Norco Plastics Inc., a Chino, Calif.-based contract manufacturer, invested in a new 2,800-ton injection molding machine to boost its manufacturing capabilities as it marks its 50th anniversary.
The Borche brand press boasts a 980-ounce capacity and is among the largest in Southern California, according to Norco Plastics owner Jack Williams, who has been part of the plastics industry since 1953 and was inducted into the Hall of Fame of the Western Plastics Pioneers in 2021.
Founded in 1974, family-owned Norco Plastics has served a variety of markets from automotive and appliances to plumbing and toys with 25 molding machines that ranged from 30 tons to 1800 tons.
Now the Borche beast tops out the fleet.
With the 2,800-ton press, the company can produce larger and more complex components with exceptional precision, Williams said in a phone interview.
Norco Plastics has been taking on more commercial and industrial projects with its larger presses in recent years, Williams said. The new Borche will be able to meet demand for products like pallets and rolling recycling carts.
"This new machine is going to open up doors," Williams said. "We're excited to produce bigger parts and handle different types of molds like stack molds with the trend toward bigger molds and higher capacity."
Williams bought the business, which was originally based in Norco, Calif., soon after it opened. He was moving to California and learned about a machine shop that was available from his home builder, who had actually started the venture but then had trouble growing it and switched careers.
"I bought four machines and a large air compressor from him and started from there," Williams recalled. "It was one of those things where nothing was planned, it just happened."
Williams based the business in Chino and grew it over the decades. At one point it reached $30 million in annual sales, but most years are closer to $15 million.
As a lot of the contract work for smaller parts moved to Mexico in the 1990s and China in the 2000s, Norco Plastics invested in larger presses to capture projects for big parts best made in the United States to reduce shipping costs.
For the 2,800-ton press, company officials see plastic pallet production as a good fit, especially as the cost of wood pallets rise.
"I think that market is going to increase in size and the freight on the items is getting prohibitive," Williams said.
Plastic pallets cost more but are lighter weight, more durable, resist moisture and damage, clean easily and have a longer lifespan, which makes them better suited for frequent reuse compared with wood pallets, which are cheaper up front but might need repairs beyond single-use applications.
To prepare the Norco Plastics facility for the new press and possibilities, the company had to put in a "serious" foundation, according to Operations Manager Robert Morck.
"This required some demolition and digging. It almost like we were installing a pool," Morck said in a phone interview.
If enough work comes in for the new press, the operations manager expects about 10 jobs to be created at the facility, which runs 24/7.
For now, the company is holding steady with about 50 employees, which is one of the highlights of Williams's ownership.
"If you can manage to keep your people while doing a good job in a state that's not manufacturer-friendly, that's an accomplishment," Williams said.
He has been in the plastics industry for 72 years, starting as an apprentice tool/diemaker at Wilson Plastics before moving on to Clevite Corp. and then Van Dresser Corp., where he worked as a plant manager at its Bakersfield, Calif., site, which built seats and urethane foam for car seats.
Williams relocated to Southern California in 1972 and formed Norco Plastics in 1974.
Now Williams' son, John Williams, who has master's degrees in both aeronautical engineering and accounting, serves as Norco Plastics CEO.
John Williams said the company's dedication to quality and continuous improvement has been the driving force behind its success for five decades.
"With the addition of this state-of-the-art machine, we are taking our manufacturing capabilities to new heights," John Williams said in a press release. "The 980-ounce capacity of the Borche machine allows us to tackle larger projects and deliver even higher-quality products. As we celebrate our 50th year, this investment reflects our ongoing commitment to innovation and excellence."