All posts by DeKALB Molded Plastics

DeKALB Celebrates 20 Years Under Rodgers and Walters’ Leadership

DeKALB Molded Plastics is thrilled to be commemorating 20 years of local ownership under Jeff Rodgers and Rick Walters, and 38 years overall of successful business, relationships, and service to the community.

Founded in 1978, DeKALB Molded Plastics is a custom structural foam molder specializing in large, multi-nozzle plastic products. DeKALB was one of the first ISO 9002 certified (currently 9001:2015) structural plastics molders in the US. In 1997, Jeff Rodgers and Rick Walters purchased DeKALB from their parent company, JSJ Corporation. While the two serve as owners, Walters is also the President and CEO.

“We couldn’t be happier to be celebrating 20 incrediblely productive years with our team members and the community,” says Walters. “From the start, DeKALB has aimed to be a one-stop shop for your plastic and assembly requirements, and I think we’ve achieved that status and then some.”

One of DeKALB’s biggest differentiators under the leadership of Rodgers and Walters has been their commitment to the local community of Butler, Indiana.

“DeKALB is really engaged with our community because you have to make where you live a really good place,” says Walters. “That’s a combination of work, home, and anything else that’s around you. We work hard to make sure we put our time and our talents back into our community. A lot of people will help financially but really it’s about the time. It’s about getting out there, making contributions, and engaging – that’s what brings the win.”

The entire DeKALB organization will be hosting a party on Sunday, September 10, 2017, to officially celebrate their 20 years of outstanding leadership.

Level Three AchieveWELL

DeKALB is proud to be recognized as a Three Star AchieveWELL organization.

AchieveWell-BannerLevel3AchieveWELL is an award winning, proven strategic process, developed by the Wellness Council of Indiana, which provides a road map to the destination of a good workplace while recognizing excellence in the field of health promotion. AchieveWELL works with companies and organizations by providing tools and coaching help to create a more consistent work place.

To become a Three Star AchieveWELL organization, DeKALB made several strategic changes to help promote wellness throughout the organization.  Implementing wellness was well received amongst our leadership team and become apparent by their participation and encouragement in companywide challenges, up to and including the president/CEO.  Challenges were a great to introduce wellness into our culture and helped build moral and camaraderie amongst the employees.  And, there’s nothing wrong with a little friendly competition.

In addition to challenges, we also introduced healthier vending machine options.  Healthier items are encouraged but we don’t take away people’s choices by eliminating completely.  Healthier selections are available at a slightly lower cost which is yet another encouragement.  Improving our overall communication and education opportunities was key for our employees to be successful in their wellness journey.  Provide the information and opportunity, the rest is supported by their strategic focus to live healthier.

Wellness is ingrained in both DeKALB’s mission and vision. We are not satisfied with a Three Star AcheiveWELL certification, and DeKALB is committed to becoming Four Star certified in 2017 and Five Star in 2018.

MAPP Innovation Award

DeKALB also received the 2016 MAPP Innovation Award. Capturing over 120 votes for the water manifold entry, voted on by plastics professionals in the United States, DeKALB won the award by a landslide.

Along with the title the award came with a monetary to award our employees for a job well done, free entries to a future plant tour event, special recognition during the 2016 MAPP Benchmarking Conference, and recognition in the national industry publication Plastics Business.

Dedication to Customers and Community Drives DeKALB’s Culture

Our mission at DeKALB Molded Plastics is simple: To provide customer satisfaction that is unsurpassed in the structural plastics industry. This starts with our internal strategies. All of our employees are instilled with this mission, always providing the best possible service for our customers and embracing our community, whether it be in the office or off the clock.

We understand that our employees are the backbone of DeKALB, hence our industry Excellence Award for Employee Relations. We’re proud of the devotion towards a healthy company culture which creates dedicated and passionate employees, which is key to a happy customer. From company golf outings to DeKALB cook outs, there are numerous events held to keep our employees engaged in the culture that surrounds us. Our employees even enjoy free Fitbits to help track and monitor their health.

