Sustainability Archives - Hoffer Plastics

Advancing a Circular Future Through Flexible Packaging

Hoffer Team — Thu, 20 Nov 2025 22:19:47 +0000

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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Shaping the Future of Flexible Packaging with Ultrasonic Welding

Hoffer Team — Thu, 06 Nov 2025 19:33:04 +0000

Plastics Machinery & Manufacturing captured the successful collaboration between Effytec, Dukane, LD Pack and Hoffer Plastics, highlighting how industry leaders came together to advance sustainable packaging. The article showcases:

Effytec’s servo-driven GP32 form-fill-seal machine manufacturing sustainable pouches
Dukane’s innovative SynQro ultrasonic welding technology
LD Pack’s high-performance sustainable film
Hoffer’s proprietary P22 spouts

By combining decades of injection molding expertise with cutting-edge plastic closure engineering, Hoffer played a key role in developing the first large-format, mono-PE, fully recyclable spouted pouch. Designed for precision and performance, Hoffer’s P22 spouts from its Trust-T-Lok line ensure a perfect weld interface with recyclable films, enabling reliable sealing without distortion or leaks, even in temperature-sensitive applications.

By uniting expertise in machinery, materials and closures, these partners are setting new standards for sustainable pouch packaging. See how.

Read the full article

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Hoffer Plastics Debuts Expanded Lok Line at PACK EXPO Booth N-5138

Hoffer Team — Tue, 23 Sep 2025 17:44:58 +0000

Flexible and rigid solutions deliver more choices, more value and more impact.

SOUTH ELGIN, Ill. (September 23, 2025) – Hoffer Plastics announced today the expanded Lok family of closures, debuting at PACK EXPO Las Vegas (Sept. 29–Oct. 1), Booth N-5138. Building on a legacy of customer-driven engineering, the new line extensions give brands greater versatility, speed and value across flexible and rigid formats – while enhancing performance, reliability and shelf appeal.

Product highlights

Hoffer’s Trust-T-Lok Drop-In Cap & Spouts runs on existing pouch filling equipment without modifications and cuts plastic by 18.5%. Patented tamper-evident technologies boost product integrity and consumer trust. Caps are available with FDA-compliant PCR content upon request and are fully compatible with existing machines, including mono-PE and mono-PP structures, making this closure recycle-ready.
The new Trust-T-Lok P22 Spouts ease the shift from bulky rigid bottles to slim, efficient pouches, cutting material costs, energy use and CO₂ emissions. Up to 26 truckloads can be consolidated into one. Larger printable surface area enables bolder branding on store shelves. The spout is offered in tamper-evident, child-resistant and spray-hose versions on one versatile spout base for universal use on pouch making equipment.
38 mm & 28 mm Rigid Caps offer expanded options with uncompromising tamper evidence, faster lead times and compatibility with glass, PET and HDPE. These caps are ideal for fresh juices, dairy, kombucha and energy drinks. The 38 mm format comes in three distinct options-Hoffer Drop Lok, Standard Double Lead and DBJ neck finishes tailored to the niche premium beverage sizes most commonly seen at Whole Foods and Fresh Market.

“Every addition to the Lok line was designed with our customers’ biggest challenges in mind – reducing costs, improving performance and sustainability and making their brands more visible on shelf,” said John Strubulis, Senior Product Manager at Hoffer Plastics. “Our commitment at Hoffer extends far beyond supplying closures. Our commitment is to engineer solutions with real business impact.”

Meet us at PACK EXPO: To schedule an in-booth interview with John Strubulis, contact Jody Delie at jdelie@trefoilgroup.com.

Learn more: Visit our landing page for product specs and resources: https://hofferplastics.com/sem/lok-family-packaging-enhancements/

About Hoffer Plastics

Robert “Bob” and Helen Hoffer founded Hoffer Plastics in 1953. Over 70 years later, the company continues its commitment to driving success for its customers, employees and the industry. A full-service contract manufacturing partner, Hoffer produces more than three billion plastic parts annually with a consistent 99.45% on-time delivery record. The company serves customers in markets that include flexible packaging, medical, automotive, consumer, industrial, health & beauty 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 its Lok family of products. For more information, visit www.hofferplastics.com.

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Driving Sustainable Manufacturing with Technology and Talent

Hoffer Team — Wed, 10 Sep 2025 18:10:33 +0000

Plastics Technology sat down with Hoffer Plastics vice president of quality excellence Jim Stoffel and environmental and sustainability specialist Hannah Mooberry to explore how the company is redefining what sustainability means in injection molding.

By pairing decades of operational innovation with fresh expertise, Hoffer’s sustainability strategy goes far beyond recycling. Investments in automation, closed-loop water filtration and energy-efficient presses have driven a 30% cut in carbon emissions, a 50% reduction in water usage and less than 1% of material sent to landfill.

