Why do our hard cases make our customers so happy?
It’s no accident – it’s by design
Our product design team looks at every specialty case project with a level of enthusiasm that will surprise you. So will the cost.
The first time a customer is looking for your product, chances are they’ll see our product first. With that in mind, our design team will work with you to build the perfect case for your product: one that conveys a consistent message of quality, function, and style.
Our case design specialists will work closely with you to produce a case that:
- Protects your products
- Displays it Attractively
- Easy for your customers to maintain & store
Sized & Configured to You and Your Customer’s Needs
Our most economical designs are based on PFC’s proprietary line of modular exteriors – our stock cases. We’ve already made the investment in the most costly parts of the case, and can fit your products into a size and configuration that suits both you and your customers. These can be shipped out quickly, sometimes as soon as 48 hours from the time of your order.
Our custom cases provide you with more options, from modifying a stock case all the way to a complete custom hard case design. If you can imagine it, we can design and build it.
*for custom cases minimums apply
Strength
Because integrally molded interiors are part of the case structure itself and not glued or snapped in later, the overall case is stronger and more shock absorbent.
Product Protection
The air space between the double walls prevents shocks to the case exterior from being transferred to the case interior – providing superior product protection.
Economy
The exterior and the interior of a double‐wall blow molded case are molded as a single piece. That means that an interior designed specifically to package your product is integral to the overall structure of the case – not a separate insert that is made separately and installed later. That makes them surprisingly affordable.
Utility
The air spaces between the double walls are extremely useful. In the top or “lid” of a case, that air space is often used to store product manuals, forms/checklists, and marketing materials. In the bottom or “base” of a case that air space is an ideal place to store ancillary items – things like cables and hoses can be easily “stuffed” into a cutout to hold them securely in place. Impacts to the case exterior are not immediately transferred to the case interior.
Working with PFC
Everything is made in one of our factories, where our teams work on site every day. We source our materials domestically, and nothing is farmed out to other companies, here or overseas.
Quality Assurance & High-End Design
Over the last 40 years we have designed literally thousands of cases and case interiors for customers in hundreds of different markets.
PFC’s design team is your best choice
Given that we developed many of the processes used in the industry today, we understand the requirements for hard cases, aesthetics, and the double-wall molding process better than anybody. We also offer many design features that are not possible with other molding techniques. Our design team creates efficient, effective designs that don’t just look good on a diagram – they translate to great cases: cases that work well and are built to last. The result is more than a design solution: it’s a case that complements, in fact becomes a part of, your product.
How the design process works
A sales representative will team up with you to discuss your project in detail. We need to know as much as possible about your products, how they are used and in what quantities to offer a cost effective package. Are you looking for custom foam or custom molded interior hard cases? Once we have your information, we provide a photographic layout and quote, generally within a few days. If it’s convenient for you, we’ll communicate the information by email. Once we have approval of the concept the actual design process begins.
We’ll start with your needs and preferences
During the design phase, we take many factors into account. We look at the biggest issues, from delivery deadline and cost concern, down to the smallest details. We consider everyday things like how the case will balance out when it’s carried, to whether we should utilize the double-wall feature as a cushion. When you work with our design team, we’ll make sure your case meets all your needs.
We are Employee-Owned
Because we are an employee-owned company, you can be sure everyone who works on your specialty case has a vested interest in making you happy. Whether it’s an initial product run, a reorder, or a stock case off the shelf, you can expect to receive a quality case that makes you, and us, proud.
Check out our different cases and options, and then contact our office. We always enjoy building another great customized case.
Quality Control
PFC’s Quality Checklist begins with our trained sales staff’s attention to your needs and their extensive knowledge of all our products. They collaborate with our engineering department (which includes our terrific product design team). A team leader will work with you to design the most cost-effective solution for your product. Our experienced production department then kicks in, ensuring the manufacturing process goes smoothly. Everything is made in one of our factories, where our teams work on site every day. Nothing is farmed out to other companies, here or overseas. Everyone at PFC takes responsibility for timely delivery and consistently high-quality cases free of defects.
