Plastic Ingenuity

Cross Plains, WI | Mazomanie, WI | Maumelle, AR | Oxford, NC | Tooele, UT

Since 1991, Plastic Ingenuity has partnered with Pearson Engineering on more than 57 HVAC and process piping projects across multiple facilities nationwide. Plastic Ingenuity is one of the largest custom thermoforming companies in North America, serving the healthcare, food, and consumer goods industries with both plastic and biodegradable packaging solutions.

Long-Term Partnership

For over three decades, Pearson Engineering has been the trusted mechanical engineering partner helping Plastic Ingenuity expand capacity, improve efficiency, and support sustainability goals. Our work spans continuous improvements at their Wisconsin operations in Cross Plains and Mazomanie, as well as major facility projects in Maumelle, Arkansas; Oxford, North Carolina; and a completely new plant developed in Tooele, Utah.

Scope of Services

Our engineering services have included:
• Medical clean room expansions and remodeling
• Process piping for new manufacturing lines
• New chiller plants (three total) and large chilled/condenser water distribution systems
• Cooling towers and sump tank/pumping systems
• Large rooftop HVAC units (130–150 tons each) for space and process cooling
• Make-up air units to support expanded production areas
• Airflow distribution improvements using fabric DuctSox
• Process exhaust and containment hood upgrades
• Heat recovery and capture systems from major equipment such as air compressors
• Energy audits to identify efficiency opportunities
• Office dehumidification troubleshooting and performance recommendations

Results

Through these projects, Pearson Engineering has helped Plastic Ingenuity strengthen manufacturing resilience, improve environmental performance, and ensure consistent, high-quality production environments that meet stringent industry requirements.