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Manufacturing Case Studies

Reaching Goals With PSI


PSI takes a green approach to its work, with products made from recycled materials that perform as well as those that are not.

If there is anything that is a priority for food and beverage companies, it is product safety. A company cannot have an unsafe item reach a consumer, and Polymer Solutions International (PSI) Inc. helps their customers reach that goal with products that are designed to help drive safety and cleanliness in their supply chains.

Among its offerings, The Newtown Square, Pa.-based company offers a number of styles of plastic pallets, focusing on the hygienic pallet market.  It is one of the few companies to offer a non-halogen, non-toxic flame retardant pallet. PSI also offers the option of anitmocrobial additives to further reduce the chance of contaminants reaching the product area, according to owner and CEO Daniel Kelly.

PSI also offers pallets manufactured from a variety of plastics and additives, custom matching the product to the customers’ needs.  This allows PSI to focus on lowering the total cost of ownership and to help customers meet their safety goals.  For example, producing a pallet from materials that make the plastic detectable with industry standard metal detection or x-ray equipment reduces the chance of the material becoming a contaminant in a food or pharmaceutical product. “We’re looking for products that last longer, help make the supply chain safer, and take up less space,” he says. “It’s a constant work in progress.”

When Kelly founded PSI in 1997, he had already devoted 15 years to returnables, recycling and injection molding, supplying numerous industries. When the famous mineral water company wanted to switch from square to round bottles, it reached out to him to develop a plastic rack that fit its needs.

After setting out on his own, Kelly co-designed a product, taking great care to ensure it met Perrier’s needs. At the time, “This was the biggest bottled water company giving me an order,” he recalls, explaining that its success was critical to PSI’s survival. “We needed the first one to be very successful to get onto the next.”

After PSI satisfied Perrier, it went on to launch its ProStack stackable, modular bottled water racks market wide. With the success of the bottled water racks, PSI expanded into other industry solutions and custom products for a number of Fortune 100 clients and across a wide range of industries. “We are best at developing something that didn’t exist,” Kelly says, noting that the firm also moved into material handling with its pallet products.

Superior Products

Today, PSI sells its modular bottled water racks in 105 countries. In the past three years, it has grown by 98 percent, which has helped it earn spots on the Inc. 5000 list. “We’ve got a shot of making it for next year, too,” Kelly says.

PSI’s clients today include many of the world’s top beverage companies. One such CSD customer recently hired PSI to design a custom enclosure and delivery system for its top of the line soda fountain machine. “The rollout has gone quite well,” Kelly reports.

One of the factors that drives PSI’s growth is its focus on quality. Over the years, “We made some very well-designed products that last forever,” he says, noting that some are still being used in the field after more than two decades.

The company also has taken a green approach to its work, with products made from recycled material that perform as well as those that are not. “We want to make sure we’re always supplying a quality product that exceeds the customers’ expectations,” Kelly says.

This concern over customer satisfaction allows PSI to thrive. “If you don’t deliver, you could shut their plant down,” he asserts. “Keeping our customers in in production is critical.”

Kelly sees a strong future ahead for PSI, which will continue using recycled material in its products. In fact, the company buys back from clients racks and pallets that have reached the end of their useful life so the material can be reprocessed and used again. “We try to close the loop everyday,” he says.


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