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| Award-winning ag plastics began in Iowa shed |
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PRESTON, Iowa — When Terry and Nancy Kieffer birthed their nationally-recognized agribusiness out of an Iowa farm shed in 1993, they probably never would have imagined that 16 years later their plastics company would be making indispensable parts for some of the biggest agricultural names in the world.
“We literally started on our farm in a machine shed,” said Nancy Kieffer, vice president of Plastics Unlimited, Inc. in Preston, where her husband, Terry, serves as president. “We decided that we wanted to start a business in the plastics industry.
“After we purchased the Thermoformer (a forming machine that heats and molds the plastic products into various shapes for agricultural machinery and equipment), we had to find projects that we could produce. We wanted a name that could include a variety of plastic processes; our intentions were ‘unlimited’ product lines from the beginning.”
Located in a 67,750 square-foot facility at Preston’s industrial park, the Jackson County-based company manufactures thermoformed, urethane, composite molding and fiberglass parts for such international agricultural giants as Bobcat, Rite Hite, Gehl, General Electric and Caterpillar.
In addition, Plastics Unlimited makes supplies for several large agricultural equipment companies, with products ranging from agricultural hoods and shrouds, to industrial shields and guards, vending machine parts and urethane OEM (original equipment manufacturer) parts.
“We basically started business-to-business,” Kieffer said of the company’s early days. “In the beginning, we made very little profit on the initial project; we were just trying to get in their door.
“I think our honesty helped a lot,” she added. “We never promised anything that we felt we couldn’t accomplish. As time went on, the customer would ask us if we could do another project for them, and (then) another and another. We’ve had a lot of customers in excess of 10 years.”
The Kieffers, who are also soybean farmers, bought their first Thermoformer, an Osborn brand, at an estate auction in Moline, Ill., where the couple received an offer to visit a neighboring thermoforming company, Grimm Brothers Plastics Corp. in Wapello, Iowa.
“They offered guidance and mentoring as needed,” she said. “We graciously accepted their offer immediately, and still value their guidance and friendship today.”
But before the couple even started Plastics Unlimited, she said they knew nothing about the plastics industry, so they quickly enrolled in educational classes.
“We learned about the newest technology and equipment at the seminars that we attended,” Kieffer said. “We also found it extremely valuable to network with people in the plastics industry. To us, it seemed a lot like the farming community: Everyone was extremely helpful.”
In 2005, the company developed an innovative patent-pending, tool-less engineered composite (TEC) process that creates a fiberglass/thermoplastic mix, using up to 20 percent soy-based resin, which turned out to be a more durable and lightweight product, with a top-of-the-line “class A” finish.
“We offer thermoforming, urethanes, fiberglass and the TEC process,” Kieffer said. “In the initial meeting with our sales and design team, we ask the customer questions like: What will the product be used for? What’s the life expectancy of the product? Will it be exposed to the elements and sun?”
As a result, the TEC process has brought several new customers to Plastics Unlimited, resulting in company sales growing by about 50 percent each year from 2005-08 and sprouting a stronger employee-employer relationship.
“We’re currently the only thermoforming and composite business owners who are also soybean farmers,” Kieffer said. “Our businesses represent a complete circle in renewable resources. We believe in doing what’s right for Iowa, and that includes doing what’s right for our workers.
“Unlike other fiberglass production methods, our TEC process requires no permit because there are no emissions. Also, the soy-based resin doesn’t have a strong odor, so it’s more user-friendly for workers.”
Although Terry is the primary entrepreneur and salesperson who develops new processes that create new products for existing and first-time customers, Kieffer said the entire family is involved in the company’s operations, which includes an additional 10,000 square-foot facility used for off-site storage.
“Whenever we added an expansion, he’s overseen and often helped with the project, along with our sons, Travis, 19, and Dakota, 18,” she said. “We both travel to a lot of trade shows to find new customers for our processes and products. Our daughter, Amanda, 14, also helps in her free time.”
In 2004, the Kieffers purchased Fabri-Glass Composites, located in Moline, Ill., which specializes in composite molding, molded fiberglass insulation and water jet cutting. Both Plastics Unlimited and Fabri-Glass Composites are certified ISO 9001:2000.
To date, Plastics Unlimited has been nationally honored by the Society for Plastics Engineers and American Composites Manufacturers Assoc., as well as given the Venture award by the state of Iowa for leadership, innovation and creation of job opportunities. Most recently, Plastics Unlimited earned the Iowa Farm Bureau Federation (IFBF)’s prestigious Renew Rural Iowa Entrepreneur of the Month award for March, because of the company’s success, innovation and utilization of renewable resources.
Sandy Ehrig, IFBF economic development administrator, said winners are owners of rural businesses that are making a positive impact in their communities. “Great vision and innovation by Iowa entrepreneurs can take an idea out of the backyard to an industrial park, and transform a company run by two people into one that employs 50,” she said.
Today, Plastics Unlimited – which has already undergone three expansions – has 100 employees, including a staff of designers, mold makers and production personnel.
“That’s especially significant in a town like Preston, that has a population of less than 1,000,” Ehrig said. “Iowa Farm Bureau is proud to recognize innovative businesses that embrace agriculture and renewable resources, while creating high-quality jobs for rural Iowans.”
For young agricultural entrepreneurs wanting to start their own businesses, Kieffer said she suggests entering into them without fear. “Don’t be afraid to try it,” she said. “It’s probably easier to try it when you’re younger. It does take a lot of time and energy; it’s definitely not a nine-to-five job. Common sense is a great asset.”
But she also suggests that entrepreneurs have another form of income to rely upon, especially since most start-ups aren’t immediately profitable.
“We kept farming and I had another source of income for the first couple of years,” she said. “Don’t be afraid to ask for help. Most of the time, people are more than willing to help if you ask for it.
“Also, check out your local colleges to see what they have to offer,” she added. “Often they are a huge asset with training, and if they don’t offer it, they can direct you to someone that can help.” |
| 4/15/2009 |
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