What Sussex IM does

Sussex IM is a privately held, family-owned precision plastic injection molding contract manufacturer headquartered in Sussex, Wisconsin. Founded in 1980 and operating across two co-located facilities (a main plant at N65 W24770 Main Street and an Advanced Manufacturing Facility at N52 W24500 Lisbon Road), the company runs more than 60 injection presses spanning 25 to 725 tons, 150,000+ square feet of climate-controlled warehousing, an ISO Class 8 clean room for medical and RFID-embedded production, and supporting metrology and automation cells (including a Hexagon scanning CMM and in-house robotics). It is qualified to ISO 9001:2015, ISO 14001, ISO 45001, and ISO 13485, and has earned an EcoVadis Bronze Medal (2025) following a prior Silver rating.

The company sells vertically integrated contract manufacturing programs to enterprise OEMs across seven verticals: agriscience, consumer goods, food service, healthcare, industrial, medical & pharma, and residential durables. Core offerings combine precision injection molding with design for manufacturing (DFM), prototyping, in-house automation, multi-shot and insert molding, in-mold labeling (IML) with digital printing, pad printing and decoration, mechanical assembly, quality/metrology, and end-to-end logistics including VMI and Amazon FBA support. Differentiated technical capabilities include a proprietary two-shot RFID insert mold, AI-assisted DFM, AI vision inspection, predictive maintenance on press and mold health signals, and energy-aware production scheduling. Named enterprise customers include Kraft HEINZ, GOJO, and Q30 Innovations; subsidiary Sussex Brands also markets consumer product lines such as ONETUMBLER customizable drinkware and the Mr. Lid and Connectivity+ brands.

Sussex IM generates revenue through quote-based, multi-year enterprise contracts priced per part on volume, material, and complexity, with no public pricing tiers. Go-to-market is direct enterprise field sales driven by an RFQ process and cross-functional program teams, supported by content marketing (The Sussex Solution video series, blog, LinkedIn), industry events such as MD&M West 2025, and an RFQ funnel on the company website. The company is geographically concentrated in the US Midwest but supports international shipping; distribution is direct to OEMs with no disclosed channel partners or resellers. Sussex IM employs between 251 and 500 people and is led by President/CEO Megan Tzanoukakis with a CFO, VP of Manufacturing, and a Director of Engineering/Chief Technical Officer.

Name

Sussex IM

Legal name

Sussex IM

Website

https://sussexim.com

Company type

Private

Founded year

1980

Operating status

Operating

Headcount range

251–500 employees

Short description

Sussex IM is a Wisconsin-based, family-owned precision plastic injection molding contract manufacturer serving enterprise OEMs across agriscience, consumer goods, food service, healthcare, industrial, medical/pharma, and residential durables through vertically integrated molding, assembly, decoration, automation, and fulfillment services.

Ownership category

akta.pro rank

Product category

Plastic Injection Molding Contract Manufacturing

NAICS

Plastics Product Manufacturing (3261), Other Plastics Product Manufacturing (32619), Industrial Mold Manufacturing (333511)

akta.pro primary industry

Custom Injection Molding & Contract Manufacturing (Job Shops/CMs) (IMANAFAJ)

akta.pro secondary industries

Packaging Injection Molding (Caps, Closures, Thin-Wall, IML) (IMANAFAA), Insert & Overmolding (Metal/Plastic, Multi-Material) (IMANAFAI), Consumer Products Injection Molding (Housewares, Toys, Personal Care) (IMANAFAE)

Keywords

• Plastic injection molding
• Contract manufacturing
• In-mold labeling
• Insert molding
• Multi-shot molding

Headquarters

HQ city

Sussex

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Infrastructure, Supply Chain, Technology or R&D, Marketing or Sales

Revenue model

1. Custom Plastic Injection Molding Services: Full-service injection molding manufacturing from concept to consumer. Includes precision injection molding, design for manufacturing, tooling, and production. Revenue generated through per-part pricing based on volume, material, and complexity.
2. Contract Manufacturing Services: Vertically integrated contract manufacturing including assembly, decoration, automation, logistics, and fulfillment. Extended services drive additional revenue from OEM programs requiring complete solutions.
3. Material Selection & Processing: Processing of engineering-grade and commodity thermoplastics with material selection expertise. Six large silos for bulk resin storage for high-volume programs.
4. Prototyping Services: Plastic prototype manufacturing including 3D printed prototypes and aluminum/soft steel prototype molds for limited-run production testing.
5. Logistics & Fulfillment: Warehousing, packaging, and shipping services. Includes VMI programs, Amazon FBA support, freight consolidation, and distribution center routing.

