Category Archives: Custom Molding

The Benefit of Using Recycled Resins   

| Posted in Custom Molding, Injection Molded Plastics, Plastics Manufacturing, Quality, Recycling | Posted by

As plastic products become more common throughout the world, we increasingly become more concerned about the effects it has on the environment. Many people call for waste control solutions, while others call for restrictions, reduction, and a push for strong recycling programs. Manufacturers are able to recycle plastic by shredding and reducing plastic products into pellets that can then be re-processed. These pellets are then re-molded into another useful product and provide value once again.

At DeKALB, recycling is exactly what we do – we process 100% recycled resins in many of our structural foam molded products to make sure old materials get a second life. Re-using plastic waste helps reduce our carbon footprint by keeping plastics out of landfills and creating products that can be used for another generation.

Cost Savings Opportunities

Using recycled resins can result in a significant price reduction in many products. Resin savings can be as much as 50% more compared to virgin resins, while some products can be made with up to 100% recycled material. DeKALB encourages our clients to consider the benefits of integrating recycled resins into their products when we first sit down to talk with them. We encourage the use of sustainable manufacturing solutions as it benefits both the customer and the environment.

The resin market can often fluctuate in price and product availability, especially during times of uncertainty. Many molding companies will lean more heavily on recycled materials when virgin resin costs increase dramatically or are not available. DeKALB consistently uses recycled resins to reduce customers’ daily costs, not just as an exception during unstable market times.

Where Our Recycled Resins Come From

DeKALB processes millions of pounds of recycled resin material each year in our structural foam molded products. Most recycled resins in DeKALB’s products are polyethylene (PE) and polypropylene (PP), although additional thermoplastic resins are recycled as well.

DeKALB purchases much of its recycled resin from recyclers or reclaimers who process the resins from post-consumer and post-industrial materials. These companies will process scraped products by sorting, cleaning, and grinding the material into pellets ready for molding new products.

DeKALB also directs scrap materials from our operation to be recycled rather than be sent to a landfill.  No matter if the recycled pellets come from home, the office, or a manufacturing facility—everyone benefits when plastics are re-used.

Choosing the Right Resin

With DeKALB’s wide selection of thermoplastics, we have the right material to suit the needs of your product’s specifications. Both Commodity and Engineered grade resins can be molded using recycled resins, and additives can also enhance product performance, strength, impact, or UV protection. Some resins and additives include:

  • High-Density Polyethylene (HDPE)
  • Polypropylene (PP)
  • Polystyrene (PS)
  • Acrylonitrile Butadiene Styrene (ABS)
  • Polycarbonate (PC)
  • Nylon (PA)
  • Glass Fiber or Beads
  • UV Protection
  • Fillers / Reinforcements
  • Impact Modifiers
  • Rubber

DeKALB’s plastic parts, fillers, and reinforcements are guaranteed to make a strong and long-lasting manufactured product. We can mold almost any recycled thermoplastic resin, which helps keep more debris out of landfills and get us one step closer to a cleaner future.

Benefits of Using Recycled Resin

We help companies save money, and surpass the uncertainty in price changes and resin shortages, by utilizing recycled resin instead of virgin resin for plastic manufactured products.

Some of the main benefits DeKALB can offer our customers with recycled materials are:

  • Lower cost
  • Long life expectancy
  • Increased strength and durability
  • Lower cost for molding
  • Excellent substitute for other materials

Leaving a Greener Footprint

Pushing for cost savings and sustainable alternatives is what makes DeKALB stand out from the competition. Our thermoplastics are manufactured with 100% recycled material, and some resins can even be recycled multiple times, all depending on the demand of the product and its purpose. The green advantage is taking recycled material while considering quality specs and ensuring they still pass the standards of new virgin resin.

