Safety – DeKALB Molded Plastics’ Top Priority

Safety truly is a feeling, and everyone can recall a time where they did not feel safe. This uncomfortable emotion usually brings one action to the forefront – leave as soon as possible.

At DeKALB Molded Plastics, safety is everything. When our employees come to work or when guests visit, we want them and their families to know that DeKALB is a safe place.

We believe from top to bottom at our company that safety requires everyone. When we feel safe, we are more productive and happier. When being safe, we maintain a sense of security for everyone who enters our building.

Why Workplace Safety Matters

While there will always be critical safety regulations for every business to follow, ensuring the safety of everyone takes work. In January 2021, Honeywell conducted a survey that found that 68% of workers do not feel completely safe in their buildings.

In a study conducted by Lockheed Martin, they developed a safety culture that resulted in employee productivity increasing by 24% and factory costs decreased by 20%.

Beyond safety being a basic human right, developing a safe work environment creates happier, more productive employees who are less accident-prone, decreasing downtime.

Making Workplace Safety Our Top Priority

In late 2019, while attending the annual Manufacturer's Association for Plastics Processors, Inc. (MAPP) Benchmarking Conference, DeKALB was struck by the powerful story shared by keynote speaker Kina Hart. Kina shared the horrific tragedy of how she lost her arm within an hour of the first day of her summer job at age 20. Kina’s living testament for safety reminded us about how we need to make safety personal.

Kina’s inspiring message empowered us to reflect on our thought process and reemphasize the importance of safety throughout our company. After completing our 2020 goal planning, our top priority was ensuring that we were fully committed to safety. The result of our planning was a zero-tolerance policy on accidents in the workplace. Outlined in our updated Safety Policy, DeKALB is dedicated to creating a safe work environment because we are unwilling to give up anyone’s safety.

“Our goal was to create an environment where people no longer felt like they were reprimanding someone if they ask them to put the safety glasses on,” said Doug Bonecutter, general manager at DeKALB Molded Plastics. “We wanted to create a sense of caring about others regarding safety to the point where I have to say something or I may regret it.”

How DeKALB Refocused Safety Efforts

Having a safety policy is just the start. The next step is to create a culture where everyone buys into it. While DeKALB Molded Plastics has always committed to safety, we saw an opportunity to encourage growth by having employees think about their personal safety and the safety of those around them at every opportunity.

We implemented several different tactics to make this happen:

  • Safety Tab on our Website: From our manufacturing floor to the website, safety is vitally important to us – which is why it is the first tab on our website. Our safety page includes our safety policy and our first safety video, which explains our zero-tolerance goal.
  • Revised our Coaching Philosophy – The DeKALB Way: To make safety the priority of everyone, we have empowered our employees to call out unsafe situations. Every leadership person at our facility can do a coaching event with any employee to talk about something they see them doing right or something they need to change related to safety. We created this philosophy not to call out mistakes but to ensure that all of our employees are safe.
  •  Instituting the Stop, Call, Wait System:
    • Stop – the person or activity that is going on unsafely.
    • Call – to have it fixed or get the proper PPE, etc.
    • Wait – before resuming, to ensure that the situation is safe or the PPE is on.

This system allows everyone on the floor to point out good things or give reminders related to safety. There are blue cards for employee-to-employee interaction - helpful for building a family culture that cares enough about each other to immediately take action to stop at-risk behavior or recognize safety leadership.

  • Ready to Respond: At DeKALB, we are thrilled that our entire company has bought into safety, which has extended well past following our guidelines. Currently, almost one-third of our employees are certified CPR and first aid first responders. Recently one of our employees on the floor stepped up and went through training to be a certified CPR and first aid teacher, allowing us to train additional personnel right at the plant as needed.
  • Weekly Safety Talks – Each week, every person in the facility attends a safety talk, led by the supervisor, where employees and departments who meet their safety contact goals are recognized. These meetings also provide the opportunity to reiterate the safety theme of the month. DeKALB also tracks overall safety contacts as a KPI and discusses them at these meetings.

In addition, we have revamped our safety committee and meet monthly. US Compliance partnered with DeKALB to help update all of our written programs, ensuring our training is complete along while helping to train someone at the facility to allow for them to be certified to lead instruction for new employees.

Overall, safety at DeKALB is an all-out effort by everyone every day. Safety not only requires you to look out for your safety, but by practicing safe work habits, you are also looking out for everyone around you.

"Our program has changed the mindset that safety is the responsibility of the company, to it being the responsibility of everyone," said Bonecutter.

Safety Recognized - The DeKALB Difference

In early 2021, MAPP awarded DeKALB Molded Plastics with their 2020 Safety Award, a significant reflection of the hard work that all of our employees have done to make DeKALB a safe environment for everyone.

“Every single person here is engaged in our safety effort, and our employees have embraced the safety contact process,” said Marcia Lee, Human Resources Manager at DeKALB Molded Plastics. “It is a point of pride in getting recognized for the good things that you are doing and the work that everyone is involved in to make sure that we are all safe.”

