Partner In Plastics: Superior Plastics

Founded in 1997, Superior Plastics of Plain City, Ohio, has established itself as a leading global provider of highly-engineered custom injection-molded components. Serving diverse industries, including global automotive, industrial adhesives, childcare safety, and office furniture manufacturing, the company’s commitment to quality, efficiency, and innovation has positioned it at the forefront of the industry. This success story highlights how Superior Plastics’ strategic partnership with Milacron, supported by nearly three decades of reliable machine performance and exceptional service, has been instrumental in driving operational excellence

With a workforce of 150 dedicated employees operating 24/7, Superior Plastics produces over 207 million parts annually using 50 injection molding machines. The company’s emphasis on quality is underscored by its ISO certification, a testament to stringent manufacturing standards and customer-focused approach. Its experienced leadership team, comprised of engineers and business professionals with over a century of combined service, continually strives to enhance efficiency and product quality, with the help of Milacron.

The Milacron Advantage: Quick Commissioning, Precision & Seamless Collaboration

Superior Plastics first partnered with Milacron in 1998 when the custom molder acquired its first all-electric Roboshot injection molding machine through independent representative Shay Burris, now Superior’s General Manager.

“The Milacron Roboshot was ahead of its time back then in the all-electric category, showcasing a forward-thinking approach toward energy efficiency and high-performance manufacturing,” said Burris.  

Currently, 25 of Superior’s 50 IMMs are Milacron Roboshots, including a remarkable 550-ton model – the fleet’s largest – that was commissioned in record time, demonstrating the seamless collaboration and technical expertise between the two companies.

Unparalleled Machine Uptime and Reliability
One of the most significant advantages of the Milacron Roboshot platform is its exceptional uptime, which is essential for a demanding production environment like Superior Plastics. In custom molding, where precision and on-time delivery are critical, machine reliability directly impacts overall efficiency and customer satisfaction – a combination that serves well for Superior.  

This high level of dependability ensures minimal production interruptions, leading to reduced downtime and lower maintenance costs. Consequently, Superior can consistently meet tight deadlines and deliver high-quality parts, reinforcing their reputation for excellence in a highly competitive industry.

Leveraging the Roboshot for Precision, Efficiency, and Sustainability
Superior’s decision to adopt the Roboshot several decades ago represented a strategic advancement, as the platform was ahead of its time with exceptional precision, operational efficiency, and dedication to environmental stewardship. Today, the all-electric architecture not only minimizes material waste but also reduces energy consumption, thereby aligning seamlessly with Superior’s commitment to sustainable manufacturing excellence.

Burris notes, “The Roboshot provides outstanding accuracy thanks to FANUC’s dynamic technology, with no oil or hybrid components.”

Beyond energy savings, the all-electric precision delivers several key technological advantages:

• Enhanced repeatability and consistency: The electric servo drives enable extremely precise control of injection parameters, ensuring consistent part quality across large production runs and reducing scrap rates.
• Faster response times: The machine’s rapid and accurate response to control inputs allows for optimized cycle times, increasing throughput without sacrificing quality.
• Improved part quality: The high-precision control minimizes variations in shot volume and pressure, resulting in parts with tighter tolerances and better surface finishes.
• Reduced mechanical wear: The absence of hydraulic components means fewer moving parts subject to wear, leading to lower maintenance costs and increased machine longevity.
• Greater process flexibility: The precise control of injection speed, pressure, and temperature allows for complex molding processes and the production of intricate, high-quality parts.
• Environmental benefits: The elimination of hydraulic oil reduces potential environmental hazards and disposal costs, reinforcing Superior Plastics’ sustainability initiatives.

Overall, the all-electric Roboshot allows Superior Plastics to produce high-quality, consistent parts more efficiently and sustainably, giving them a competitive edge in the industry.

Superior’s Roboshots Deliver Legacy and Longevity  
Superior’s all-electric Roboshot fleet ranges from a 33-ton model, commissioned in the late ‘90s, to their newest 550-ton, commissioned earlier this year, thanks to Milacron’s proactive support and the reliability of the FANUC-driven system.

Burris explains that Superior typically keeps its Roboshots for up to ten years before reselling them to plastics manufacturers that are just starting out or are possibly not running quite the volume that Superior does on a regular basis.

“We can often get up to 60% of the retail value on a seven-to-ten-year-old Roboshot machine, so we sell them off while they’re still in great shape, and then replace them with Milacron’s next-generation model,” he says. The Roboshot 33T is an exception to Superior’s resale rule, according to Burris. This particular model is a vintage Cincinnati Milacron  Roboshot from 1999. Eventually, Superior plans to showcase this unique machine to highlight the legacy the platform has delivered for the brand through its dynamic capabilities.

“When that Robo 33T finally goes, it will be a display piece for our company – it will never be sold nor scrapped,” Burris said. “As of mid-2025 it’s still running strong at more than 30 million cycles!” 