Maintaining excellence with reclaimed products helps clear old post-consumer and post-industrial parts from making their way into landfills. DeKALB has recycled over 20 million pounds of recycled product in a single year, as stated by the CEO, Rick Walters. That recycled product has helped keep our planet clean as well as help consumers with significant cost savings in the long run. Every client we work with drives our green initiative to help them find quality parts for half the cost. Recycling is simply the right thing to do!

The DeKALB Difference

For over 40 years, DeKALB Molded Plastics has earned its reputation in the plastics industry for best-in-class quality products and services. We are dedicated to providing the best solutions and customer care that make a difference. We are an ISO 001:2015 certified full-service provider offering customization and value-added options, from structural foam molding to gas assist molding services. Our highly skilled team will work alongside our clients to produce the best quality products every time.

Want to know how DeKALB is paving the way for a more sustainable future? Contact us today to learn more.  

Value Added Services News

| Posted in Custom Mold Plastic Products, Custom Molding, Gas Assist Molding, Structural Foam Molding | Posted by

At DeKALB we offer an array of value added services to complement your molded plastics needs. We pride ourselves on the ability to provide our customers a wide range of services.

Our team has the ability to utilize existing products and fabricate them to create customized components. Our capabilities include cutting-straight and angles, assembly, bonding, welding, inserting, routering and drilling. At DeKALB, we also providing painting services, utilizing both solvent and water based painting systems with complete masking capabilities. We provide numerous painting systems, including: acrylic, water, and urethane based, as well as multiple masking, color, and textures.

DeKALB provides complete plastic and assembly solutions, from simple sub-assemblies to complete assemblies that are packed and shipped right to your customers’ door. We have the capabilities for sonic and induction welding, enclosure and component assembly, bonding and emabonding. We also have the capability of specialty packaging, bulk packaging, and consumer-ready packaging with custom labels and decals.

Our numerous years of experience in the manufacturing industry guarantees the highest quality products at the right price. We keep track of these products with our inventory management systems. These solutions reduce your work load and increase the efficiency of your supply chain.

At DeKALB, we are constantly looking for new ways to make operations for our customers more efficient.

Custom Molded Plastics

| Posted in Custom Mold Plastic Products, Custom Molding, Gas Assist Molding, Structural Foam Molding | Posted by

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

| Posted in Custom Mold Plastic Products, Custom Molding, Structural Plastics | Posted by

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.

Dynamic Opportunities in Focused Markets

| Posted in Custom Mold Plastic Products, Custom Molding, Plastics Manufacturing, Safety Device Structural Plastics | Posted by

DeKALB Molded Plastics made a strategic decision in 2014 to focus on multiple market segments. Our goal is to expand our market focus to offer quality structural plastics to industries that promote better quality of life. Our main three segments are Medical Enclosures, Safety Devices, and Special Material Handling. Each brings their own unique value to DeKALB and provides the opportunity to display our capabilities in different ways.

Market Segment

Medical Enclosures – Typically are molded with engineered resins with value added operations such as inserting, painting, silk screening, and/or kitting. Volumes may vary in quantity. This segment meets our core competencies both from a molding and finishing perspective.

Safety Devices – Safety is the number one focus within DeKALB and anytime we can provide product within that industry, we consider it a win. In addition, we currently have a customer using 100% recycled material in their product. Not only are we providing a safety product but also focusing on being green.

Specialty Material Handling – This segment goes well beyond pallets. Any product used to store or transfer could be placed in this market segment. The structural foam process provides product that is light weight yet durable in strength. In addition, not only are virgin materials utilized in these products but also regrinds to save on costs.

Our development processes are continually improved and perfected to fit the needs of specific industries. As we continue to expand our offerings and capabilities, we have researched other market segments, such as Recreational and Lawn/Garden. DeKALB is always looking for new opportunities and strives to offer the highest quality of products and service. While we focus on our deliberate market segments, each are carefully evaluated to ensure the needs are within our capabilities and align well with DeKALB’s overall growth strategy.