Discover how Hoffer integrates sustainability into every aspect of its operations. From its regrind systems to carbon tracking, Hoffer is redefining how innovation and environmental stewardship can work together hand in hand.

Read the full story

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Enhancing Packaging Performance Through Cap and Spout Selection

Hoffer Team — Mon, 11 Aug 2025 20:33:26 +0000

Packaging Strategies spotlighted three ways the right plastic cap and spout can deliver a strategic edge, with perspectives from John Strubulis, Hoffer Plastics’ Senior Product Manager. In today’s crowded CPG marketplace where packaging can be a direct reflection of your brand’s values, selecting the right fitment is not just about functionality. It’s a strategic decision that shapes consumer perception, achieves regulatory compliance and reflects sustainability efforts.

John emphasizes that the right spout contributes to more than just leak-proofing and sealing. It is an essential component of delivering a high-quality product. By prioritizing precision, performance and environmental responsibility, pairing the right fitment with your flexible packaging becomes a fundamental part of achieving packaging excellence.

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Hoffer Plastics Champions Micromolding in Medical Manufacturing

Hoffer Team — Tue, 29 Apr 2025 16:09:03 +0000

Medical Product Outsourcing sat down with Hoffer Plastics director of engineering, Brian Beringer, to discuss the company’s approach to medical device innovation in a rapidly evolving market driven by advanced manufacturing technologies. Beringer shared insights into how Hoffer is leveraging cutting-edge techniques, specifically micromolding and additive manufacturing, to support the fast-paced demands of the medical device industry.

Micromolding is playing a key role in enabling medical device manufacturers to produce highly precise, small-scale prototypes quickly and cost-effectively. This has allowed Hoffer to meet tight tolerances while accelerating time-to-market. These innovations not only enhance manufacturing efficiency but also support more effective design-for-manufacturing (DFM) collaboration early in the development process. Beringer emphasized that simplifying tooling and optimizing part design have led to reduced costs, less maintenance and better scalability.

Read more from Medical Product Outsourcing.

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Sustainability is an all-around concept for Hoffer Plastics

Hoffer Team — Wed, 26 Feb 2025 21:11:45 +0000

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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Hoffer Plastics to Showcase Advanced Manufacturing Capabilities at MD&M West Booth #1797

Hoffer Team — Tue, 28 Jan 2025 12:00:00 +0000

Learn how automation and sustainability are driving increased speed to market and quality

SOUTH ELGIN, Ill. (January 28, 2025) – Hoffer Plastics, a custom plastic injection molder serving a range of medical-focused markets, is excited to announce its participation in MD&M West at the Anaheim Convention Center from February 4-6, 2025. At booth #1797, attendees can experience the company’s commitment to healthcare manufacturing, advanced automation capabilities and sustainability initiatives, all of which contribute to faster time-to-market and improved product quality for customers.

As a MedAccred-certified manufacturer, Hoffer Plastics specializes in the injection molding of non-invasive medical components for various applications including test kits, medical packaging, at-home monitoring devices, drug delivery, diagnostics, wearables, respiratory care, cardiology and more. Also serving the dental and veterinary industries with high-quality, intricately molded parts, the company ships more than three billion parts annually. Hoffer Plastics boasts a proven track record of precision and efficiency from start to finish – including design for manufacturability (DFM), tooling, injection molding, assembly, and more – all with a 99.45% on-time delivery rate.

Hoffer Plastics leverages seven decades of experience in injection molding and deep understanding of the medical device industry to support companies with manufacturing of high volume non-surgical components. Employing its engineering expertise to support customers’ R&D and micro-molding to produce small parts with exceptional detail for prototyping, medical customers have a single-source partner for product development through assembly.

“Our team is eager to connect with industry leaders and demonstrate how our ongoing investment in cutting-edge technologies and sustainable practices empowers our customers to bring critical medical components to market faster and more efficiently,” shared Alex Hoffer, Hoffer Plastics Co-CEO. “We believe in collaborative partnerships that drive innovation. At MD&M West, we invite you to experience our customer-centric approach firsthand.”

Technology Advancements: Driving Efficiency and Cost-Savings

Hoffer Plastics leaders will be available to discuss the benefits of its latest automation technology integrations. The company has implemented a fleet of Autonomous Mobile Robots (AMRs) and collaborative robots (cobots) that seamlessly integrate into the production process. This advanced system handles a wide range of tasks, including:

Automated part inspection: Ensuring consistent quality and minimizing defects.
Automated filling and palletizing: Streamlining packaging and logistics.
Automated material handling: Optimizing transportation and storage within the facility.

