Shapes distributor and fabricator Modern Plastics is adding a second location for production of face shields needed during the COVID-19 pandemic.
Shelton, Conn.-based Modern is leasing a production and warehousing location in nearby Derby, President Bing Carbone said in a Nov. 13 email to Plastics News.
"With increased product demand, we needed additional manufacturing space beyond our Shelton facility," he added.
Modern also is buying new machinery for the second site and is moving some equipment from Shelton to Derby, Carbone said. He added that the Derby site will be used for both finished goods storage and on-site large-scale manufacturing of the shields.
Production at the new site is expected to begin by the end of November or early December. "We expect this will be a long-term deal," Carbone said.
Modern began making the glycol-modified PET face shields in March and soon was making 300,000 per month. Carbone said the firm needs to increase production to 600,000 shields per month and may eventually make as many as 1 million per month.
The expansion will allow Modern to add 60-65 new jobs. The city of Derby is working to extend a bus line for workers at the new site. The shields are made with all domestically-sourced materials.
Modern distributes plastic shape products based on engineering resins including sheet, rod, tube and film. The firm also offers custom plastics fabrication. The firm generates about 60 percent of its sales from the medical sector.
Modern Plastics was founded in 1945 by Joseph Carbone, Bing Carbone's grandfather. The firm first did auto glass installation in the 1960s before moving into plastics. The company is part of Irving, Texas-based North American Plastics.