CHICAGO — Quick question: Which plastics molder owns 300 Boys?
The answer is Double H Plastics, a food-packaging molder in Warminster, Pa. Double H has purchased its 300th injection molding press from Dr. Boy GmbH of Fernthal, Germany, and its U.S. unit, Boy Machines Inc. of Exton, Pa.
Boy officials presented a plaque to Double H in a Sept. 8 ceremony at the factory.
Double H has the largest concentration of Boy machines in one location, anywhere, according to Boy.
To see what Double H makes, look at a lid on a yogurt container. The company developed a way to mold an outer plastic ring around a circular, or rectangular, coated paper or plastic insert. Double H also molds lids for cheese spreads.
Food Packaging often uses molds with a large number of cavities. But Harry Harp Jr., who founded Double H 25 years ago, stuck with lower-cavitation molds and multiple small machines. The lids are molded in one- and two-cavity molds.
Harp got into injection molding to diversify his extrusion business, according to his son, David Harp, who is plant manager. The company bought Versaform, an insert molder in Exton that had been making the plastic lids on a 200-ton Windsor machine running stack molds.
Stack molds, even though they ran a high number of cavities, presented problems. If one cavity didn't work properly, it could shut down the whole mold.
David Harp said his father used single-cavity molds to develop new products. He ended up scrapping the stack molds and going with small-cavitation molds, and small Boy machines, for the entire Double H packaging operation.
Double H's first Boy machine, purchased in 1985, is still running.
Most of the molder's Boy presses have clamping forces of 24.2 tons. The company also has some 55-and 88-ton Boys.
Double H now is managed by Harp's three sons, Joe, David and Harry Harp III. David Harp said the owners like Boy's after-sales support and the durability of the machines.