Our Process

Innovative Product Development

Designing from “Art to Part” is our motto. The process of designing that “just-right package” to meet your needs begins in our Product Development Department, where our award-winning International Design Teams work with the latest technology to transform your package vision into reality.

Our global design teams work with the latest SolidWorks CAD/CAM software to transform your package vision to reality. The 3-Dimensional Electronic Drawings are a critical collaboration tool that let us conceptualize, communicate, and convert your ideas into innovative package designs. The software allows collaborative drawing notes to be made and saved in a vault, that is linked to the parent drawing, in a matter of minutes. 

Our virtual design process offers shorter lead times due to concurrently developed package designs. Also, 24-hour design services are provided on mission critical projects by leveraging our global design teams located in:

• U.S.A. (Wisconsin)
• DENMARK
• MALAYSIA
• CHINA

Sample Model Shop

You benefit from the services of our high tech Model/Sample Department, where 3D solid models are made by experienced technicians who CNC a combination of plastic composites to create an accurate mold representation. A sampling of vacuum formed parts using either a RenShape or aluminum modeling tool are then sent to you for design approval. In addition, 3D printing capabilities are available to rapid prototype your product to ensure the samples we provide align with your design intent.

The vacuum formed samples aid both you and the Prent Designer in proving out the general size, fit and function of the part before investing in full production tooling.

International Tool Build

Once your team has approved the sample parts, our Tool Design Engineers, CNC Programmers and Machinists begin the process of fabricating your aluminum tool. Our four (4) Tool Build Centers are located in:

• U.S.A. (Wisconsin)
• DENMARK
• MALAYSIA
• CHINA

We have over two dozen matched CNC mills positioned in Prent's global facilities. Our tool centers are the largest in the industry; including a custom, state-of-the-art automated CNC machining center in Wisconsin, U.S.A., which allows for continuous 24/7 milling without the need of multiple workforce shifts.

Global Thermoforming

Upon completion, your tool is set up on a Prent designed and built production thermoformer where pilot parts are provided to you for approval before a validation run is scheduled.

Prent’s ten (10) Global Thermoforming Centers are the heart of our operations. At each greenfield facility, we take pride in our production excellence and thermoforming to Lean Six Sigma standards—on identical Prent designed and built thermoformers—in Class 8 Clean Rooms.

• U.S.A. (Janesville, Wisconsin - 2 facilities)
• U.S.A. (Flagstaff, Arizona)
• MEXICO (Rosarito)
• PUERTO RICO (Yauco)
• COSTA RICA (Heredia)
• DENMARK (Holbaek)
• MALAYSIA (Johor)
• CHINA (Shanghai - 2 facilities)

Our manufacturing process is monitored throughout the production run to achieve 100% part traceability, repeatability and meet your Cpk/PpK requirements. Sophisticated robotics perform pick-and-place operations, while artificial intelligence technology, designed in-house, aids in 100% inspection of critical to quality dimensions. Inspected parts are then packed into poly bag-lined shipping cartons or bulk containers.

Secondary Operations

When additional requirements are needed on your part, Prent offers secondary services that address an extensive range of automated, robotic and custom processes.

If you are considering outsourcing some of your requirements due to increased pricing pressures, labor and training costs, inefficiencies, erratic quality, validations and other challenging factors, let Prent’s Secondary Operations in the U.S.A., China or Malaysia service your needs.

Our services include:

• Match metal part trimming
• 2-dimensional trimming
• RF and sonic sealing
• Heat sealing
• Tyvek and lid stock sealing
• Labeling
• Pad printing and hot stamping
• Laser etching
• Contract packaging
• Part assembly
• And more…

Quality Assurance

Prent’s long standing commitment to quality management started in 1993 when we became the first thermoformer in North America to become ISO Certified. Today all our facilities continue to be ISO 9001 and/or ISO 13485, plus more.

Leveraging our employees, systems and technology, Prent drives continuous improvement in our products and services. Our Quality Management System (QMS) focuses on providing products and services that meet or exceed your requirements and offer continuous process improvements.

Best practices are used to ensure only the highest quality products are produced at all our global facilities. Ongoing global departmental summits are held to educate, share, unify and implement advances in best practices, critical systems and equipment. Knowledge sharing also occurs at each individual facility, where continuous education programs enhance employee skills and knowledge.

Sales & Production Control

Facilitating the smooth, on-time flow of parts to customers is the job of our dedicated Customer Service teams. Because we believe it's important for you to have one point of contact, our Customer Service team not only provides you with fast answers to inquiries, but also understands your specific needs.

Our Global ERP System / Manufacturing Execution System integrates real time global data and processes across multiple departments and locations. We have visibility of all information from Order Entry to Shipments and everything in between. Our Sales Service and Production Control specialists are monitoring the progression of your order the entire time.

Logistics

When your product is ready for shipment, it's labeled for traceability and barcoded for inventory control. You have a variety of programs to choose from—including Just-in-Time manufacturing, KanBan, VMI (Vendor Managed Inventory), and Ship-to-Stock convenience so parts can be placed directly in your inventory for immediate use.

In addition, Prent’s One-Way and Returnable Bulk Container program can enhance product protection, reduce CO2 emissions, and improve freight efficiencies by eliminating corrugate, skids and related packing materials.

Bulk Containers offer customers many advantages, including:

• Ability to densify trucks to reduce shipping costs
• Durable, clean packaging
• Increased part protection
• Warehouse optimization – stackable containers….no racking needed
• Closed loop packing – easily collapsible containers for return shipment