually.

Thanks to G2’s innovative leadership and relentless operational improvement, Plastics News recognized Hoffer Plastics as 2012 Processor of the Year.

Building upon a strong foundation for growth, William transitioned to his new role as Chairman of the Board in 2020, paving the way for his three children – Gretchen, Charlotte and Alex – to take the helm.

Generation Three: Collaboration for the Future

Since taking on leadership roles – and becoming co-CEOs last year – siblings Gretchen Hoffer Farb, Charlotte Hoffer Canning and Alex Hoffer have worked together to steer Hoffer Plastics through unprecedented challenges.

Now, with the company stronger than ever, they’re focused on creating an even more vibrant tomorrow by further cultivating our formidable strengths: entrepreneurial spirit, innovative energy and core values.

• Leading Boldly to Inspire Change: Inspired by their grandfather’s innovative spirit, G3 does not sit back and wait for change. They lead it. Take our new co-CEO model, or the new investments in automation, capabilities (i.e., micro molding), product development and beyond. These bold steps forward are only possible with financial strength, and a culture of operational excellence.
• Investing in New Technology: We continue to reinvest 10+% per year back into new equipment – automation, robotics, the co-generation plant, new processing machinery and beyond. These investments not only help us better serve customers with high-precision parts. They also make our workplace more fun, rewarding and inspiring for new ideas!
• Innovating New Products: Among those new ideas is the Lok family of products: Hoffer’s patented caps and spouts for flexible and rigid containers that preserve product safety, enable recyclability and differentiate on-shelf. Proprietary closures represented a bold departure from our foundation in injection molding but opened new opportunities for our team and customers.
• Investing in People: Staying true to one of the vital lessons of our history – that people matter – G3 recognizes the importance of strengthening the team with new expertise. Just look at our latest hires. Our Vice President of Operations, Director of Human Resources and Business Development Manager are helping us meet customers’ evolving needs while driving what’s next.

The best part? G3 is just getting started.

Recognizing Our Achievements. Readying for What’s Next.

From the humble beginnings of a single-injection molding press, Hoffer Plastics has come a long way over 70 years. In this article, we’ve explored only a sampling of the many remarkable innovations that continue to define our legacy.

We’re proud of the best-in-class manufacturing operation we’ve built – and even prouder of the way we’ve upheld our founding values along the way. With our people-first sensibility, we’re excited to take on the future together with you!

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