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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SOUTH ELGIN, Ill. (March 3, 2025) – Hoffer Plastics, a leading provider of custom injection molding solutions, is excited to announce its speaking engagement at PTXPO 2025, North America’s premier molding and moldmaking event at the Donald E. Stephens Convention Center in Rosemont, Illinois. Attendees can join Hoffer Plastics’ Discovery Workshop on March 18^th from 2:00 to 2:30 pm in Room 14 to learn how the company’s investment in automation technology-including autonomous mobile robots (AMRs) and collaborative robots (cobots)-is driving efficiency, improving worker safety and enhancing overall manufacturing performance.

At PTXPO 2025, Hoffer Plastics will present Cobots & AMRs: Boosting Productivity While Empowering Employees, featuring team members Jim Stoffel, vice president of quality excellence, and Adam VanMeter, automation project manager. The session will explore the impact of automation on production processes, workforce optimization and enhancing overall business success through technology. The team will share how Hoffer Plastics ongoing investment in cutting-edge manufacturing technology is paying dividends for both the company and its employees. These advancements are driving greater efficiencies and employee satisfaction, simultaneously providing valuable opportunities for workers to upskill and gain more technical expertise.

“We are excited to share how the integration of AMRs and cobots have significantly increased speed on critical operations such as part inspection, palletizing, material handling and transport, saving over 20,000 hours of manual labor annually,” said Stoffel. “We’ve built our reputation on operational excellence, and our 99.45% on-time delivery rate is a testament to that dedication. We continually invest in processes and technology to ensure we not only maintain these high standards but also challenge ourselves to raise them even further.”

VanMeter added, “By automating repetitive tasks, we are allowing our employees to focus on innovation and quality while reducing work that causes physical wear and tear. Our investment in automation has helped us streamline operations, reduce downtime and maintain the highest levels of precision for our customers. These innovations not only drive efficiency but also create opportunities for our employees to develop higher-level, in-demand skills, reinforcing our commitment to workforce development.”

The Hoffer Plastics Discovery Workshop is a must-attend event for industry professionals looking to gain valuable insights on implementing automation to drive production efficiency, strengthen manufacturing excellence and improve employee wellbeing.

For more information about PTXPO 2025 and to register, visit www.ptxpo.com. For more information about Hoffer Plastics, visit www.hofferplastics.com.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% 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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SOUTH ELGIN, Ill. (October 15, 2024) – What happens when you bring together a state-of-the-art packaging equipment manufacturer, an innovative plastic welding technologies leader and an award-winning injection molder? A sophisticated new mono-material polyethylene (PE) packaging solution that was created from the combined expertise of Effytec, Dukane and Hoffer Plastics. The efforts of this joint collaboration will be on display at Pack Expo in booths W-26018, S-1700 and S-4321 from November 3 to 6 in Chicago.

Brand owners – with packaging applications across health and beauty, food, personal care, industrial products and more – will be excited to learn how they will benefit from the collaboration and expertise of respected industry innovators:

• Effytec (Booth S-1700), an innovator of form-fill-seal and pre-made pouch fill-seal machinery for a range of packaging types, identified a solution with a smaller footprint, lower cost and decreased welding times.
• Dukane (Booth S-4321), whose patented SynQro technology is critical to this solution’s success, delivered a single-step spout-to-film ultrasonic sealing process with precise servo-driven control, lowering cycle times to under one second.
• Hoffer Plastics (Booth W-26018), a best-in-class injection molder and recipient of IndustryWeek’s 2024 Best Plants Award, integrated its lightweight P22 spouts from its Lok family product line known for its superior tamper evidence and seal integrity.

“Historically, the industry has been challenged in finding an affordable, efficient solution to seal mono-material films due to the complexities associated with films, spouts and standard sealing processes – including heat sealing and ultrasonic welding,” said Roger Stainton, Effytec USA President. “Together, we’ve created a solution that enables us to ultrasonically weld spouts to mono-material films in a one-step process that can produce 40 pouches per minute.”

This solution is pivotal in the industry’s shift toward mono-material packaging, which is essential for end user recyclability and eliminating landfill waste.

“The results of this collaboration meet the needs of brands and co-packers eager to bring a sustainable product to market,” said Petr Vasko, Dukane’s European Applications and Tooling Manager. “Together, we’re delivering green technology, fast cycle times and precise sealing for modern, sustainable packaging lines.”

How Collaboration Created a Sustainable Solution

Effytec began by producing a kit that could effectively integrate mono-material films onto its servo-driven GP32 form-fill-seal machine. This kit included additional rollers to advance the film without stretch, pressure regulators, new metal alloy sealing bars to support better temperature transition, and other components that could overcome historical challenges of working with unique mono-material films.

