Key Characteristics

  1. Annual Sales: $15 million

  2. Location: Asheboro, NC, off I-73 on Hwy. 220 near Seagrove, NC

  3. Facility: 52,000 sq.ft., metal pre-fab, sprinkled.  Air conditioned climate controlled manufacturing area.

  4. Employees: 72

  5. Injection Presses: 21 ranging from 35 Ton to 720 Ton, including 6 all electrics and 1 hybrid.

  6. Other lines: 2 brush making lines. 2 hot melt glue lines.

  7. Secondaries: Hot Stamping, Pad Printing, Ultrasonic Welding, Fusion Welding, Machining, Assembly, Sublimation printing.

  8. Warehouse: 30,000 sq.ft. leased space in Seagrove.

  9. Ownership: JBDJ, LLC (Lail family) and Sapona Manufacturing Co. Inc. 50/50, privately owned, financially strong.

  10. Founded: 2004

  11. Certifications: ISO9000.  UL Molder., Two team members are RJG certified Master Molder II

  12. ERP:  Fully integrated custom ERP system.

Management Personnel

PARTNERS! Sapona Plastics is a joint venture between Sapona Manufacturing and the Lail family, previous owners of a very successful molding business in North Carolina. It's a great combination of financial strength and plastics experience. But most importantly, it's a great partnership with you the customer.

FAST! Modern electric and hydraulic injection molding presses ranging in size from 55 to 720 Ton insure consistent production. Multiple high speed assembly machines and robotics handle complex jobs. Secondary process and packaging capabilities are designed to meet each customers requirements. Quick response is provided with experience and resources to meet most any need from design to distribution. We are centrally located on the East coast at the center of the nation's 2nd largest interstate highway network. Plus we operate 24 hours a day so you can sleep soundly knowing we'll have your order to you on time.

RELIABLE! You can trust our quality because our processes are compliant with GMP, ISO13485 and ISO 9000 quality system standards and we have highly trained personnel, including formerly certified quality engineers, technicians, and auditors. We pride ourselves on honesty and integrity. You can be confident that significant changes will not be made without your approval, and we will do what we say or we'll let you know immediately.

LOW COST! Sapona Plastics' philosophy is to provide service and value to our customers. We back this up with highly efficient manufacturing operations and very attractive pricing. North Carolina is a right to work state and the region's labor pool is the 10th most cost effective in the nation. Our power reliability and cost are among the nation's best, and we achieve even lower rates through our peak shaving program. Our maintenance program keeps molds in top condition and we provide expert project management on tooling purchases, repairs and refurbishments.

Sapona Plastics, LLC is a rapidly growing injection molding and assembly
company located near Seagrove, NC, producing plastic products for the personal care, consumer goods, construction, housewares and automotive markets. The operation in Seagrove encompasses 52,000 sq.ft. and employs around 120 people. The business started in April 2004 with 10 molding machines and has capacity at the current facility for over 20 molding presses. Recent machines added are all electric machines which run faster and use as much as 25% less energy. Processes include thermoplastic injection molding, insert molding, and over-molding. Primary products include lip balm containers, brushes, control and cable enclosures, filter components and a variety of other custom products. In addition to polypropylene, polyethylene, nylon, ABS, PVC, TPE, PBT, polysulfone, polycarbonate, acetel and high impact styrene, the company processes various engineering grades including blends, flame retardent, glass filled as well as recycled reprocessed plastics. Secondary operations include assembly, labeling, decorating, spin welding, fusion welding, hot melt glue assembly, ultrasonic welding, foam filling, brush bristling and heat staking. Warehousing and distribution are offered from the ample size facility near Interstate 73/74 and a short distance from I-40/I-85. Sapona has an additional 30,000 sq. ft. warehouse two miles away for large volume order fulfillment. Part and mold design project management service is provided with a network of local tool shops and international sources and in house CAD.
Scientific MoldingTechnology.html

“My life would be easier if all our suppliers were more like Sapona.”


Copyright 2016 Sapona Plastics, LLC

Lean ManufacturingLean.html