Pricing tiers

Go-to-market motion1 record

Distribution channels2 records

Marketing channels6 records

Core offering

Sussex IM is a precision contract plastic manufacturer providing end-to-end injection molding services from concept to consumer. The company operates vertically integrated facilities in Wisconsin with more than 60 presses (25–725 tons) producing custom plastic components for OEM brands across agriscience, consumer goods, food service, healthcare, industrial, medical/pharma, and residential durables. Service offerings include design for manufacturing, prototyping, tooling, molding, assembly, in-house automation, decoration (pad printing and IML), insert and multi-shot molding, quality/metrology, and logistics/fulfillment.

Product overview

Sussex IM is a precision contract plastic manufacturing company offering plastic injection molding as its core platform, supported by vertically integrated services including Design for Manufacturing (DFM), prototyping, in-house automation, assembly & finishing, decoration (pad printing and in-mold labeling), multi-shot/insert molding, quality & metrology, logistics & fulfillment, material selection, reshoring support, and transfer tooling. Their product architecture centers on turnkey injection molding programs that coordinate molding, post-molding assembly, and fulfillment under one roof. The company also manufactures consumer product brands including ONETUMBLER Drinkware (mass-customized travel tumblers with IML) and wall-mounted dispensers (for soap, sanitizer, and paper towels with smart device and RFID integration). Specializations include in-mold labeling (IML) with over 30 years of experience, two-shot/multi-shot molding, RFID insert molding, and serialization/tracking capabilities.

Differentiator

Problem solved

Functional benefit

Brands

• ONETUMBLER: Custom travel mug product line featuring in-mold labeling decoration, available in 12oz to 20oz sizes with unlimited label customization options.
• Mr. Lid
• Connectivity+

Products and services

• Precision Injection Molding High-quality, efficient injection molding services for durability and repeatability, supporting high-volume production programs with more than 60 presses ranging from 25 to 725 tons. Built for OEM manufacturers across multiple industries.
• Assembly & Finishing Mechanical assembly, hardware insertion, sub-assembly builds, and post-molding operations including pad printing and kitting, integrated with molding production schedules for OEM customers.
• In-House Automation Custom-built automation systems including robotics, press-side vision, PLC programming, continuous motion assembly, auto conveyor systems, and sonic/hot plate welding, designed and built in-house for OEM production programs.
• Design for Manufacturing (DFM) Engineering support for part design, material selection, gate placement, tooling requirements, and moldflow simulation reviews conducted before tooling is finalized for OEM customers.
• Logistics & Fulfillment End-to-end fulfillment including 150,000+ sq ft of climate-controlled warehousing, domestic and international shipping, Amazon FBA support, VMI programs, freight consolidation, and retail/DC routing for OEM customers.
• Material Selection Engineering support for plastic molding material selection based on performance and end-use needs, with experience processing over 100 engineering-grade thermoplastics including commodity and specialized resins for OEM programs.
• Prototyping Plastic prototype manufacturing using 3D printed samples (Objet30 Pro PolyJet printer) for early geometry assessment, and aluminum/soft steel prototype molds for functional testing and material behavior validation.
• Quality & Metrology Advanced inspection and quality verification including Hexagon 7-10-7 Global Blue S scanning CMM, offline CAD programming, SPC, leak and pressure testing, force and load testing, color spectrometry, and custom fixtures for OEM quality programs.
• Reshoring Support for bringing production back to the U.S., including tooling transfer assistance, resin safety stock management, and seamless transition of existing OEM programs to Sussex IM facilities.
• Transfer Tooling Assistance with mold transfers from other facilities, including a transfer checklist and process to ensure seamless transitions without production delays for OEM customers.
• In-Mold Labeling (IML) Precise, durable in-mold labeling with custom automation and 30+ years of expertise, providing permanent label integration with scratch- and scuff-resistant surfaces, supporting digital printing for mass customization.
• Insert Molding Injection molding with embedded components including threaded inserts, PCBAs, sensors, and RFID tags, with thermal and mechanical modeling to protect sensitive elements during molding for OEM applications.
• Multi-Shot/Two-Shot Molding Advanced two-shot and multi-shot plastic injection molding for material integration within the press, used in applications including RFID tag embedding and soft-touch overmolds on rigid housings for OEM customers.
• Decoration Pad printing and other decoration processes aligned with tooling decisions to protect surface quality and repeatability at scale, including metallic, multicolor, high-resolution, holographic, and soft-touch finishes.
• ONETUMBLER Drinkware Custom travel mug product line featuring four tumblers (12oz to 20oz) with unlimited in-mold label design combinations for mass customization, utilizing IML decoration with serialized QR codes for traceability and consumer engagement.
• Wall-Mounted Dispensers High-quality wall-mounted dispensers for soap, sanitizer, paper towels, and sharps, with customizable IML decoration, RFID inserts for authentication, smart device integration, and sustainable material options.

