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Lean Manufacturing
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Strong Values & Unmatched Customer Service

Sussex IM runs over 60 injection molding machines – ranging from 25 to 725 tons. We have experience processing over 100 engineering-grade performance resins. Our manufacturing floor has the latest model molding machines, along with some of the very first we ever purchased! As an industry leader in custom injection molding, we keep moving forward with cutting-edge technologies and lean manufacturing practices. Our state-of-the-art Innovation Center is the hub of Sussex IM, where dedicated employees converge to create the quality products our loyal customers expect.

Our Mission is to solve problems to satisfy consumer needs

Our Vision is to mold and fulfill the future for our employees and customers

Our Core Values are Customer Focus, Ethics, Communication, and Teamwork

Facilities/Locations

Sussex IM is centrally located in Sussex, WI; approximately 30 miles from the General Mitchell International Airport (MKE).

  • 2 Manufacturing Facilities
    • HQ Facility – 122,000 sq. ft.
    • Advanced Manufacturing Facility – 87,000 sq. ft.
      • 2020 Expansion of additional 71,000 sq. ft.
  • 67 Injection Molding Machines
    • 25T – 725T
  • ISO 8 Class Clean Room Capacity

HQ Facility

Advanced Manufacturing Facility

Our People

Our People

Sussex IM is a Midwestern, family-oriented business built on trust, teamwork, communication and ethical decision making. We work together to utilize our skills and wealth of experience to find the most efficient and cost-effective solutions for our customers. At Sussex IM we promote furthering education and continuous improvement. We strive to hire from within and aim to allow every employee the opportunity to grow within the organization.

The SIM Team:

  • Values Partnerships
  • Cares about every customer
  • Finds solutions
  • Is relatable and proactive

At Sussex IM, Our People Are Everything.

Our People

Sussex Brands

Through our Business-to-Consumer division, Sussex Brands, we handle end-to-end operations for branded consumer products and ship directly to leading national and international retailers. We are proud to be a “Made in the USA” manufacturer and are driven to provide consumers solutions that fit into their everyday lives.

Brands Include:

  • Mr. Lid: Sussex IM’s Patented Storage Solution

Our History

1977, The Beginning: Our story begins with Lorand Spyers-Duran, an ambitious Hungarian immigrant. He came to our shores in 1956 and settled in Sussex, WI and worked for Hartland Plastics. An eager entrepreneur, he left Hartland to form the company that would become our corporate DNA’s point of origination.

Lorand and three partners formed Sussex Plastics, Inc. here in Sussex. The four partners secured auctions in search of production equipment. In short order, they secured used-but-servicable machinery and set up shop.

SPI’s first purchase orders came from Liquid Metronics (LMI) for metering pumps and ancillary components. Over forty years later, those products are still made by Sussex IM.

1980’s, Blow Molding Takes Off: And the company four-decade tradition of expertise begins with Blow Molding- vastly different from injection molding. A hot tube of plastic drops down between the mold halves. The mold closes and air is blown into the mold to form a hollow part. The first part, Candy Cane handles. As many as 14 million, running year-round.

SPI also added on 40,000 square feet of capacity, including office space, warehousing and manufacturing specifically to handle this surge in demand.

In 1987, we were named Avon’s Supplier of the Year. “Quite an honor, for a 10 year old company, that is.”

1990’s, Bigger & Better: The company added on another 45,000 square feet for offices, warehousing and manufacturing. In addition, silos were added to house resin.

By the end of the decade, the company was acquired by Rexam, the $6 billion multinational packaging behemoth.

2000’s, Innovation to Grow: The company’s customers faced an “innovate-or-die” competitive environment. The customer-centric firm anticipated this landscape, and built its bleeding-edge, 10,000 square foot Innovation Center.

In addition to the Innovation Center, the company integrated its state-of-the-art Motan System; and for enhanced comfort and productivity, air conditioned the manufacturing plant.

2010, Sussex IM Purchase: Due to the ‘08-’09 recession, Rexam was in the process of shutting down/consolidating plants. 3 employees from the management team: Phil Salzman, Keith Everson, and Dave Guagliardo had the opportunity to buy back the business and ended up saving approximately 220 jobs. The company was returned to its core values and Sussex IM (Injection Molding) Inc. was formed in 2010.

As a result, a long run of annual double-digit growth continues to this very day. Another plant expansion took place, this one for 12,000 square feet. Further, Sussex IM South – our Advanced Manufacturing Facility- is planned at 86,000 square feet to further customer satisfaction for increased capacity and streamlined pellet to pallet work-flow schemes.

2020’s, New Look & New Opportunities: Due to the COVID-19 pandemic, Sussex IM received a surge in demand in the Health & Hygiene market. This increased demand led to Sussex’s expansion into the medical market with the addition of an ISO Class 8 Clean Room. As Sussex continues to expand and evolve into different markets, a rebrand took place to help portray our vibrant culture and our modern technology.

Sussex also invested in an addition to the Advanced Manufacturing Facility of an extra 71,000 sq. ft. for manufacturing and temperature-controlled warehousing space.

Sussex IM received the 2019 Supplier Innovator of the Year from Gojo Industries.

Sustainability

With a responsibility to the community in which we do business, Sussex IM is committed to protecting the environment and the health and safety of our employees, customers, and neighbors. We also encourage and support our employee’s involvement in community environmental activities.

We believe that environmental, economic and human needs can be met simultaneously.
We develop and implement practical measuring and reporting systems to ensure we are continuously reducing our impact on the environment.

Sussex IM Sustainability Practices:

  • Returnable Packaging
  • Post-Consumer Recycled Material
  • Bioresins
  • Regrinding for Reuse
  • Energy Efficient Machines and Facilities

ISO Certifications

Sussex IM complies with the Global ISO (International Standard of Operations) Standards
with respect to safety, quality and the environment.

Certifications Include: ISO9001, ISO14001, ISO45001, ISO13485

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