DeKALB Molded Plastics wouldn’t be the company it is today without the support of the community. That’s why the team at DeKALB holds a variety of events giving back to the town of Butler. Every year we host the Annual Recognition Dinner, paying homage to the Butler Police, Fire, and EMS departments, giving each member a small token of our appreciation as well as a donation to each department. While we consistently donate to organizations recommended to us by our employees, one of our favorite charitable contributions is to the local Butler school system. DeKALB is also a proud corporate sponsor of the Big Brothers Big Sisters program. In recent years, we have participated in the United Way Day of Caring, a volunteer opportunity to lend a helping hand to local nonprofits and give back to the great community that embraces our company.

At DeKALB, it’s very important that all of our employees are on the same page. Synergy is promoted through communication. This is what builds our culture at DeKALB. With a combination of unsurpassed customer satisfaction, community involvement, and employee recognition, we are able to create an enjoyable work place and maintain our strong reputation. Giving back not only helps the community and our team members, it helps DeKALB become a better company for our customers.

DeKALB Molded Plastics President Rick Walters Appointed CEO

Butler, IN – DeKALB Molded Plastics’ incumbent president, Rick Walters, added Chief Executive Officer to his title effective March 1, 2016. The move comes from DeKALB owner Jeff Rodgers, who has long planned on relinquishing more responsibility to Walters.

“This is a decision that should have been made a couple of years ago,” said Rodgers. “Rick has done an admiral job of managing DeKALB Molded Plastics, and this promotion signifies my continued confidence in his skills.”

Having worked at DeKALB his entire career, Rick Walters has an established network of professional partners and friends. His technical knowledge and understanding of the importance of team help support employees throughout all areas of the organization.

With new authority, Walters seeks continued success for DeKALB. The first of his main priorities is to advance DeKALB’s development plan, building the next generation of leaders and maintaining status as a premier structural plastics molder. He also strives to capture new business opportunities by promoting DeKALB’s value-added capabilities and the structural plastics process.

“DeKALB exists because of the great employees who understand how to be successful and know how to bring real value to our customers. I have always enjoyed being a part of our group and am blessed to be their leader,” said Walters. “I really care about each of them. Being CEO enhances my opportunity to promote individual creativity and help tell their story. I’ll cheer and channel their ideas for our team successes, and our celebrations will be intense!”

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About DeKALB Molded Plastics:

Founded in 1978, DeKALB Molded Plastics is a custom structural foam molder specializing in large, multi-nozzle plastic products. As one of the first ISO 9002, currently 9001:2008, certified structural plastics molders in the US, DeKALB offers a variety of value-added operations, including in-house post mold painting, plastic decorating capabilities, kitting, and assembly requirements for programs ranging from single stand-alone products to complex, multi-component, multi-operation programs. For more information on DeKALB Molded Plastics, please call 260-868-2105 or visit www.dekalbplastics.com.

Media Contact:

Teresa Schell
President | Vive, LLC
414.292.1291
tschell@vive4mfg.com

Custom Molded Plastics

Custom molded plastics are the heart and soul of DeKALB Molded Plastics. DeKALB is one of the first ISO 9002 certified structural plastics molders in the United States. With presses ranging in tonnage from 300 to 750 tons and over 30 years of experience in the structural foam industry, there isn’t a project the team at DeKALB can’t tackle with precision and quality.

DeKALB specializes in large, multi-nozzle plastic products while offering in-house painting, decorating, kitting, and assembly capabilities. Deliverables range from single stand-alone products to complex, multi-component, multi-operation programs.

