About Palm Plastics
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The story of Palm Plastics is as much about innovation in product manufacturing as it is the story of a simple philosophy that guides the company’s success: continuously make improvements, however small they are, and the business will transform to meet the needs of the market.
Palm Tooling was founded by tool maker, Jack Sullivan, in the 1960s as a specialist toolmaking and moulding business. Looking to sell the business in the late 80s, neither Jack nor the new owner, Robert Wilson, could have foretold the recession to come would put a massive strain on investment in Australia. After many years of hard work and maintaining a focus on the importance of sustainability throughout the business, Palm Plastics is almost unrecognisable today. Technologically advanced machinery and processes place the company at the forefront of innovation and design globally.
Robert Wilson drew on experiences working for large consumer goods marketers as well as his background in engineering when looking for a business. He recognised the potential of Palm Plastics to evolve as a company that could manufacture and market consumer goods. With experience in sales and marketing, Robert recognised an opportunity to use his broad skills to manufacture and market plastic drinkware.
Robert’s past experiences have instilled in him a customer-centric attitude that demands the end-user’s needs are addressed in every product category, and each product designed and marketed. Fit for purpose design is a mandate of all product research and development. He knew that a customer-focused company wouldn’t happen without a workforce that was motivated. Respect and trust underpin the loyalty and commitment of staff at Palm Plastics. All employees are valued equally within the business, and decisions are made in concert with those directly affected. As a result, the staff at Palm Plastics place a high value on their role within the company and the products are of an extremely high quality, whilst being cost competitive with imports from Asia.
Despite high interest rates and a crippling recession, Palm Plastics grew in the early 1990s. During the first five years of the decade, the principles that guide the business were formed: drive the costs down, cut out the middle man and constantly invest in the business. Continual improvements were made to machinery, processes, training and product development. By 1995, Palm Plastics was manufacturing and marketing a stackable tumbler, which is still in production today and sold at Target stores nationally. A wine glass and champagne flute followed, as well as plates and bowls. Today, there are six lines of more than 30 items marketed under the Palm Unbreakable umbrella, including Palm Unbreakable Alfresco, Palm Unbreakable Party, Palm Unbreakable Boating, Palm Unbreakable Camping, Palm Unbreakable Poolside and Palm Unbreakable plates and bowls.
By 2002, Palm Plastics glassware customers included Myer, Barbeques Galore, House and stores in the United States. Palm Plastics drinkware held a 20% share of the plastic drinkware market domestically. However, an increase in the popularity of cheap imports squeezed share down to the single digits. Market share has only recently begun to recover with innovative products targeted at niche consumer segments and an expanded range for mass market retail and end-use. The long-term strategy is to eventually become the safe drinkware brand of choice in Australia. This ambitious goal will require a breadth of product that meets the needs of consumers from both a style and practical perspective. Research is currently underway to determine how consumers are most likely to use unbreakable glasses and tableware in the coming decade as well as preferences in materials, colours and designs.
The product excellence achieved in the automotive sector directly impacts the manufacture of drinkware; the Palm Unbreakable line is unique in the market in not only being made in Australia, but having a seamless glass and features such as a non-slip base and stackability. In 2004, Palm Plastics used computer controlled Battenfeld injection moulding machinery from Austria to produce the first two-shot injection moulding plastic glasses in Australia. Using robotics and computerisation, the Battenfeld two-shot moulding machines can produce specialised functional and decorative plastics on a very short turnaround cycle. Today, Palm Plastics is not only a leader in the design and production of high quality polycarbonate drinkware, but continues to supply high precision automotive components found in Toyota, Ford, GM, Porsche, Volvo trucks and Hyundai vehicles.
A heavy investment in software was also made in 2004 with the introduction of a SAP accounting platform which today manages a paperless office for the manufacturing, accounting and information needs of the business. Automation of the Palm Plastics factory has increased quality output as well as minimising human resources.
Managing Director, Robert Wilson, a keen sailor, was inspired to create drink ware for the outdoor enthusiast.
By 2009, the two-shot moulding process and an exhaustive two-year research and design cycle contributed to the introduction of the Palm Unbreakable Boating and Palm Unbreakable Camping ranges. Unable to find an unbreakable glass specifically for marine use, Robert designed a glass that featured a non-slip base, could easily be stacked and stored, yet satisfied a sopphisticated design aesthetic. Both the Boating and Camping ranges feature a non-slip base and the Palm Unbreakable Camping range glows in the dark – a first for high quality polycarbonate drinkware. The Palm Unbreakable Boating range was launched at METS Amsterdam in November, 2009 and is now available throughout Europe and South Africa. The range was launched in Australia at the Sanctuary Cove International Boat Show in May, 2010 and is available nationally through Bargain Boat Bits stores and specialty boating retailers.
In 1994, Palm Plastics invested in the Mattec on-line machine monitoring and quality control system. Mattec gives a precise view of job schedules and machine performance, assessing changes that affect quality and output, which not only save time and cost but forces continuous improvement. In 2010, a further investment was made in Mattec to incorporate new and enhanced features.
Ongoing investment in the upgrading of equipment and replacement with newer and better machines and processes will continue to drive costs down and increase quality. The improved performance of the factory continues to define the success of Palm Plastics through its third decade under Robert Wilson’s leadership. A heavy emphasis on technology and research ensures that the factory and office use state-of-the-art software and machinery to produce auto parts and fine quality plastic drinkware.
In 2010 Palm Unbreakable will launch a line of plastic glassware for entertainment venues in response to dangers associated with glassing attacks, whilst Palm Plastics will commence research and development into new materials that address the changing requirements of consumers. The results will be seen in products released in 2011.
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