As for the hoped-for benefit of attracting forward-thinking employees, Schaefer-Weaton is confident it will come to fruition in the long run. She believes the project shows all of its customers, many of which have green initiatives of their own, that AIPC is planning to be around for many years.

The primary purpose of the Powerpacks is to help AIPC achieve peak shaving with greater efficiency and reliability. AI-based controls ensure this by automatically charging the Powerpack’s 16 lithium-ion battery pods when electricity rates are at their lowest and discharging energy at times of high usage (or peak demand) to avoid or reduce costly demand charges.

It is safe to say that the debate about the environmental impact of plastic will continue. But, it is also a fact that many manufacturers of plastic products are quietly becoming greener.

Two UK contract moulders – Merriott Plastics and Talisman – have just combined to create a multi-site, multi-competence business.

“I consider it a strategic investment for our future,” explains Schaefer-Weaton. “We are in it for the long haul—for our customers, our employees and the community of Fairfield.”

Andrew Lawrence remarked that the company is excited to be bringing together the wealth of expertise and knowledge that exists within its businesses, thus creating a formidable team.

That legacy tradition is considerable: Talisman (known as LGG Charlesworth until 2018) is more than one hundred years old while Merriott Mouldings began production in the village of Merriott, Somerset in 1938 and ICM in Rochester, Kent in 1947. Each company is a member of the British Plastics Federation and has contributed greatly to the growth and culture of UK Plastics plc.

Champion added: "Throughout the new company our key focus will always be about doing the right thing for our customers. Andrew and I therefore encourage all to call up, get in touch and put this  commitment to the test. We are also exhibiting at Plastics Live 2024, Coventry Arena, June 12-13, 2024 so please make a date to visit our stand then."

A good example is Fairfield, IA-based Agri-Industrial Plastics Co. (AIPC), which specializes in the blow molding of large-scale industrial parts. These include fuel tanks for the turf equipment, power sports, agricultural and marine industries.

Changing times, however, require a dynamic response to business that builds on tradition: Shaun Champion Talisman Plastics managing director notes that ‘growth at Talisman in the last 5 years has seen us doubling our turnover and making major investments in people and equipment. This merger enables that rate of growth to continue – providing ‘win-win’ for us - but also great things for our customers, current and future.’

Schaefer-Weaton says that AIPC’s energy load is fairly consistent over the course of the year, with peak loads in the 2,500 to 3,000 kilowatt range. Weekend loads can drop to as low as 100 kilowatts, though they are higher when the company runs weekend shifts during busy times.

The newly expanded company will provide customers - particularly in the Midlands, South West and South East - with improved and local product development, manufacture, logistics and technical support.

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The joint technical moulding capacity from both companies provides machinery capability from 25 to 1,100 tonnes, including injection, compression and composite moulding services for products weighing from 5 grams to 10 kg.

A white paper from developer Ideal Energy estimates that the project will save AIPC an average of $55,000 per year for the foreseeable future. Equally important, it will prevent 9,377 tons of CO2 from entering the atmosphere over the next 25 years. The CO2 number is equivalent to that produced by burning more than 10 million pounds of coal.

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Indeed, Merriott Talisman customers in primary group markets such as automotive, electrical, defence and air and fluid movement can now look forward to the many benefits that will flow from the new business which is expected to turnover in excess of £15m sales this year.

Each Powerpack is modular, scalable and durable enough for outdoor use. It is also AC-coupled, rather than DC-coupled, meaning it operates completely independent of the solar array. This ensures that if the array or energy storage system goes down (for whatever reason), the other part of the installation will continue to operate.

The AIPC plant features a 517-kilowatt, roof-mounted solar array that works in tandem with a 430-kilowatt-hour energy storage system composed of two battery-powered Tesla Powerpacks. During the day, the solar panels generate energy, which charges the Powerpacks and powers all manufacturing operations.

Jim was a senior editor of ASSEMBLY and has more than 30 years of editorial experience. Before joining ASSEMBLY, Camillo was the editor of PM Engineer, Association for Facilities Engineering Journal and Milling Journal. Jim has an English degree from DePaul University.

Blow molding is energy intensive and regularly produces electrical peaks at the facility. To better handle the costs associated with these peaks, AIPC installed a unique solar and energy storage system in 2019.

“We run 27 [production] lines 24 hours a day [on weekdays],” says Lori Schaefer-Weaton, president of AIPC. “This [creates] huge utility bills. Some of the [system] payback will be strategic, longer term, by building excitement around working [here] and being part of something bigger.”

The new grouping will be led by Shaun Champion of Talisman and Andrew Lawrence, Merriott Plastics. Lawrence said: "We are truly delighted to announce this historic merger; bringing both these industry names together in the service of our customers and for UK manufacturing - while also honouring the legacy tradition that has brought us together."

Founded in 1978, the company operates a 340,000-square-foot advanced manufacturing facility. The plant is equipped with 20 monolayer accumulator-head blow molding machines and seven multilayer continuous extrusion machines. Robotic automation is also present, to complement a clean and modern work environment.