DeKALB’s product offerings are diverse and focused, including:

In the Specialty Material Handling market, DeKALB produces rigid plastic pallets, folding transport boxes (for bulk and liquid products), and other applications that protect valuable and perishable household items (food, textiles, and medical components). In the Medical market, DeKALB produces a variety of intricate products, ranging from ultrasound and densitometers to MRI helmets and medical beds. Their main concentration is to produce products that contain, support, and protect medical equipment. DeKALB’s Safety Enclosures and Devices focus on protecting and preventing individuals and property from harm with the creation of barriers, stands, and guardrail blocks.

DeKALB has perfected two main plastic manufacturing processes: structural foam and gas assist. Structural foam molding (Fig. 1) is a process in which foamed plastic flows through the mold, surface cells explode, and a solid skin forms against the walls of the mold. Meanwhile, the core of the newly created part cools to a cellular structure. The end result is a part which is up to 20% lighter and three to four times more rigid and durable than solid plastics. This innovation can replace a myriad of materials, including wood, metal, concrete, and fiber glass.

structural-foam-molding-process

The gas assist molding process (Fig. 2) utilizes nitrogen gas that is injected into the polymer melt as soon as the resin is injected into the mold. The nitrogen displaces the polymer in thicker areas, hollowing out the part and making it significantly lighter. This is a low-pressure injection method that prevents sink marks and the ‘characteristic swirl’ that occurs during structural foam processing. In addition, cycle time is reduced due to faster cooling, equating to a lower cost component.

gas-assist-injection-molding-process

Beyond competitive pricing, DeKALB prides itself on superior customer service, warehousing capabilities, and on-time deliveries. One glance at the Client Testimonials page on dekalbplastics.com tells the story of DeKALB’s consistency, quality, responsiveness, competitive pricing, and technical support.

Custom Foam Molding: Process, Solution, Success

It’s a Thorough Process:

At DeKALB Molded Plastics, our team excels at providing comprehensive custom foam molding solutions for (structural plastic) molded products.  When added value is required on a part such as painting, kitting or fabrication, DeKALB is your single source for custom foam molding solutions. We provide design assistance, will engineer the optimum moldability of a part, and manufacture custom-molded structural foam to print specifications. And we do it quickly and cost-effectively.

  • Engineering support with MoldFlow
  • Design Assistance
  • Complete Project Management
  • Strong Expertise and Internal Resources

It’s a Complete Solution:

DeKALB has built a reputation around high quality standards for structural foam materials. We are committed to providing innovative ideas to the part development process, but more importantly, building long-term relationships through superior customer service. To maintain a high level of service and quality, our team meets each morning to review the progress of every project and net out daily goals. The overall goal is to pass our knowledge and expertise in structural foam materials directly to our customers and set the bar high for long-term success.

It’s a Group Success:

DeKALB offers superior customer service as this is critical to the success of our business. The company is committed to meeting customer requirements for delivery, quality, responsiveness, pricing and technical support. That is how DeKALB aims to become our customers’ single source for plastic and assembly needs. We’re proud of the fact that the majority of our customers have been with us for many years.

What are some plastic assembly requirements that DeKalb Plastics has performed?

Transcript:

We’ve had everything from whether it’s just bolting another piece on to cutting their part and hot plate welding a cover piece back onto a sheet onto it, to liner assembly. We have particular one that it’s a pickup truck toolbox and parts come out. We have some little pieces that are molded elsewhere, hardware is all right there. It comes out and runs through an assembly, goes into the box with the instructions with the mounting hardware, gets the in customers barcode label on the corner of the box. If you go to the store, nobody else has touched it. The way it went away from our machine is exactly the way the customer gets it. We provide that level of solution if that’s what’s needed.

What is DeKALB’s plastics manufacturing size capabilities?

Transcript:

Many people come to DeKALB Molded Plastics because we can make large parts. Large parts, structural foam, gas assist, very, very well. We can make products up to 150 pounds at our facility, but really it’s the type of process that we can do. Because they are so large, we can be cost effective with the rate reduction, and again, providing the characteristics that you need for your large part. We present warp, creep, all the building stresses that come with an injection molded part go away with structural foam.