DeKALB Champions Seat Support Pallet

| Posted in Custom Molding, News, Structural Plastics | Posted by

“I would recommend working with DeKALB because of their ability to plan very well and not let any issues fall through the cracks.” Mitch Kujawa, Polyflex

The Challenge

Polyflex was in the market for a structural plastics company to produce the bases for a seat support pallet, as they did not have a large enough press to run the project. The seat support pallet was being produced for the end manufacturer, Magna, who supplies for Chrysler. The final purpose of the seat support pallet was for seat material handling, so that seats can be brought through the assembly line.

DeKALB was chosen due to their ability to design ribs and manage overall mold ability of the part. The project required four towers, which the team worked to fill properly with correct nozzle configurations. Attachment points and interfaces with the steal components were analyzed by the team to ensure proper functionality as they went from steal to plastic pallet.

DeKALB’s Solution

DeKALB partnered with a tool source to ensure the tool was molded properly and according to quality standards. Advanced Quality Planning (APQP) was utilized in the designing and tooling phases to ensure a successful outcome. Additionally, regular meetings with the tool source were managed by the DeKALB team to make sure Polyflex/Magna was comfortable with the process and all timelines were met.

Communicative Approach

The team at DeKALB started the project with a strong program management approach. They made certain to communicate any potential design concerns upfront; with a solution plan already in place. This strategy included all initial design meetings.

Once in the tool quoting phase, regular meetings were scheduled with Polyflex and DeKALB to identify any concerns and report progress. Polyflex was very communicative and comfortable with this process as the DeKALB team planned structured agendas in order to identify issues as well as provide solutions to solve them.

In addition to weekly meetings, team members were easy to reach by phone and email. They responded quickly with answers to any questions or concerns. Overall, the DeKALB team was very proactive and did a great job of displaying how any change would affect the overall timeline.

Successful Result

Everyone at DeKALB was very committed to the success of this project and the mold trial was realized without a hitch. Polyflex managed the buildup at their facility and then sent to Magna to complete the final review.

In the end, all parties were very pleased when the first run of the tool was realized and approved as qualified by a tool expert and production is set to begin in May 2014. Polyflex could not be more satisfied with the project management displayed by DeKALB and would recommend the team based on the positive outcome of the seal support pallet.

How can DeKALB help with plastic injection needs?

| Posted in Custom Mold Plastic Products, Custom Molding, Plastics Manufacturing | Posted by

Transcript: DeKALB Molded Plastics is a custom molder of injection plastic products. We specifically do structural foam, gas assist. You may have an idea and you’ll have a basic concept and we are able to produce the entire product for you. You bring us your idea and we’ll take it from concept to finish production. We will assist you with design. We will connect you with the tool shops. We will provide those services. We will launch your product for you, and then we will be your producer. You still will own the tool. It’ll be your product, but we will be your manufacturing arm.

What custom molded solutions can DeKalb Plastics deliver?

| Posted in Custom Molding, Plastics Manufacturing | Posted by

Transcript: We’ve had several things that customers have come to us and they have an issue. One in particular that the tank I spoke of earlier or the toilet in the basement, that particular tank, they were having trouble with leaks and stuff like that. After we were molding for a little bit, they came back and asked us what do you put in your plastic that’s different from the other guys. I don’t know what the guys put in, but we just put in what we said we were going to put it. Pay attention to quality and we understand that the general basics of the application so we know what’s our limit that we can do here and we’re not violating that. It’s about integrity.

What is Special Material Handling?

| Posted in Custom Molding, Plastics Manufacturing, Structural Plastics | Posted by

Transcription:  One of the target markets for DeKalb Molded Plastics is specialty material handling. We do pallets. We do containers. But really we do things that are specific to an application. It may be a metal product. It may be a medical product, but it has to be handled and protected really well and that’s what we do really, really well. A lot of people do pallets, a lot of people do the big containers, but we will specialize. Special totes, things protect and keep these things safe.

Can Dekalb create my custom molding product?

| Posted in Custom Molding | Posted by

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.