Monoflo International

MODEX 2024 is in the books — and what a show it was! This year, we went bigger and better than ever before. We unveiled a brand new 2800 SF booth displaying our latest cutting-edge designs for the world of reusable transport packaging. We had a Japan Steel Works America, Inc. machine and FANUC America Corporation robot crafting Monoflo automation containers with In-Mold Labeling (IML) and real-time barcode verification. We hosted a soulful live performance from rising southern rock band and Monoflo family members The Red Clay Strays. And, most importantly, we had a tremendous time reconnecting with old friends and meeting new ones. A big thanks to everyone who joined us during this special week!

In 2024, our NP4840-06 Nestable Pallet saved millions of pounds of material from entering the supply chains of the largest retailers in North America. As we look back on last year, we are proud to highlight this pallet's incredible impact on sustainability and efficiency. By using nearly two lbs less raw material than a competitor's model, we helped our customers significantly reduce their environmental footprint. Metro Inc., one of the largest retailers in Canada and whose pallets you see crafted in this video, saved nearly 50,000 lbs of material from entering their supply chain. C&S Wholesale Grocers, the largest wholesale grocery supply company in the United States, reduced material usage by more than 20,000 lbs. Performance Foodservice, one of the largest food distributors in the United States, eliminated over 20,000 lbs of material. Dollar General, one of the most iconic retailers in North America, conserved nearly 15,000 lbs of material. These case studies are just a fraction of the material we helped our customers save in 2024. Our commitment to innovation and sustainability is not only good for the environment — it’s good for our customers’ bottom lines, too. We engineered our high-pressure injection molded pallets with market-leading strength-to-weight ratios, and our continuous investment in the latest state-of-the-art manufacturing technology drives higher quality, faster cycle times, and lower costs for our customers. Throughout our manufacturing processes, we leverage decades of expertise in superior design, engineering, and production to make pallets that outlast and outperform the competition. (Discover our full range of Pallets here: https://lnkd.in/enacibbR)

Our Stack Only Automation Containers really do stack up. If you stacked up every Stack Only Automation Container we manufactured in 2024, that stack would measure over a staggering 3 million ft in height! Taller than a mountain, yes. Taller than 100 Mount Everests, actually. Our industry-leading manufacturing processes leverage decades of superior design, engineering, and production to craft products that outlast and outperform the competition. In this video, we are crafting an order of Stack Only 6040-270-G2 Welded Base Automation Containers for one of the largest retailers in the United States. When automation projects are on the board, we use over 40 years of experience to design and engineer intralogistics packaging that precisely integrates with your automation initiative. The welded bottom on this container design provides a smooth interior and exterior, ideal for customers transporting large volumes of smaller components. Moreover, the flush base allows for easy cleaning and sanitizing. Our investment in technology – showcased in this fully automated production cell equipped with two Japan Steel Works America, Inc. injection molding machines, an Emerson welder, and a FANUC America Corporation robot – drives higher quality, faster cycle times, and lower costs for our customers. As North America’s leading supplier of intralogistics packaging, with millions of units in automated systems, no other manufacturer offers more product depth, breadth, and expertise than we do. (Discover our full range of Automation Containers here: https://lnkd.in/e5b5BG4b)

Walk A Mile In Our Totes? How about 1,500 miles? If you lined up every Distribution Container we manufactured in 2024, they would stretch over 1,500 miles. To put that in perspective — that line of containers would stretch from New York City to Denver! We don't just manufacture the most totes. We manufacture the best totes, too. By replacing the metal hinge pin and reinforcing several key impact areas, our Distribution Container design is the safest, strongest, and most cost-effective today. As the first company to fully automate the manufacturing process of Distribution Containers, this is an operation we have been optimizing for our customers for decades. In this production cell, one Japan Steel Works America, Inc. injection molding machine crafts the base of the containers, while the other crafts the attached lids. Two WITTMANN USA robots transport the parts from the machines onto conveyor belts, where a pair of FANUC America Corporation robots are waiting to hot stamp, assemble, and stack the Distribution Containers before they are shipped out the door. This fully electric operation — continually fine-tuned by our best-in-class production team — is the industry's fastest, most efficient, and most sustainable production cell. Team Monoflo is proud to manufacture more reusable transport packaging to help safely and efficiently move products from source to store than any other company in North America, year after year. (Discover our full range of Distribution Containers here: https://lnkd.in/eNFwFYkb)