Quantifiable outcome

• High-volume programs with 27 molds successfully executed with tight timelines
• +3 more outcomes

Named customers7 records

Segments7 records

Ideal customer profiles3 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

AI capability9 records

Feature12 records

Partnerships

Three partnerships are on record, tiered core.

• ASEPTcoreStrategic or Co-development Partner · 20 September 2024ASEPT is a global leader in dispensing solutions. Partnership with Sussex IM on the HEINZ Keystone 3.0 Dispenser resulted in IMDA Award recognition. ASEPT provides dispensing technology expertise while Sussex IM delivers injection molding and IML capabilities.
• Inkworks PrintingcoreTechnology or Integration · 20 September 2024Inkworks Printing collaborated with Sussex IM on the HEINZ Keystone 3.0 Dispenser project, providing high-quality printing for in-mold labels that were then integrated into injection molded parts.
• TOLYcoreStrategic or Co-development Partner · 26 April 2018Strategic alliance between TOLY and Sussex IM. TOLY is a leading European manufacturer of cosmetics packaging and beauty solutions. Partnership expands capabilities and market reach for both companies in the beauty and cosmetics packaging segment.

Scale indicators13 records

Recent moves7 records

Expansion highlights6 records

Direct peers

• Stack Plastics: Custom plastic injection molder offering design assistance, tooling, molding, and assembly. Comparable mid-tier contract manufacturer serving similar consumer, medical, and industrial segments.
• Protolabs: Digital manufacturing service bureau offering injection molding, CNC, and 3D printing for prototypes through production runs. Competes directly for short-to-mid volume OEM programs and rapid-turn tooling in the same customer set.
• Placon: Wisconsin-based plastics manufacturer combining thermoforming and injection molding with IML decoration for consumer, food, and medical packaging. Overlaps in IML, food-service, and medical packaging contract work.
• EVCO Plastics: Wisconsin-based custom plastic injection molder offering contract manufacturing for OEM customers across multiple industries, with a similar vertically integrated service model. Direct competitor for Midwest-OEM programs.
• Plastic Molded Concepts: Custom injection molder serving industrial, medical, and consumer markets with design, tooling, molding, and assembly services. Direct competitor for mid-volume, multi-vertical OEM programs.
• Crescent Industries: Custom injection molder with in-house tooling, automation, assembly, and value-added services. Competes for FDA-regulated and industrial OEM programs requiring engineering-grade thermoplastic expertise.
• Tessy Plastics: Custom injection molder with vertically integrated tooling, automation, assembly, and fulfillment serving medical, industrial, and consumer customers. Closely comparable in program scale, medical certification footprint, and decoration capabilities.
• Mack Molding: Family-owned contract injection molder providing design, tooling, molding, and assembly services for industrial and medical customers. Comparable footprint, customer mix, and vertically integrated service model.
• Kaysun Corporation: Mid-sized custom injection molder providing engineering resin processing, insert molding, and assembly for industrial and consumer OEM customers. Closely comparable in technical molding and multi-shot/insert programs.

Broad incumbents

• Avient Corporation: Global specialty polymer materials and services company offering engineered materials, color masterbatch, and specialty engineered formulations used as inputs in molded parts. Operates broadly in plastics rather than as a competing custom molder, but intersects with Sussex IM at the resin-selection, sustainability, and design-services layer.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks5 records

Key highlights7 records

Customer concentration

• YouTubeyoutube.com/channel/UCgSjvyFpfAocRPtnFQCyW0w
• Facebookfacebook.com/simplastic
• LinkedInlinkedin.com/company/sussex-im
• Instagraminstagram.com/sussex_im1/?hl=en
• Xx.com/SussexIM

Compliance5 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles8 records

Subsidiaries2 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Sussex IM