Revolutionizing Lights-Out Manufacturing



Morse Drive


Since the company’s inception, PCI’s Morse Drive facility has expanded from an original size of 10,000 square feet to its current size of 40,000 square feet. The facility houses 47 fully-automated manufacturing cells (35 – 500 ton) and is home to our entire administrative, business development and engineering team. Morse Drive is also home to “Automation Lane”. This encompasses new technologies in automated insert molding as well as automated layer packing of highly engineered components.

Bunsen Drive


The Bunsen Drive facility has operated on a fully-automated, “lights-out” basis since its opening in 2011. After nearly four years in operation and peaked production capabilities, 2015 marked a notable year with a 23,000 foot addition, allowing for an additional 28 manufacturing cells to be implemented as growth continues.

The fundamental premise of the manufacturing strategy at Bunsen Drive is to run the facility “lights out,” with no direct labor used to produce components. State of the art material handling systems, part conveyance systems, and robotics allow parts to be produced without the need for human involvement. This is the growth strategy for Plastic Components Inc. and this is how the company remains globally competitive.

Bunsen Drive is the future of manufacturing and is in fact, one of its kind. The United States Government issued PCI a patent to validate the processes that take place within the facility. Every detail from the lighting to the part conveyance system, has been meticulously planned. This attention to the little nuances of a manufacturing plant is what separates this facility from others in the world. Infrastructure expansions will set the stage for the additional production presses.

The acquisition of a five-ton crane now allows the facility to be outfitted with larger machines. This will provide PCI and our customers the ability to spread the highly efficient manufacturing process across a wide array of press sizes, depending on demand. PCI looks forward to Bunsen Drive being a key area of growth.

Syracuse Plastics of North Carolina, Inc. (SPNC)


Acquired on March 1, 2019, SPNC is a regional manufacturer of engineered and high precision injection molded components for applications in the industrial, water and pool products, telecommunications, power products, food processing, and other markets.  This acquisition expands PCI’s capabilities, adding larger tonnage presses, lower volume program capabilities, and value-added services.

The company is located in Cary, N.C., and operates out of a 55,000-square-foot facility with 37,000 square feet for manufacturing, 14,000 square feet of warehouse space and 4,000 square feet for offices. SPNC's 23 injection molding presses range from 35-1,100 tons.  SPNC is ISO 9001:2015 certified. 

In addition to molding, SPNC also supports:

-Assembly -Drilling -Silk Screening
-Inserting -Pad Printing -Hot Stamping
-Heat Staking -Specialty Packaging Needs -And more

Learn more about SPNC at  www.syracuseplasticsnc.com.


Why PCI?

We embrace the words of Thomas Edison: There’s always a way to do it better..find it. For close to 30 years, PCI has been challenging the status quo through technology, automation and engineering expertise to provide our customers with a strategic partner for their “mission critical” injection molding needs.

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