Our industry-leading BC 4844.5 Bulk Container design saved millions of pounds of plastic for North America’s largest automotive companies in 2024. By using over 20 lbs less raw material in our Bulk Containers than a competitor's model, we helped General Motors — a longtime customer of Monoflo for nearly two decades — eliminate over 500,000 lbs of material from entering their supply chain. Monoflo Bulk Containers are crafted with a unique combination of the latest high-pressure injection molding technology and a proven hot-plate welding process that delivers the best strength-to-weight ratio in the business. This incredible achievement for General Motors is just a part of our ongoing commitment to sustainability and innovation in the reusable transport packaging industry. Stay tuned in 2025 to see how much more plastic we will save from entering North America’s largest supply chains! (Discover our complete line of Bulk Containers here: https://lnkd.in/gB-J2PFK)

This is just one of the thousands of shipments Team Monoflo sent out the door to our valued customers in 2024! We are proud to report that last year, our throughput grew over 15% compared to the year prior. It is thanks to the incredible efforts of our teams in our Virginia and Kansas facilities that we have the industry-best lead times our customers rely on. Our state-of-the-art 325,000 SF warehouse in Winchester, VA, which you see in the background of this video, accommodates the tens of millions of containers, trays, pallets, and bulk containers we manufacture annually. Strategically positioned between our two Virginia production facilities and immediately off Interstate 81, the facility also delivers exceptional freight savings for our customers and supports those who utilize Monoflo Logistics Services (MLS). MLS is our full-service logistics support system that offers flexible short-term storage for customers to manage the inflow of reusable packaging to their sites — including the management and execution of container, tray, and bin inductions into AS/RS warehouses. Stay tuned next week for more highlights showcasing our exponential growth in 2024. (Learn more about Monoflo Logistics Services here: https://lnkd.in/eajh2rtm)

Today, we are crafting an order of massive, custom-built SO 8060-400 Stack Only Automation Containers for one of the largest retailers in the world. These containers measure a whopping 800 mm (~31.5 in.) long, 600 mm (~23.5 in.) wide, and 400 mm (~16 in.) tall. A container this big needs a big machine to run it — and that is exactly what we have here in this large-tonnage KraussMaffei injection molding machine, recently added to the Monoflo fleet. We utilize this machine to manufacture larger Monoflo products such as our Bulk Container Collar Systems, Nestable Pallets, and, of course, this SO 8060-400 Stack Only Automation Container. Every inch of this custom container was designed and engineered by Monoflo to exacting tolerances, ensuring reliability and complete conveyability in this retailer’s high-speed automated warehouse system. When it comes to automation projects, over a decade of strategic relationships with top system integrators help facilitate end-user-to-integrator relations, and our project-driven, custom designs with rapid prototyping enable us to manufacture precisely what our customers need — even with compressed schedules. As North America’s largest supplier of intralogistics packaging, with tens of millions of automation containers and trays manufactured to date, Team Monoflo is fully equipped to service any custom automation application. (Discover our full range of Automation Containers here: https://lnkd.in/e5b5BG4b)

Happy New Year from Team Monoflo! Before we closed out 2024, we asked some of our Tooling, Production, Customer Service, Sales, and IT team members about their personal and professional goals for the upcoming year. It was inspiring to hear everyone's aspirations and plans for growth! As we step into the new year, we are excited about the opportunities and challenges that lie ahead. Here's to a 2025 filled with growth, success, and happiness for everyone!

2024 was a year of massive growth for Team Monoflo. Not just for our company, but on social media, too. With thousands of new followers now tuned in to our mission of crafting better plastics, many of you may be asking: What is it like working with Monoflo? 
Meet Monoflo.

We are moving some heavy metal between production halls today at our Virginia HQ! This particular mold is a crucial component in our manufacturing process, designed to produce high-precision parts with exceptional quality. Behind our world-class, fully automated manufacturing processes is the best Production team in the business. They utilize the latest state-of-the-art equipment from companies like DJ Products, Inc to exchange and transport molds within our facilities and keep production flowing. Jeremy, one of Monoflo’s skilled Set Up Technicians, is transporting this mold to the tool shop. There, it will undergo scheduled preventative maintenance to ensure it operates at peak performance when it is placed back into our production fleet. Our Production, Tooling, and Maintenance teams consistently collaborate to execute the preventative maintenance and quick mold changes that contribute to our industry-best lead times for our customers.