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Direct Pack, Inc. (DPI), a leader in sustainable, full circular, thermoformed plastic packaging, announced that it has expanded its North American manufacturing operations with the opening of Direct Pack Baja in Mexicali, Mexico. (Photo credit: Direct Pack)

New manufacturing facility

Direct Pack Inc mitigates supply chain disruptions with expanded North America manufacturing operations

Azusa, CA, United States

  • Direct Pack stands up new Baja manufacturing facility in just 10-months, strengthens position to deliver customer orders amid global supply chain challenges
  • Production at Direct Pack Baja started in September; all products will be made of post-consumer recycled PET
  • Full circle recognition: DPI's long-term customer partner Driscoll's has received the Sustainable Packaging Coalition' 2021 Innovator Awards in Responsible Sourcing for their sourcing of PET clamshells with post-consumer recycled content from PET thermoforms

Direct Pack, Inc. (DPI), a leader in sustainable, full circular, thermoformed plastic packaging, announced that it has expanded its North American manufacturing operations with the opening of Direct Pack Baja in Mexicali, Mexico. The company was able to build, equip and staff the new facility in a short 10-months and is now able to supply a higher percentage of their North American customer partners with products built in the region. This has also better positioned the company to meet its customer obligations in spite of the current global supply chain challenges.

The other DPI manufacturing facilities, including Sun Valley CA, Rockingham, NC and Guadalajara, Mexico, are all operating three-shifts, resulting in a fourfold increase in North American production capacity in the last 24-months.

"As we continue to grow our operations, we remain focused and deeply committed to sustainability and innovation with full emphasis of "Circularity" and an ultimate goal of making PET plastic an infinite resource," said Craig Snedden, President of Direct Pack, Inc. "In the last 24 months, DPI has recycled and reused 36 million pounds of post-consumer recycled PET plastic thanks to the continuous operations across our manufacturing facilities."

Direct Pack Baja

Direct Pack Baja is a 200,000 sq. ft. facility that is capable of PET solid-state polymerization, sheet extrusion, thermoforming, automated labeling application, warehousing and distribution. Production of thermoformed food packaging for supermarket, foodservice, growers and processor customers started in September. Direct Pack Baja will employ as many as 80 people during the full rollout of the production equipment, which will take place over the next five months.

The addition of Direct Pack Baja allows DPI to further expand its full circular business model. The company actively works with material recovery facilities (MRFs) to collect used PET plastic clamshells and other packaging – both their own and from other suppliers – and using it to make new packaging. When recycled, PET plastic is an infinite resource.

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