Sustainability

Beyond Recycling: Powering a Circular Future in Plastics

At Hoffer Plastics, sustainability is built into our DNA. For more than 70 years, we’ve treated efficiency, innovation and environmental responsibility as the foundation of how we shape ideas into products and progress into impact. Every initiative, from power generation to water and energy reduction to circular material design, advances a single goal: creating lasting value with less impact.

The result: less than 1% of materials sent to landfill, a 50% reduction in water usage and a 30% cut in carbon emissions since 2022 while maintaining world-class quality and throughput.

As much as 20% of a package’s plastic weight comes from its cap and spout. These components often determine whether packaging is truly recyclable, and that’s exactly where Hoffer makes a difference.

Introduction

Why Sustainability Matters in Injection Molding

Across the plastics industry, sustainability is moving from statements to measurable action. Brands today expect partners who can help them reduce emissions, energy use and waste without compromising quality or performance. Regulations, consumer expectations and corporate ESG commitments have made verified impact a core requirement for manufacturers. At Hoffer, we see this not as a challenge but as an opportunity to lead by example and transform how plastics manufacturing supports a cleaner, more efficient future.

How Hoffer Leads the Change

Our Illinois campus operates an on-site co-generation power plant installed in 1991 that supports both our operations and the regional grid. Our internal recycling program, launched in 2007, diverts more than 350,000 pounds of plastic from landfills each year and earned Hoffer Plastics the Illinois Governor’s Sustainability Award.

In 2025, Hoffer Plastics received the VIA Spark Award for Social Responsibility recognizing our long-term commitment to environmental stewardship and community engagement.

Today we’re advancing toward carbon neutrality by 2035 and ISO 14001 environmental management certification in 2026, supported by a dedicated environmental and sustainability specialist and company-wide commitment to continuous improvement.

Our Approach: Practical Circularity

We believe sustainability and manufacturability go hand in hand. Our approach connects design, materials, process efficiency and data transparency to drive measurable improvement.

Circular Design Integration

As part of the global shift toward the circular economy, we engineer products that keep materials in use longer by designing for recyclability, repairability and reduced material consumption.

Mono-Material Systems

We transition multi-component assemblies to single resins such as polyethylene (PE) or polypropylene (PP) to support full-package recyclability and simplify recycling streams.

Recycled Content Innovation

In collaboration with film suppliers and brands, we’re validating up to 30% post-consumer recycled (PCR) content in packaging fitments, combining material responsibility with functional performance.

“Circularity isn’t achieved in isolation,” says Jim Stoffel, VP of Quality Excellence. “It’s a supply chain effort. We’re collaborating across partners to design PE and PP systems that are recyclable, safe and high-performing.”

Sustainable by Design

Designing and Manufacturing for Recyclability, Efficiency and Waste Reduction

Mono-Material Innovation

Designing caps and spouts that match the pouch material (PE or PP) allows recycling as a single unit.

Lightweight Engineering

Reducing plastic content in fitment designs while maintaining safety and performance.

In-process Regrind & Material Recovery

On 70% of our presses, integrated robots collect and grind runners for reintroduction into production. This closed-loop process helps Hoffer achieve less than 1% material waste.

Customer Collaboration

Working with major brands to integrate recycled resins while validating product performance through Design for Manufacturability (DFM) and Design for Recyclability (DFR) principles.

Consistent Validation

Advanced process monitoring keeps quality high and ensures production stability while maintaining waste levels.

Carbon Emissions Reduction

Hoffer Plastics is taking bold, measurable action within our company, community and the plastics industry to reduce emissions and build a cleaner future. Our journey toward carbon neutrality is fueled by passion, precision and accountability.
We developed a custom carbon calculator to compile years of data and integrates information from suppliers and logistics partners to capture emissions across our full value stream. This comprehensive view helps us target the most effective initiatives to reduce energy use, improve efficiency and advance material recovery.
We are committed to reducing total emissions by 5% each year and achieving carbon neutrality within the next decade. Today, 40% of our electricity already comes from renewable energy, reflecting our dedication to cleaner power and more resilient operations.

Materials & Circularity

Hoffer primarily molds polypropylene (PP) and polyethylene (PE) – lightweight, recyclable resins that align with flexible packaging sustainability goals.

Our materials strategy is built on choice, performance and circularity:

Mono-Material Solutions

We design closures and fitments from the same resin families as pouch films (PE or PP) to enable full-package recyclability without separation.

Recycled Content

We partner with suppliers to qualify up to 30% post-consumer recycled (PCR) resin in approved packaging applications while maintaining strict performance and color standards.

Compostable and Bio-Based Options

We regularly evaluate compostable additives and bio-based resin blends for customers seeking renewable, low-impact solutions.