Milacron Roboshot Product Management Analyst, Jaqui Schrieber, has created a series on Total Cost of Ownership (TCO) on the platform. “Customers sometimes forget the high re-sale value of Roboshot as part of the TCO equation, but Superior gets it, and is using it to their total advantage,” she said.

Long-Term Partnership and Commitment to Service
The culmination of Milacron’s four-decade partnership with FANUC, the Roboshot is a versatile and precise all-electric machine.  It features the next generation of artificial intelligence (AI) with mold and eject protection and injection molding preventative maintenance features that keep plastics processors running smoothly.

 “Milacron and FANUC have maintained a strong partnership, delivering incremental upgrades that consistently enhance the performance and reliability of the Roboshot, all while maintaining simplicity for the operator,” Burris said. “The unmatched consistency and precision we achieve with these machines are a direct result of this ongoing innovation.”

As a technology-driven company that values accuracy, automation, and successful downstream applications, Superior has consistently found that the Milacron Roboshot checks all these boxes, ensuring its production remains efficient and reliable at various ranges and applications.

Burris also credits the longstanding relationship with Milacron to the first-class field service his company has received. He cites Milacron’s Sr. Service Engineer, Randy Ellis, as pivotal in ensuring smooth operations, especially during critical moments such as the rapid commissioning of the 550-ton machine earlier this year.

“We had thankfully anticipated that our customer might require production on short notice, so we had the new machine quotes and options prepared in advance,” explained Burris. “However, the urgency escalated faster than expected and we had to act immediately. Thanks to Milacron and Randy’s responsiveness, we were able to meet the demand seamlessly.”

An electronics engineer by trade, the Milacron field service veteran of 36 years recalls, “I received the call and was onsite at Superior Plastics within hours. Once the machine arrived, I powered it up, completed the check sheet, installed the mold, and had it producing parts within two days.”

This swift response exemplifies the strength of the partnership, as well as the shared commitment to delivering exceptional service and technological excellence to customers.

Beyond his technical expertise and prompt responsiveness, Ellis has fostered a genuine friendship with Burris and the team at Superior. Over the years, his consistent presence and personal dedication have built a foundation of trust and camaraderie that extends beyond mere service calls.

“Us plastic guys are a tight-knit community,” Ellis said. “And it goes both ways,” recalled Ellis of a time a few years back when he took his mom and dad to Superior Plastics for a tour of the central Ohio facility that isn’t too far from his family’s 300-acre farm “They bent over backwards for my parents, just like good friends would do.”

Burris says Ellis’ deep understanding of Superior’s operations and his steadfast commitment to their success demonstrate that his support goes far beyond troubleshooting – it indeed reflects a true partnership. He cites that Ellis’ proactive approach and genuine care for their business have made him an integral part of the Superior Plastics family, ensuring that they always feel confident and supported in their pursuit of manufacturing excellence.

Burris describes Ellis as “the best in the business!”

Impact on Customer Success
The successful collaboration between these two companies is evident through Superior’s exceptional customer ratings and high-quality standards. Their automotive clients, for instance, rely on parts like engine mounts, stability control clips, and interior handles-components that demand tight tolerances and reliable mass production. The industrial adhesives, childcare parts, and office furniture sectors also benefit from the precise and dependable injection molding processes they’ve come to know from Milacron.

 “The flexibility and specifications of the Roboshots are extraordinary,” said Burris. “They almost never have limitations, which allows us to adapt quickly to customer demands.”

The platform’s extended tie bars and increased tonnage package ensure few limitations, explains Milacron Roboshot Product Management Analyst, Jaqui Schreiber. “This level of reliability and versatility directly contributes to Superior’s success in delivering high-quality, precision parts on time, every time for its customers,” she said.

Schreiber also explains that in a climate-controlled production setting, such as that of Superior’s plants, maintaining consistent conditions with minimal disturbances is essential for ensuring accuracy, reducing defects, and maximizing productivity. She notes that hydraulic machines, which generate more heat and noise, are less ideal in situations like this because the excess heat can disrupt temperature stability, making it challenging to sustain the precise conditions needed for high-quality, automated production.

A Valued Partnership Garners Sustained Success
Superior Plastics exemplifies how investing in reliable, high-performance equipment, paired with exceptional support, can propel a manufacturing company toward sustained success.

“Our nearly three-decade relationship with Milacron has been built on a foundation of trust, technological advancement, and shared commitment to quality, “ Burris said.

As Superior continues to grow and innovate, the company’s alliance with Milacron will undoubtedly serve as a blueprint for manufacturing excellence.

By prioritizing machine reliability and ongoing innovation, Superior Plastics and Milacron have established a new benchmark in the custom injection molding industry. This partnership consistently delivers high-quality, precision-engineered products to customers around the globe – it’s a relationship that reflects a shared commitment to excellence and continuous improvement. Together, they have built a foundation of trust and operational excellence that will advance Superior’s success and sustained growth for many decades to come.