Case Study: Portage Plastics Corporation achieves first-year payback and under 0.5% product return rate with Zontec’s Synergy 2000

For Portage Plastics SynergySPC Paid for Itself in the First Year

Portage Plastics Corporation (PPC), a high‑volume thermoforming supplier serving food, automotive, medical and consumer markets, needed a flexible Statistical Process Control (SPC) solution to collect and analyze data across widely varying jobs and quickly detect production issues (oven/heating, material, trim press vibration, etc.). To meet that challenge, PPC chose Zontec and its Synergy 2000™ (Synergy SPC) software for its ease of use, Windows‑based interface and personalized support.

Zontec implemented Synergy 2000 across two sites, providing real‑time data capture, detailed querying (including row‑level analysis), operator data entry and historical trending to enable preventative action. The result: major reductions in errors and man‑hours, the system paid for itself in the first year, and PPC’s product return rate dropped to less than half a percent.

Portage Plastics Corporation

Heidi Beaver

Quality Technician