During the past five years, demand for plastic products has increased as much as the demand for Internet services. Well, maybe not quite that much.

But plastic is being used in once unheard of applications, and now there's even talk of plastic beer bottles and truly biodegradable plastic.

"There are many applications, and technology is always evolving,” said Maureen Healey, senior director of state government relations for the Society of the Plastics Industry in Washington, D.C. "Plastic is economical to make, and it's becoming the product of choice.”

Not only is research presenting new opportunities for old products, but new products themselves are also emerging.

In January, Cargill Dow Polymers, a joint venture between Cargill and Dow Chemical Co., announced plans to build a $300 million facility in Blair, Neb., to produce polylactide polymers.

Applications for the plastic made from natural plant sugars could include blow-molded bottles, clothes, packaging, cups and other everyday products.

"What's exciting about this technology is its multitude of applications and the fact that plastics can come from renewable resources such as corn,” said William S. Stavropoulous, president and CEO of Dow Chemical.

Products made from the polymers would have the integrity of other plastic products, but would degrade in landfills like other plant-based products.

Agricultural shift

As in Nebraska, several states known worldwide for their agricultural-based economies are strategically building the plastics industry in their communities.

In Iowa, plastics is a $3 billion-a-year industry, employing more than 18,000 people, according to figures from the state of Iowa.

To keep up with the growing demand for skilled workers in the plastics industry, the Iowa Plastics Industry Consortium launched the Iowa Mold Builders Apprenticeship (IMBA).

Through a fiber-optic Iowa Communications Network (ICN), employees in training can link up with the best instructors from Iowa's industry and community colleges. Students attend classes twice a week at 12 ICN-connected sites.

Fully interactive video communication allows apprentices to participate in discussions and ask questions. Apprentices must complete 144 hours of instruction and 2,000 hours of hands-on training annually during the four-year program.

Iowans have been quite responsive to the industry's demands for qualified workers, said Terry Kieffer, president of Plastics Unlimited in Preston, Iowa.

"The Plastics Consortium, the apprenticeship program, the ICN - it all helps to give us the people we need,” he said.

In 1993, Kieffer and his brother, Gene, opened their thermo-forming operation in a machine shop on the family's farm. In 1997, the partners moved into a 15,000 square foot building, and the brothers are in the planning stage of another expansion.

"Iowa is still No. 1 in raising corn and beans in the world. But when it comes to workers, they know how to do more than produce agricultural products,” said Kieffer. "You give them a job and give them the right tools, and they can do anything. They self manage. They are thinking people. You put them on the production floor, and they will prove it to you there.”

Plastics goes high-tech

Wisconsin is another state that has targeted the plastics industry for growth with specialized training for the plastics industry. The University of Wisconsin's three locations offer students the opportunity to learn new skills using the latest technology.

The Northwest Wisconsin Manufacturing Outreach Center at the University of Wisconsin-Stout campus, in Menomonie, gives companies access to the school's labs, faculty and technical equipment. Business and research services are also available.

The Center for Plastics Processing Technology at the UW-Platteville campus features a training center and technical services.

Companies may also use its high-power laser, blow former, molecule orientation analyzer, 75-ton compression molder and 75-ton compression thermo-former. At the UW-Madison campus, companies can tap the scientific and technical resources of one of the nation's leading research universities.

Wisconsin's technical colleges also provide customized training services that include CAD, CAM, electronics, machine tool, mold and parts design, plastics properties and testing and geometric testing.

"One thing that is important to us is training,” said Glen Yurjevich, president and CEO of Creative Forming, the parent company of Alphatec Extrusion. "We've been able to train our people, keep them here without a high turnover rate and promote from within.”

In November 1999, Creative Forming invested $2 million to add 50,000 square feet to its 108,000 square foot facility in Ripon, Wis. Over the next three years, the company will invest another $4.5 million. From the state, Creative Forming received $75,000 in Customized Labor Training grants.

"Wisconsin is very active in the plastics industry, and there are some grass roots programs for manufacturers,” said Yurjevich. "Plastics companies get together with schools to put together programs that help recruit and train prospective employees.

"The system encourages people to finish school and take certain courses of study to enter the plastics industry. It ensures that we have well-educated, bright people to move into our organization.”

As valuable as the training programs may be, however, you have to start with good workers.

"We have a stable, educated work force with a great work ethic,” said Yurjevich. "In a small town, where people work becomes very important to them, so we maintain a family atmosphere where they are willing to come in and put forth the extra effort.”

Ohio is another hotbed for plastics companies. Numerous plastics companies expanded in the Akron area in the last year.

In Aurora, in Portage County, Branston Co. announced a $24 million expansion to its plastic injection molding plant.

In nearby Garrettsville, Michael Disken Enterprises underwent a $500,000 expansion to its injection molding facility.

Getting the word out

The issue of workers (trained or otherwise) is a priority everywhere, admitted industry experts. As the states promote their economic benefits to companies, they must also promote their lifestyle benefits to workers.

"In agricultural states they are having a hard time keeping workers in the state,” said Healey. "The population is aging, and people graduating from college are moving out. They need to offer an appealing set of conditions.

"For example, legislation that will require a minimum wage higher than the national average and lifestyle benefits - health care, child care, low cost of housing - would entice businesses and workers to come into a state.”

Bonnie Limbach, vice-president of public affairs at SPI, said educating the public of the plastics industry's potential is key.

"There is a lack of understanding in the work force that there are very good jobs in the manufacturing industry - it's not just line work,” said Limbach. "There is a lot of computer work involved and a lot of decision making involved. Our challenge is to get the word out.”