Berry Plastics

Berry Plastics

 

Who:

Originally Berry Plastics was established in 1967 under the name Imperial Plastics. In 1972, the injection molding company entered the container market and in 1983, Imperial Plastics was purchased by Jack Berry, Sr., and renamed Berry Plastics. From 1988 through 2014, Berry Plastics Group, Inc. has completed nearly 40 acquisitions and began trading on the New York Stock Exchange in October 2012 under the ticker symbol BERY. Worldwide, Berry Plastics has 75 companies (most of which are in the US)

Today Berry Plastics has…

·         300 Million pounds of closures produced annually

·         2,885 primary manufacturing machines

·         13,000+ customers

·         3.7 billion Thermoformed cups produced in 2013

·         751 active granted patents

·         30,000+ skus

·         16,500+ employees

·         2.5 billion pounds of resin purchased annually

Products & Services:

·         Packaging

o   Flexible: Stretch Film, Food Film & Packaging and Supermarket Film

o   Hybrid: “NuSeal” Recloseable flexible containers, “Rigid Lens II” Flexible container with a recloseable rigid lid.

o   Rigid: Recloseable food containers, Drink Cups, Bottles, Closures (Lids/Caps), Home & Party Products, Overcaps, Medicinal Vials, Jars, Tubes

·         Protection Solutions:

o   FIBC (Flexible Intermediate Bulk Containers)

o   Medical

o   Supermarket Film

o   Personal Care Film

o   Institutional Can Liners

o   Agricultural Film

o   Sheeting

o   Trash Bags

o   Seal for Life (cathodic protection, self-healing corrosion prevention and sealing, tape-based protection, heat shrinkable technology, and liquid sealing)

·         Tapes & Adhesives

o   Tape: Duct, Foil, Masking, Plumbing, Electrical, Double-Sided, Wire Harness, Cargo Pit, Woven, Non-Woven, Flashing, Film, Foam, Transfer, Preservation & Sealing, Surface Protection, Moisture Barrier, Clean Room, Color Coding & Labeling

Materials:

·         Polyolefin

·         Polypropylene

·         Polyethylene (Berry Plastics is the largest single consumer in the world)

Markets:

·         Personal Care

·         Household

·         Food

·         Beverages

·         Foodservice

·         Health Care

·         Industrial

·         Transportation

Forming:

·         Thermoforming: manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product.

1.       Virgin material mixed with reground material

2.       (45% virgin to 55% reground material)

·         Melted into sheets

·         Thermoformed into uncut sheets of the desired product

·         Leftover or scrap material goes through 2 grinders to be used again

·         Injection Molding: is a manufacturing process for producing parts by injecting material into a mold.

1.       Plastic enters the mold at 500 degrees

2.       Closed loop 60 degrees water cooled molds to harden the plastic into the desired shape

·         5-12 sec/cup

·         4 sec/lid

3.       Once molded polyethylene requires 7 weeks to fully cure

4.       Polyethylene can be remolded 10-14 times before it cannot be used

Cutting:

Once the product is molded into the desired shape, the sheet passes into a press at the end of the line and stamped out of the sheet then collected for packaging.

Finishing:

Onsite ink lab with a PMS color system

·         Up to 8 colors

·         Dries almost instantly when exposed to high heat

·         Quality checked for consistency by customer’s needs

·         Excess ink is recycled by adding color dyes for later jobs