The most critical component of this kit was the integration of Dukane’s patented SynQro ultrasonic welding technology. SynQro’s unique design drives ultrasonic energy through two sonotrodes from both sides of the spout in synchronized motion, delivering consistent and uniform seals. Its servo-controlled process provides infinite control over sealing force, ensuring the right amount of pressure for highly accurate and hermetic seals of these films to Hoffer Plastics’ spouts.

Hoffer Plastics’ P22 spout was an instant match to the technologies produced by Effytec and Dukane. The PE cap, which is a lightweight design that offers superior tamper evidence, greater seal integrity and compliance with choke-proof specifications, was an immediate fit with the solution due to the spout’s standard design which integrates energy directors critical for ultrasonic welding compatibility.

John Strubulis, product manager at Hoffer Plastics added, “Our spouts have found a home in this partnership with Effytec and Dukane. We believe in the power of partnerships – especially one that leads to viable sustainable solutions that accelerate customer success while minimizing our environmental impact. This innovative ultrasonic welding solution not only creates a mono-material spouted pouch that enhances recyclability for end users. It also reduces energy consumption by 70-80 percent compared to heat-sealing methods. We are grateful for our partnership with Effytec and Dukane and look forward to innovating even more together.”

Those interested in learning more can visit booths W-26018, S-1700 and S-4321 at Pack Expo.

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 Effytec
Effytec USA manufactures horizontal form-fill-seal pouch machinery and pre-made pouch fill-seal machinery for packaging all types of products in flat three- or four-sided seal sachets, stand-up pouches with re-closable zipper, cap or shaped pouches for the food, beverage, pharmaceutical, cosmetic and industrial industries. Effytec Packaging was founded in Barcelona, Spain by some of the best minds in the horizontal-form-fill-seal pouch machine industry. The goal: Make the best HFFS machines in the world. Effytec’s remarkable growth since inception says that our customers believe we are achieving that goal. For more information, visit https://www.effytecusa.com/.

About Dukane
Dukane develops ultrasonic solutions that meet the unique requirements of each customer’s application. For customers who know their exact needs, we listen, understand, and deliver a quality product that meets exact specifications. For customers looking to start from a concept, we foster a consultative relationship, leveraging our five decades of experience to develop cutting-edge solutions to the most challenging welding needs. Established in 1922 as Operadio, we have served several industries and provided time tested technological breakthroughs. We take on distinct challenges, accepting each project as an opportunity to enhance our eye for innovation. We put customer relationships at the forefront of everything we do. For more information, visit https://www.dukane.com/

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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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Custom injection molder set to exhibit in booth #1566 and present on collaboration to drive product innovation.

The medical manufacturing community will soon convene in Anaheim to elevate and advance medical device manufacturing excellence. Among these experts will be Hoffer Plastics (or “the Company”), a custom injection molder, who will exhibit at MD&M West at the Anaheim Convention Center from February 6-9, 2024. Hoffer Plastics expert, Millie Nuno, will also be presenting at SPE/MPD’s MiniTec Conference as part of this event, reinforcing the Company’s expertise in advancing healthcare excellence.

Nuno, Hoffer Plastics’ vice president of sales, will join MiniTec as part of the session New Product Designs Highlighting & Enabled by Medical Polymers on February 6 in room 201ABCD. Her session will highlight the importance of innovation, new technologies and fresh ideas to propel the medical industry forward. Specifically, Nuno will delve into the collaborative design, development and launch of the innovative closed-loop EnteraLoc enteral device. Hoffer Plastics leveraged its flexible packaging expertise and innovation to incorporate its Trust-T-Lok leak-proof spout into the 510(K) FDA-approved device for safe, convenient nutrition delivery. Nuno will cover the award-winning project’s vision and goals, collaboration across multiple partners, technical hurdles and more.

Attendees are also invited to visit Hoffer Plastics at booth #1566 to learn about the Company’s expertise in a broad spectrum of capabilities that meet custom medical product and packaging requirements. Visitors can also learn more about Hoffer Plastics’ integration of advanced technologies, including a vision inspection system that has already saved 55,000 hours on the Company’s shop floor and a palletizer that eliminates the need for employees to move more than one million pounds of product. Team members will also be on-hand to discuss the Company’s niche expertise and capabilities, including micro molding.

“We are excited for the industry to meet with our team at MD&M and understand how our unwavering commitment to advancing our customers’ healthcare manufacturing solutions can be seen throughout every facet of our manufacturing processes.” said Alex Hoffer, Hoffer Plastics Co-CEO. “Driven by an unrelenting dedication to precision, quality and sustainability, we mitigate risk, accelerate time-to-market and enhance operational efficiency to achieve critical business objectives while protecting patients and end users every day.”

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, in-home monitoring devices, drug delivery, diagnostics and more. Shipping 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.

Contact Kirsten Hewitt (khewitt@trefoilgroup.com or 925-699-8071) to schedule an in-booth interview with Hoffer Plastics’ Vice President of Sales, Millie Nuno.

