Plastic Components, Inc., in Germantown, WI Breaks Ground on 23,000 Square Foot Expansion for “Lights-Out” Manufacturing Facility

By more than doubling the space for the company’s state-of-the-art injection molding systems, Plastic Components, Inc. will strengthen their position among international competitors with medium and high-volume production of defect-free parts in their revolutionary “lights-out” facility.

Plastic Components Inc. (PCI), a leader in plastic component prototype design, development, and manufacturing, has recently broken ground on a 23,000-square-foot expansion at N118 W18845 Bunsen Drive. The state-of-the-art facility specializes in a manufacturing process that requires no direct labor.

In September 2014, PCI was issued US Patent No. 8,827,674 B1 for the groundbreaking process related to a specialized injection molding factory system and an associated facility made up of machines on the first floor, with the resin supply located on a mezzanine level.

The Bunsen Drive facility is one of the few “lights-out” manufacturing operations in the world with the capability to run 24 hours a day, 365 days a year. Expanding our capacity to produce more defect-free parts only makes us stronger in a globally competitive market.

The expansion to the “lights-out” facility will more than double the existing space, increasing the building’s size to approximately 40,000 square feet and enabling PCI to add 20 more machines over the coming years to support current growth and expected demand. Construction at the Bunsen Drive facility is scheduled to be complete by November 2015.

Plastic Components, Inc. was founded in 1989 in a 10,000 square foot facility with three molding presses and a vision to build a “fully-automated” manufacturing facility as a low-cost, world-class producer of small & medium-sized plastic injection molding parts. The company has expanded to three facilities, totaling over 75,000 square feet, shipping more than 70 million parts per month to customers worldwide, and was recently recognized as Plastic News 2015 Best Places To Work.