Structural foam molding is a process in which we use similar thermoplastics but you use blowing agents and you use colorants, and the blowing agents allow you to expand the material into the mold at a much lower pressure than you would on a high injection pressure system. What that does that gives you very good structural strength, it gives you the ability to save between 15-20% of your thermoplastic materials, it gives you the ability to make larger parts of that structural condition that you may not be able to do within a high pressure injection molding process.
The summer issue of Manufacturing Today highlights DeKALB Molded Plastics’ commitment to strategy and investments which support not only the manufacturing process but also employees.
An excerpt of the article:
Founded in 1979, DeKalb Molded Plastics has spent more than 34 years building its reputation in the structural foam industry. A custom structural foam molder, DeKalb specializes in structural foam injection molding and gas assist molding, and large, multi-nozzle plastic products.
DeKalb was one of the first ISO 9002-certified structural plastics molders in the United States. Among the company’s services are in-house post mold painting; plastic decorating capabilities; kitting and assembly requirements for programs for single standalone products; or complex, multicomponent, multi-operation programs.
We basically stay within the range of high density polyethylene to engineering structural plastics. If we go into the high temperature stuff where you’re going to need a oil heater, something beyond that 700-800 degree melt range, really, if the tool needs to be above the boiling temperature of water, and then we don’t play in that zone. In that area, in the three-sixteenths to quarter to three-eighths inch part thickness, four pounds to 150 pounds, that’s kind of our boundaries.
Butler, IN – Structural foam molder, DeKALB Molded Plastics was recognized as the 2012 Processor of the Year finalist at the annual PlasticsNews Executive forum on March 6, 2013. DeKALB was nominated for this prestigious award by suppliers Kibbechem, FGL Precision Works, Plastic Solutions; customer Trinity and CPA Baden, Gage and Schroeder. The criteria process includes a comprehensive view in seven categories: financial performance, quality, customer relations, employee relations, environmental performance, industry/public service and technological innovation.
DeKALB was honored with a second award, the PlasticsNews Excellence Award for Employee Relations. The positive attributes at DeKALB Molded Plastics not only recognize excellent cash and inventory management but a strong commitment to the employees. President, Rick Walters supports the successful wellness program promoted by Human Resource Manager, Kassy Davis. In addition, Walters honors each employee on their anniversary by sharing a breakfast, lunch or dinner. A tremendous advocate to the community, each employee participates in a charitable activity that represents their passion whether it’s Big Brothers/Big Sisters, United Way, DeKALB Humane Society, or local schools to encourage manufacturing.
DeKALB is a premier molder of large structural foam parts, employing 130 people at its 80,000 sq. ft. headquarters in Butler, IN. The main market focus for the company is medical cabinetry, specialty material handling, safety products and lawn & garden.
We do not design custom plastic molding from scratch. We are a custom molder. DeKalb Molded Plastics takes designs that other people have to create the product. Sometimes that has been a napkin that may even have had a beer or coffee stain on that napkin and start to work with that so we can estimate the job. We can get other people involved, like actual design firms, and help move this idea to a product in hand. DeKalb is not set up to be plastic product designers for product molders.
AKRON, OHIO (Jan. 7, 4:20 p.m. ET) — Three custom molders — injection molders Hoffer Plastics Corp. and Rodon Group LLC and DeKalb Molded Plastics Co., which does both structural foam and injection — are the finalists for Plastics News’ Processor of the Year Award.
A team of judges from the PN editorial department in Akron picked the finalists.
There are many misconceptions about what custom foam molding means and the advantages to using it. Listen to DeKalb Molded Plastics as they describe what it means to have custom foam molded plastics and why someone might want a foam molded part.
On June 2, 2012, DeKALB Molded Plastics was awarded the “Employer Above and Beyond” honor for their continued support of employees who serve in the Guard. DeKALB employee, Skylar Jacquay submitted the nomination and is pictured in the photo.
Nominated by: Skylar Jacquay (holding plaque with President of DeKALB, Rick Walters) Event Date: June 2, 2012
Indianapolis, IN – DeKALB Molded Plastics of Butler, IN was one of forty-three companies from around the state to be honored at the fourth annual Indiana Companies to Watch. President, Rick Walters received the award at the celebration banquet held on Thursday, August 25, 2011.
The award highlights second-stage companies (defined as companies that have grown past the startup stage but have not grown to maturity) and their contributions to creating a stable US economy. The focus not only signifies steady growth, but job creation and innovation. DeKALB employed 55 teammates in 2010 and 91 is expected by the end of 2011. The application process is rigorous, including a holistic balance of employee culture, community involvement and commitment to technology in addition to stable revenues. DeKALB recently was recognized as the 2010 PlasticsNews Excellence Award winner for similar features.
Companies to Watch is intended to seek out businesses from a wide range of industries representing all regions of the state. DeKALB Molded Plastics was one of nine manufacturers, however the only manufacturer of plastics, more specifically structural foam injection molding. Additional business categories include information technology, educational services, healthcare, etc. Awardees are selected by a panel of judges summoned by the Indiana Economic Development Corporation, Purdue University and the Edward Lowe Foundation.
DeKALB Molded Plastics acknowledges the devotion to lean continuous improvements in the development of a strategic plan that has driven the company through the recession and for the years to come as well as marketing efforts that establish DeKALB as a unique structural foam manufacturer.