Traceable Sourcing

Every material option is validated for consistency, regulatory compliance and environmental integrity with data available for customer reporting.

Methodical Waste Capture

We maintain a structured sorting process that separates waste by resin type, allowing materials to be reused in-house or resold for secondary applications rather than going to the landfill.

Energy, Water & Utilities

Energy Efficiency

Hoffer reinvests up to 10% of its sales revenue annually in new electric presses and high-efficiency auxiliary equipment that optimizes energy use and process control.

Lighting Efficiency

Facility-wide upgrades deliver major energy savings and measurable CO₂ reduction while creating brighter, safer workspaces that enhance precision and efficiency.

Water Conservation

A closed-loop filtration system has reduced water consumption by 50%, recycling process water for cooling.

Automation

Use Supervisory Control and Data Acquisition (SCADA) systems with autonomous mobile robots (AMRs) and collaborative palletizers to automate material handling and production flow.

Renewable Energy

Currently, 40% of our electricity is sourced from renewable energy (33% nuclear, 4% wind, 2% solar, 1% hydro).

Key Environmental Metrics

Initiative	Impact	Equivalent Environmental Benefit
Initiative Lighting energy savings	Impact 1,744,624 kWh saved	Equivalent Environmental Benefit 1,695 tons of CO₂ (3,389,989 lbs) prevented
Initiative Water usage reduction	Impact 50% decrease through closed-loop filtration	Equivalent Environmental Benefit Enough water saved to fill 2 Olympic-size pools annually
Initiative Carbon emission reduction	Impact 35% between 2022 and 2025	Equivalent Environmental Benefit Equivalent to removing 10,408 passenger vehicles from the road for a year
Initiative Annual landfill diversion	Impact 350,000+ lbs of plastic waste	Equivalent Environmental Benefit Enough plastic to manufacture over 25 million closures
Initiative Co-generation electricity savings	Impact For 2024: saved 1,300,425 lbs/CO2. For 2025: saved 1,837,382 lbs/CO2.	Equivalent Environmental Benefit CO₂ reduction equivalencies to be added once annual data is finalized

These savings don’t stop at Hoffer’s doors. Lower energy use and higher material efficiency directly reduce our customers’ product footprints, helping them meet sustainability goals and strengthen their own ESG performance.

Tooling Sustainability

At Hoffer Plastics, extraordinary craftsmanship drives lasting sustainability. Our 27 in-house toolmakers form a dedicated team whose precision, expertise and skill set new standards for mold performance across the industry. Their work goes far beyond maintenance. It’s about continuously elevating and perfecting every mold to deliver exceptional longevity, accuracy and consistency.

Through methodical care, innovation and decades of expertise, our team achieves millions of additional molding cycles per tool, dramatically reducing the need for new mold investment, machining and energy. Each mold under their care runs cleaner, faster and longer, directly advancing our mission to manufacture more efficiently and sustainably. This culture of craftsmanship doesn’t just maintain performance, it defines it.

Energy Savings from Co-Generation

Hoffer Plastics’ on-site co-generation plant, first installed in 1991, is a cornerstone of our sustainability program. Operating year-round, it provides reliable, efficient power for our entire campus while supplying excess electricity back to the local grid every month.

This system not only offsets a significant portion of Hoffer’s own energy needs but also contributes to the stability and resilience of the regional power network. By generating clean, efficient energy on-site, Hoffer reduces dependence on external sources, lowers greenhouse gas emissions and helps support the energy demands of our surrounding community.

In 2024, by using co-generation technology, we reduced electricity-related emissions by approximately 1,300,425 pounds of CO₂.

What You Can Expect with Hoffer Plastics

Partnering with Hoffer Plastics means building products and programs around measurable, lasting sustainability.

Collaborative Design: Early engagement through Design for Manufacturability (DFM) and Design for Recyclability (DFR) to simplify parts, reduce mass and improve recyclability.
Material Expertise: Guidance on mono-material, PCR, and bio-based options to balance performance, cost and sustainability goals.
Proven Efficiency: Industry-leading results – less than 1% material waste, 50% less water use, and ongoing reductions in carbon and energy consumption.
Smart Manufacturing: Automated systems, SCADA monitoring and co-generation power that make every process cleaner, more efficient and more consistent.
Craftsmanship and Care: In-house master toolmakers extend mold life, optimize performance and reduce environmental impact through precision maintenance and innovation.
Transparent Metrics: Clear data on carbon footprint, energy savings and resource efficiency to help customers meet internal and regulatory sustainability reporting goals.

Every partnership starts with a shared commitment: transforming smart engineering into tangible environmental and performance gains.