Manufacturing

PolyJohn is the worldwide leading manufacturer of portable toilets, portable restrooms, portable sinks and accessories. PolyJohn is there when you need us, and our attention to your needs begins in manufacturing. From polyethylene resin pellets to portable restrooms, PolyJohn’s comprehensive, innovative manufacturing processes allow us to control quality from raw material to finished product at our facilities in the United States and Canada. No other manufacturer of portable sanitation products can say that.

Quality and Innovation

PolyJohn is a world-class manufacturer dedicated to a Total Quality Management business culture. Our product design and developmental engineering team utilizes sophisticated computer-aided design (CAD) software systems to create innovative, functional and long-lasting, durable products.

Raw Materials

Polyethylene resin pellets are delivered to storage silos with mixing, batching and conveying support systems to move the pellets into plastic-forming machinery. With these machines, we mix color, UV protection, and other additives into our plastics to make them the longest-lasting and most color-stable plastics available. Careful consideration is given to our polymers. Pigmented colors are scrutinized for heat and light stability. Extra additives are blended into the resins for ultra-violet (UV) radiation resistance, providing long-lasting life.

Plastic Sheet Extrusions

With these machines, polyethylene resin is blended with color concentrates and UV additives to manufacture flat, plastic-extruded sheets, which are later used in our thermoforming and CNC manufacturing operations. We can perfectly control color consistency, width, and strength of our products.

Thermoforming - Single/Twin Sheet

Thermoforming machines heat and soften plastic sheets and then force them by means of pressure (usually vacuum) over or into a temperature-controlled mold where the plastic assumes the shape of the mold. Parts made from this process such as roofs, doors and wall panels are cooled to room temperature and then machined in specially designed routering and drilling equipment to guarantee quality and consistency. With this equipment, we have mastered the science of creating a consistent result that is the same from unit to unit, day to day, year to year.

CNC Machining

We use industrial CNC (computer numerical control) routers for accurate high-speed robotic machining to trim, cut and shape plastics, composites, non-ferrous metals and wood. The five-axis capability, in addition to creating production parts, allows us to make models and prototypes for future product development.

Rotational Molding

Polyethylene resin pellets are ground to a fine mesh powder using particle-size reduction machines and then blended together with pigments and additives. This powder is then loaded into molds made from heat-conductive materials. Mechanical arms position the molds into an oven where they are rotated on two axis planes at right angles to each other so that the molds revolve in a 360-degree circle. The powder melts and coats the inside of the heated molds, yielding evenly uniform wall thickness and stress-free parts. Hollow-shaped parts such as tanks and sinks are made through this manufacturing method.

Injection Molding

Polymer resins, pigments and additives are mixed together in a cylinder that has a reciprocating screw inside of it. After the materials have been heated to a homogeneous viscous liquid, the screw forces the materials into a closed mold to form simple to complicated solid shapes. Fly screens, handles, latches and spigots are examples of this manufacturing process.

Metal Working

Trailers, high-rise building crane lifting slings and tie-down stakes for portable restrooms are manufactured in this department, as well as other products.

Assemblies

PolyJohn employs a variety of assembly techniques and testing methods. Robotics are utilized for automation in conjunction with our highly skilled craftspeople to assemble several types of sinks and portable restrooms, creating finished products that are second to none.

The Preferred Portable Restroom Supplier

PolyJohn’s manufacturing process is just one of the reasons we are the preferred portable toilet supplier. Our customer-focused service, diverse and dependable product line, global reach and willingness to go the extra mile provide peace of mind for our customers looking for a portable restroom supplier.

Custom Manufacturing

In 2023, we established Cooper Plastics to serve as our custom manufacturing division. This enables us to utilize our resources and apply our knowledge to customers’ unique plastic needs, whether they operate in the portable sanitation industry or a different industry. Our engineers can use their experience and technologies to develop and manufacture your ideal product. Our product development services include: custom product design, engineering and specifications, production process development, tool and mold design & tool and mold procurement management. To learn more, visit cooperplastics.com.