By Karissa Kopecky, marketing manager, Falcon Plastics
Most manufacturers focus the bulk of their new program startup energy on customer programs – and rightly so. But when a manufacturer launches an internal product line, like Falcon Plastics’ High Plains Trays, the same startup discipline still applies. In fact, it becomes an opportunity to test and refine best practices.
The High Plains Trays program started with a simple idea: How to turn internal waste into value. Falcon Plastics produces a fair amount of clean regrind material, especially from larger parts. Rather than outsource or discard the material, Falcon Plastics asked, “What can be built to support operations and reduce landfill contributions?”
That question led Falcon Plastics to develop reusable trays for internal shipping, made entirely of reprocessed and in-house regrind resin. But to get there, it had to treat the program with the same lean rigor it would for any customer. Here’s what was learned.
Start with the Problem, Not the Product
Too often, internal programs begin with a solution in search of a problem. What kept this initiative grounded was that it solved a very real operational challenge: material waste. We knew Falcon Plastics’ regrind was clean and consistent and that its facilities could benefit from more durable and standardized shipping trays. That clear alignment made it easier to scope the program – and to secure internal buy-in.
Falcon Plastics didn’t start by sketching product designs. It started with a discovery process that mapped out where waste was being generated, what types of materials were available and how shipping inefficiencies affected its operations. This helped Falcon Plastics build a business case rooted in cost savings, material optimization and efficiency – not just sustainability.
Treat Internal Projects with External Discipline
Because this was an internal product, it might have been tempting to skip steps, such as lighten up documentation, bypass formal tooling reviews or fast-track implementation. But Falcon Plastics made a conscious decision to follow its standard launch process from start to finish. That meant design reviews, kickoff meetings, timeline tracking and stage gates – all the usual checks and balances.
This structure especially was important because multiple departments were involved, including engineering, tooling, production and quality. Having clear milestones helped keep the company aligned, and it gave the project the legitimacy it needed to stay on track alongside customer work.
Build Flexibility into the Process
One of the biggest operational wins was scheduling flexibility. Because this was a Falcon-owned product, the company could build production into its downtime or slow periods. That meant Falcon Plastics didn’t have to displace customer orders or overload existing shifts – it could run trays during machine gaps and use the program to keep labor and equipment engaged in a smart, balanced way.
Falcon Plastics also designed the molds and materials to be compatible with a range of press sizes and regrind blends. That flexibility gave its facilities options, especially when navigating changes in customer demand or material availability.
Sustainable Manufacturing: Turning Scrap into Solutions
A big operational win was the ability to design the trays for production using nearly 100% regrind material. Because Falcon Plastics owns the mold for this product line, it had more flexibility with material sourcing – and it became a perfect fit for utilizing scrap from other internal jobs. This gave new life to what would otherwise be waste and turned sustainability into an operational advantage.
Perhaps the most rewarding part of the High Plains Trays program has been watching how a sustainability-minded initiative can become a standard part of Falcon Plastics’ operational playbook. What started as a waste-reduction project evolved into a full product line – designed, tooled, molded and improved entirely by the company’s internal teams.
It showed that sustainability doesn’t have to come at the expense of efficiency or quality. With the right operational focus, a manufacturer can do both.
Market Introduction and Customer Feedback: Staying Responsive
Once the product line was launched, Falcon Plastics remained closely connected with its customers. High Plains Trays and AmmoStak™ trays are used by manufacturers – not by Falcon internally – so it heavily relied on customer input to continue evolving the offering. Falcon Plastics gathered feedback on dimensions, stacking performance, shipping durability and handling, and used those insights to refine future molds and run conditions.
By treating the launch as just the beginning – not the end – Falcon Plastics kept itself in a mindset of continuous improvement. That feedback loop didn’t need to be formalized; it naturally came through its relationships and responsiveness.
Final Takeaway
Launching High Plains Trays wasn’t just about making “a tray” – it was about exercising operational muscles in a low-risk, high-reward environment. It gave the teams a chance to collaborate, innovate and execute – without external deadlines or expectations.
But most of all, it reminded Falcon Plastics that some of the best programs don’t start with a customer but start with a question: “What can a manufacturer do better with what it already has?”
Karissa Kopecky is the marketing manager at Falcon Plastics. An expert in marketing and content creation, she brings 15 years of industry marketing expertise in brand identity, marketing and promotions to her position. In 2019, Kopecky joined the team at Falcon Plastics to create and lead the company’s marketing initiatives, designing a cohesive brand and marketing strategy from the ground up. Kopecky resides in Brookings, South Dakota, with her husband and two daughters. In addition to her professional experience, Kopecky is also committed to improving the community and individuals around her through volunteering, advocating and supporting local community programs.
Founded in 1975, Falcon Plastics has been a trusted partner in bringing innovative solutions to market, serving a diverse range of industries worldwide as a custom contract injection and blow molder. From advanced medical devices to essential household products, Falcon Plastics specializes in delivering comprehensive services from design and engineering to manufacturing, assembly and distribution. With the capacity and expertise to handle complex, mid-to-high-volume projects, Falcon Plastics is committed to ensuring the highest quality and reliable, on-time delivery for every product, meeting the demands of each customer.
More information: www.falconplastics.com
