With this new 70,000 square foot facility, Placon accomplishes its plan
to create a standalone manufacturing location with its own brand
identity under the EcoStar name.
EcoStar purchases bales of curbside collected post-consumer PET bottles
and mixed bales of post-consumer thermoform packaging, grinds them,
washes them, and processes them into sheet and flake. EcoStar recycled
PET products include flake, LNO (letter of non-object) flake for food
packaging, and sheet products for the food and consumer products
markets. At full capacity, EcoStar will process 36 million pounds of
“We are excited about our new EcoStar facility as it enables us to
produce consumer packaging from 100% post-consumer PET recyclate,” said
the company CEO Dan Mohs.
Along with the ability to wash and recycle PET, half of the new facility
is engineered for sheet extrusion. This operational layout eliminates
non-value-added activities and reduces the total carbon footprint by
bringing the material supply chain closer to sheet production. Moreover,
the supply of post-consumer plastics processed by the facility are
collected primarily in the Midwest, streamlining local and regional
operations at every step of the process.
“Our $14 million investment demonstrates our commitment to sustainable
packaging and the reduction of solid waste. We believe that the best
way to reduce energy consumption and conserve resources, from a
cradle-to-grave perspective, is to recycle plastic packaging back into
plastic packaging, thereby closing the loop,” Mohs said.
For nearly two decades, Placon has pioneered the use of post-consumer
recycled polyethylene terephthalate (RPET) in the consumer packaging
industry. In the past seven years alone, it has diverted more than one
billion discarded bottles from landfills. According to the Environmental
Protection Agency, recycling one pound of PET instead of using virgin
material saves approximately 12,000 BTUs of energy.
The new facility has created 44 new jobs. Currently Placon employs more than 400 people worldwide.