SHARP Certified
Our Ohio manufacturing facility is SHARP Certified – OSHA’s Safety and Health Achievement Recognition Program. SHARP is one of OSHA’s recognition programs designed to recognize worksites with comprehensive safety and health management systems that incorporate strong management commitment and meaningful, active employee involvement.
We are the founders of the Double-Wall Blow Molded Case
About Blow Molded Cases
PFC cases are made of high density polyethylene (HDPE). Polyethylene is the most common of all plastics. It is frequently used to make plastic bags, plastic bottles, and food containers. As a thermoplastic, it softens and becomes pliable (and moldable) when it is heated, and it hardens and becomes rigid when it cools.
The Origins
Developed in the late 1930s, blow molding is a manufacturing process that is used to form hollow plastic parts. It is most commonly used to make plastic bottles. In principal, the basic blow molding process is similar to glassblowing. Plastic resin (pelletized raw plastic material) is melted and formed into a hollow tube or parison which is then placed into a mold. The parison is then inflated using compressed air to form a finished part.
In the early 1960s, PFC founder Peter T. Schurman realized that he could combine two hollow blow molded parts to form the lid and base of a portable container or enclosure, and the “double‐wall blow molded carrying case” was born.
Compared to many other industrial operations, blow molding double‐wall cases is a surprisingly simple process, yet one that yields amazing possibilities.
What are the benefits?
In the United States, polyethylene is made from clean and plentiful natural gas. It contains no BPA or other toxic materials, and there are no known hazards associated with HDPE plastics. H.D.P.E. is fully recyclable.
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Blow molded plastic cases are durable, no other material even comes close when it comes to impact strength
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Double wall construction provides a cushion of air between the walls to help protect your product
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Blow molded cases are resistant to solvents, oils and moisture
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Blow molded plastic cases will never rust or corrode.
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Color is molded in, so it will never chip, peal, rub off or fade
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Scratch resistant Mold-Tech™ exterior finishes stay looking good, even after years of hard use
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Mechanical latches and hinges are designed for long-term durability
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HDPE is durable and is not affected by changes in weather
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HDPE is resistant to solvents, oils and moisture
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HDPE Blow Molded cases won’t dent, rust or corrode
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HDPE plastic is recyclable
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HDPE is stronger than standard polyethylene, acts as an effective barrier against moisture and remains solid at room temperature
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It resists insects, rot and chemicals
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It is easily recyclable and can be used again and again
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Recycled HDPE creates no harmful emissions during its production or during its use by the consumer
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During its manufacturing process, HDPE leaks no toxic chemicals into the soil or water
Process Steps
Visualize what happens inside the mold: Imagine holding a deflated balloon between your thumb and forefinger and lowering it down into a large glass jug. If you then blow up the balloon, the balloon will fill the jug and take on its shape.
- First, HDPE pellets are melted and extruded to a consistency similar to modeling clay and then extruded (pushed) to form a hollow vertical tube of molten plastic called a parison.
- Next, the parison is then pinched closed at the top and bottom to, in essence, create a balloon or bag.
- The parison is then placed between two halves of an aluminum mold.
- The mold is closed to surround the parison.
- A hollow needle inside the mold punctures the parison, and compressed air blowing through the needle inflates the parison inside the mold.
- The parison takes on whatever shapes and/or contours are on the inside surface of the mold.
- When the parison cools, the mold opens and the finished part is removed and any excess material is trimmed off and recycled.
Additional Blow Molding Capabilities
If you have a custom product and are looking for a blow molding partner with the experience and expertise look no further. PFC’s Territory Sales Managers, Customer Service Representatives and Engineers will work with you every step of the way to ensure a stress-free design and production run for your product.
Whether you have an existing mold or need us to design and machine a mold for you PFC has you covered. Our in-house engineers and machine shop will work with you to design the perfect mold for your part and our manufacturing staff will produce a product that will meet all of your expectations.
And, since we do all our manufacturing in the USA, you are always welcome to visit either our Woodbridge, CT or Massillon, OH factory to see your product being made.
