Balcan Innovations Announces $200 Million Investment in Strategic Growth and US Expansion for Balcan Packaging, Plastixx, and NELMAR

The company's newly launched capex plan represents a $200 million commitment aimed at significantly expanding their US operations with 8 co-extrusion lines (W&H, Bandera), 1 printing press (W&H), 1 tuber (W&H), and 2 bag-making machines (Lemo)—set to be installed in Pleasant Prairie, WI in 2025 through 2027.  This strategic investment will increase the plant’s film capacity by more than 700% to meet the growing demands of their US customers. “For Balcan Innovations, the industrial packaging segment is not an afterthought—it's our singular focus,” stated Ron Cauchi, Balcan Innovations’ Chief Executive Officer. “We’re strengthening our US footprint with a fleet of purpose-built machinery that will enhance our service levels and packaging capabilities for customers across the Building & Construction, Lawn & Garden, and Chemical sectors, among others.”  

Balcan Innovations has also received municipal government approval to expand their 215,000 square-foot factory in Pleasant Prairie by 15,250-square-feet to accommodate the incoming assets. Additional infrastructure investments include the installation of exterior rail spurs for direct resin delivery, electrical upgrades, companywide training tools, and an expansion of their Engineering and Maintenance workforce across all sites.  

To complement their planned US growth, the now-operational 10-color MIRAFLEX II press in Terrebonne represents a portion of Balcan Innovations’ commitment to reinforcing their expansive Canadian roots. The press will be followed by a 5-layer co-extrusion line (W&H) in Terrebonne—set to be operational in early 2026, along with numerous machinery optimization projects already underway across their Montreal and Laval plants. “We’re continuing to invest in the best equipment and the best processes to serve our customers where they want to be served, whether that be in Canada or the US,” said André Desroches, Balcan Innovations’ Chief Operating Officer. “This is about creating manufacturing redundancies and positioning ourselves for what’s next, both for our company and the future of the flexible packaging industry.”  

About Balcan Innovations Inc. 
Balcan Innovations is a leading North American manufacturer of high-performance PE films, flexible packaging, and reflective insulation with five brands at their core: Balcan Packaging, Plastixx FFS Technologies, NELMAR Security Packaging Systems, rFoil, and Reflectix. 

Since 1967, Balcan Packaging has been dedicated to manufacturing high-performance PE films and flexible packaging products for a wide range of industrial applications. The brand’s history and evolution as a market leader is owed to its relentless focus on product development, custom-made solutions, and an expansive range of manufacturing capabilities. Established in 2008, Plastixx is a manufacturer of tubular FFS films and PE valve bags used to package powdery building materials, food ingredients, chemicals, and other bulk materials. It’s recognized for its unmatched quality, customer-centric approach, and innovative packaging designs. Since 1984, NELMAR has been dedicated exclusively to manufacturing tamper-evident security bags. Its singular focus has empowered it to develop some of the most-trusted security brands used worldwide by banks, armored carriers, and retailers, among other industries.