Sustainability Initiatives: A Commitment to Environmental Responsibility

Sustainability is rooted in Hoffer Plastics 71-year history and remains an essential focus for the business. Reducing plastic waste in landfills, recyclability of products at end-of-life and decreasing carbon emissions are all priorities for Hoffer Plastics in 2025 and beyond.

Furthermore, the following are initiatives underway to reduce Hoffer Plastics’ environmental footprint, including:

Water reduction strategies: Implementing water-saving technologies throughout the manufacturing process, reducing water consumption by up to 50%.
Enhanced recycling practices: Separating plastic waste by type at the machines maximizes the recyclability of production waste, minimizing landfill contributions.
Development of a carbon calculator: Assessing and quantifying the carbon emissions associated with production processes, transportation and more will enable data-driven decisions to reduce the company’s carbon footprint.

“Investing in sustainability helps us innovate and be more efficient and mindful with the resources we have available, said Vice President of Quality Excellence Jim Stoffel. “At Hoffer Plastics, there is a dedication to building sustainability into every aspect of our business. Through recent initiatives, we were able to reduce CO² emissions by 3,004 metric tons, significantly reducing our environmental impact. Visit us at MD&M West to discuss how we accomplished it.”

About Hoffer Plastics

Founded in 1953 by Robert “Bob” and Helen Hoffer, Hoffer Plastics is celebrating its 70-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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Revolutionizing Flexible Spouted Pouch Packaging with Ultrasonic Welding

Hoffer Team — Fri, 20 Dec 2024 21:17:37 +0000

Packaging World captured the successful collaboration between Effytec, Dukane and Hoffer Plastics in action at PACK EXPO. Editor Pat Reynolds visited the team at the show to spotlight Effytec’s servo-driven GP32 form-fill-seal machine manufacturing sustainable pouches with Dukane’s innovative SynQro ultrasonic welding technology and Hoffer Plastic’s proprietary P22 spouts.

Made from 100% recyclable mono-materials, these spouted pouches have wide ranging packaging applications across health and beauty, food and beverage, personal care, industrial products and more.

Having the ability to manufacture mono-materials using ultrasonic welding versus traditional heat sealing without deformity while maintaining high production levels is a game-changer for companies seeking an affordable, achievable sustainable solution.

Watch now to see this advanced technology in action!

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Hoffer Plastics Welcomes Hannah Mooberry as Environmental & Sustainability Specialist

Hoffer Team — Fri, 06 Dec 2024 18:34:24 +0000

New role reaffirms commitment to serving customers & the environment through sustainability initiatives.

SOUTH ELGIN, Ill. (December 10, 2024) – Hoffer Plastics, a leader in custom injection molding with over 71 years of excellence, proudly announces the hiring of Hannah Mooberry as its new Environmental & Sustainability Specialist. This strategic hire reinforces the company’s long-term vision of sustainability, an unwavering commitment that has been integral to the business since its inception.

A recent graduate of Northern Illinois University in environmental studies and policy, Hannah brings a fresh perspective and a strong academic foundation to this role. She will be responsible for developing and implementing comprehensive sustainability strategies including:

Partnering with Hoffer’s Focused Factories to implement a reuse, regrind resins program to reduce plastics going to landfills.
Developing a comprehensive carbon emissions calculator to evaluate waste, electricity, water consumption, upstream and downstream distribution, and transportation to inform emission reduction goals.
Collaborating with internal teams to pursue ISO 14001 certification to drive additional reductions in environmental impact.
Enhancing product recyclability and promoting circular economy principles in partnership with engineering and manufacturing.
Staying apprised of industry trends and regulatory requirements to ensure compliance through product innovation and operational enhancements.

"I'm excited to join Hoffer Plastics as its first-ever Environmental & Sustainability Specialist to directly contribute to a more sustainable future,” said Mooberry. “I'm eager to work with the entire team to implement innovative solutions and develop strategies for reducing carbon emissions. It's a privilege to be part of a company that prioritizes sustainability and continuous improvement while maintaining such high standards of excellence."

The creation of this position follows Hoffer Plastics' recent recognition with IndustryWeek’s Best Plant Award, a prestigious honor highlighting the company’s innovation, quality and operational efficiency. Building on this momentum, Mooberry will lead initiatives that focus on measuring and minimizing environmental impact to help both Hoffer Plastics and its customers meet rising demand for sustainable solutions.

“Adding this role is an important step in achieving the long-term sustainability goals set into motion by the first generation of Hoffer Plastics leadership,” said Charlotte Hoffer Canning, Co-CEO at Hoffer Plastics. “We know the critical role plastics manufacturers play in protecting the environment. It’s why we’ve been committed to sustainability from day one. Hannah’s dedicated focus on sustainability will allow us to uplevel our efforts even faster. She is already collecting and analyzing new data that will inform our strategic initiatives to reduce our overall environmental impact well into the future.”

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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