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Hoffer Plastics (or the “Company”), a leading provider of custom injection molding solutions, is pleased to announce its ‘Feed Your Future’ Production Job Fair on Thursday, November 16 from 4:00 to 7:00 p.m. The Company will be hosting the fair at its South Elgin facility, 500 N. Collins St.

The Job Fair is designed to give prospective employees a behind-the-scenes look at Hoffer Plastics while interviewing the same day. Attendees will have the opportunity to engage with the Hoffer Plastics’ Human Resources team for a 15-minute interview. Applicants may then have the opportunity to explore the facility by walking the plant floor and meeting with a Hoffer Plastics’ Plant Manager. Upon completion of their interview(s) and tour, attendees will receive three vouchers redeemable for a taco from the on-site taco truck that Hoffer Plastics is bringing to its facility for the event.

“By providing access to stable and exciting long-term careers in manufacturing, we are not just creating jobs; we are building pathways to success for individuals in our community,” said Shari Nelson, Hoffer Plastics’ Director of Human Resources. “From entry-level positions to highly skilled roles, we provide individuals with opportunities for continuous learning and professional growth in an advanced, sophisticated and engaging environment.”

At Hoffer Plastics, the belief in nurturing talent, fostering growth, and empowering the next generation of leaders in the manufacturing industry has been a guiding principle across generations of family leadership. Rooted in this commitment is a dedication to redefining the narrative around manufacturing careers. Contrary to the perception of traditional manufacturing roles, Hoffer Plastics proudly offers roles that are at the forefront of technology advancements, housed within a state-of-the-art facility, and that demand a skillset firmly rooted in STEM disciplines. As an integral part of the company’s continued commitment to giving back, the “Feed Your Future” Job Fair aims to provide individuals a chance to pursue career advancement within a dynamic, high-tech work environment that is actively shaping the future landscape of the manufacturing industry.

Beyond this event, the Company remains deeply committed to fostering a brighter future within the community. This commitment is exemplified through the Hoffer Foundation and the dedication of individual Hoffer family members, who actively contribute to a wide array of educational initiatives. These initiatives are centered around the principles of accelerating learning, acquiring knowledge, instilling values and nurturing virtues as essential elements for achieving success. From robust apprenticeship programs, leadership development opportunities, on-site summer job opportunities and more, Hoffer Plastics continues a 70-year tradition of developing manufacturing’s next generation of leaders.

For those interested in attending the job fair, there is no registration required. Interested applicants should bring their resume and be prepared to network with the Hoffer Plastics team. For more information about career opportunities at Hoffer Plastics, please visit http://www.hofferplastics.com/careers/.

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Hoffer Plastics, a leading provider of custom injection molding solutions, announced the hire of new Director of Human Resources, Shari Nelson, PHR, SHRM-CP, effective immediately. In this pivotal role, Nelson will spearhead the evolution and implementation of Hoffer Plastics’ Human Resources strategies while fostering a workplace culture that prioritizes its people.

 

Nelson brings more than 15 years of experience in Human Resources-focused operations and strategy development. Her expertise lies in guiding and managing Human Resources processes, policies and services within companies, underscored by a deep-seated passion for employee well-being. Prior to joining the company, Nelson directed HR initiatives including recruiting and staffing, employee safety, welfare and health, performance management and improvement, and more at Fleetcor. She also obtained extensive experience as Director of Human Resources at ALE Solutions where she progressively advanced in her career from HR Generalist.

 

“It is with great enthusiasm that we welcome Shari Nelson to the Hoffer team to further support our vision to be the company that always does the right thing, specifically for our employees” said Charlotte Canning Hoffer, Hoffer Plastics Co-CEO. “Shari’s extensive experience, dynamic leadership style and genuine passion for employees will be invaluable as we continue to invest in our most valuable asset – our people.”

 

This new hire reiterates Hoffer Plastics’ commitment to cultivating a workplace culture that not only attracts top-tier talent but also nurtures the development and well-being of its longtime employees. Nelson also joins to further solidify the company’s people-first sensibility by fostering trust, loyalty and confidence in its employees from the top-down and across the organization.

 

“I am pleased to join an organization with such a rich 70-year history and a steadfast commitment to taking care of its employees,” said Nelson. “Hoffer Plastics’ people-first culture and strong values of Family, Integrity, Service and Trust are the cornerstones of its consistent delivery of exceptional value to its customers. I am eager to contribute to the company’s ongoing success by leading Human Resources efforts to maximize retention while driving new recruitment initiatives.”

 

In addition to her extensive professional background, Nelson holds multiple Human Resources Certifications from the prestigious Human Resources Certification Institute and Society of Human Resources Management. She also holds a Masters degree in Counseling Psychology and a Bachelor’s degree in Psychology and Sociology.

 

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