Falcon Plastics Expands Plant in Tennessee

Falcon Plastics (Brookings, SD) announced the start of the first phase of a three-phase expansion plan for its molding facility in Lexington, Tennessee. This phase should be completed by the end of summer 2021.

Falcon said the 20,000-ft2 to be added in 2021 is for additional inventory so that two to three injection and blow molding machines can be added. Falcon said its operations team has already started planning the phase two and three expansions that will enable further machine expansions and see them go live in 2022.

Founded in 1975, Falcon Plastics is a third generation family owned, medium to high volume custom injection moulder that makes a wide variety of products. The company operates four production sites with around 320 employees; more than 120 molding machines; and 300,000 square feet of space spread across locations in Brookings and Madison, SD; Lexington, Tennessee; and Tigard, Ore .; and a partnership in a 40,000 ft2 facility in Suzhou, China.

In 2019, Falcon Plastics completed a 27,000 ft2 warehouse expansion, including upgrades and modifications to the manufacturing area of ​​its Madison, SD site. That year the company also acquired Poly-Cast Inc. – a custom injection molding company outside of Portland in Tigard, Oregon. This was the first acquisition in the company’s history.

Falcon Plastics has begun expanding its Lexington, Tennessee facility.
Photo credit: Falcon Plastics

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