"Our plastic trays are built to last for 20 to 25 years”

"Staal & Plast has been in the business of manufacturing plant trays since 1984, and we have always focused on delivering the highest quality products to the horticultural sector," Flemming Jørgensen, Sales Manager at Staal & Plast explains. The company produces high-quality plastic trays designed for optimized growth conditions, ensuring the best possible start in a controlled environment for both the propagation process and for potted plants in general.

Staal & Plast is proud of the longevity of its trays. "Our trays are built to last for more than 20 to 25 years in controlled and optimized growth environments. This is a significant advantage for growers who want to reduce costs in the long term and minimize their environmental footprint by avoiding frequent replacements," Flemming says. "Other competitive products in the market are not necessarily designed for that long-term usage."

The production process
"We manufacture our trays using the latest technology within extrusion and vacuum forming technology, ensuring consistency, high durability, and uniform tray design in every product," he notes. "Extruding our own raw sheets for tray production on a new modern high-tech co-extrusion line gives us huge advantages, as we can tailor the properties of the tray in any manner we wish. Other suppliers on the market have to buy standard sheet products with predefined properties. This enables us to deliver a custom-made, high-quality, and long-lasting product for a competitive price."

The company also utilizes recycled plastic to further enhance sustainability. "We have a strong focus on circular economy principles. By incorporating recycled materials, we reduce plastic waste while maintaining the strength and quality of our trays. We reuse all production waste from both extrusion and vacuum-forming processes. This is without compromising the unique performance and very high-quality requirements of the trays. "

Focusing on their market in the U.S. and Canada, Flemming notes they already have a production facility in Sycamore, Ill. "We have vacuum forming technology there giving the vital business option for supporting the North American market in the best possible way. Currently, we do have sufficient capacity to support the demand over there, but we would always be willing to invest in production expansion if the market development would support this."

Sustainability through efficient irrigation
"Sustainability is a big focus for us," he emphasizes. "Our use of Ebb & Flow systems not only optimizes water and nutrient delivery but also significantly reduces waste. By recycling nutrient solutions and minimizing water usage, we ensure efficient resource management without compromising plant health."

Ebb & Flow systems, also known as flood and drain hydroponics, provide plants with periodic access to water and nutrients while promoting oxygenation of the roots. "This method enhances plant growth while preventing waterlogging and nutrient runoff. Growers today are looking for solutions that align with sustainable practices. With controlled irrigation cycles and minimal environmental impact, Ebb & Flow technology is an effective way to support both productivity and sustainability," he adds.

Expanding their reach
Staal & Plast already has a strong presence in Europe but is continuously expanding its reach. "We see increasing demand from growers worldwide, particularly in regions where sustainability and efficiency are becoming top priorities," he says. The company's trays are used in various climate conditions, demonstrating their versatility and adaptability.

Flemming envisions continued growth and innovation. "Our goal is to keep developing solutions that help growers maximize productivity while minimizing environmental impact. Whether it's through better materials or enhanced tray designs, we will continue to push the boundaries of what's possible in horticultural production."