We are thrilled with the success of our refocused efforts and are quickly establishing a reputation for when you think about safety, think DeKALB Molded Plastics.

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Is Gas Assist Molding with DeKALB Right for You?

When you see a smooth-looking finish on an industrial panel or on the blades of an air turbine, there is a good chance gas assist molding was used to manufacture this product. Many products we use every day require a brighter, smoother finish that will help enhance its performance, and gas assist molding achieves that every time. Through this process, nitrogen gas hollows out thick wall sections in a molded product. Then by combining air pressure with heat, the process creates a strong, robust part with a perfectly smooth finish.

DeKALB Molded Plastics delivers aesthetically pleasing, high-quality products for your industry with the help of gas assist molding. There is no room for error in the work we do, which is why all our products made with gas assist molding are flawless and functional.

What is Gas Assist Molding?

Gas assist molding is a highly technical type of injection molding that reaches beyond traditional design capabilities and processing limitations. This type of injection molding produces large plastic parts with complex designs. DeKALB Molded Plastics manufactures products through gas assist injection molding that makes life a little better and safer.

The high-speed, low-pressure injection method that DeKALB Molded Plastics uses in production is a competitive advantage. We utilize Milacron LPIM-Structural Web and Bauer Gas Assist technologies in our gas assist molding processes.

How Gas Assist Molding Works

Like standard injection molding, the process begins when a molding machine injects a short shot of resin into the mold. Then, just as the name suggests, high-pressure nitrogen gas is injected into the melt stream following the resin injection to assist. The nitrogen displaces the resin in flow or gas channels within thicker sections of the molded product. The end product will be hollow and have thick wall sections without sink marks or the swirl appearance typically characteristic of structural foam.

The flow path of the nitrogen gas depends on the resin flow in the cavity. Resin flow is determined by the volume and viscosity of the resin, not the nitrogen gas injection. Most thermoplastic materials can be used in gas assist molding.

What is Necessary for Success

In gas assist molding, the mold design and construction must be done correctly by experienced engineering and design teams. It is vital to have a shot control on the injection-molding machine that is both repeatable and accurate. Furthermore, the precision of time and pressure is necessary for achieving desired results with this technology. DeKALB Molded Plastics takes away any stress connected to these factors as we have the premier technology, tooling, and expertise to get the job done right.

Benefits of Gas Assist Molding

With less plastic material needed to produce the part, because the hollow areas are created with nitrogen gas rather than resin, gas assist molding can be a greener solution. The process of gas assist often allows for the consolidation of multiple parts into one. The process reduces or eliminates any need for secondary assembly processes. Additionally, with less clamping force required and a reduced amount of components under stress, gas assist molding can produce higher volumes with less frequent mold maintenance or repairs.

Gas assist molding has many other benefits, including:

  • The product will be lightweight while still being strong and firm. The nitrogen gas can form hollowed-out areas within parts (such as steering wheels, handles, etc.).
  • Gas assist injection molding produces more aesthetically pleasing parts. There is a reduced risk of flaws, sink marks, and shrinking with this technology.
  • When compared to standard injection molding, gas assist reduces cooling and overall cycle time.
  • Gas assist injection molding is an easy way to convert existing large metal parts to plastic, providing a better quality alternative.

Is Gas Assist Molding Right for You?

There are numerous benefits to gas assist injection molding as an alternative to various molding disciplines, including injection molding, rotational molding, blow molding, SMC, BMC, and die cast. If the product you need has a complex design, thick geometry, or both, gas assist molding is a great option to consider.

The DeKALB Difference

DeKALB Molded Plastics has earned its best-in-class quality reputation in the structural plastics industry. We are committed to solutions, and we manufacture products that make a difference. DeKALB provides large, high-quality components with value-add options such as painting, fabricating, assembly and more. Our highly skilled team trains to produce quality molded plastics every time.

At DeKALB Molded Plastics, we’re committed to your goals. Ready to start the conversation? Contact us today to learn more.

Grateful: A Thankful Letter from the President

As the year nears the end, this period always serves as a time of reflection, a time to look back and acknowledge the challenges while remembering the highlights. In most years, we sit around a table of loved ones and go around sharing memories. While we will remember 2020 for its unique tests, and our holiday celebrations might look different, there is still plenty to be grateful for this year.

At DeKALB Molded Plastics, this year began with an optimistic outlook.  We were committed to a strong year, leading with our strategic focus on safety. As our team planned our 2020 goals, we made it clear – we will never give up on anyone’s safety. No matter what, our goal remains the same - zero safety issues! At DeKALB, safety is everyone’s responsibility. From our employees to our guests, we are committed to protecting everyone who steps foot into our facility.

Dedicated Employees at DeKALB Molded Plastics

This year challenged our staff like never before. From adjusting to new safety policies to adapting to new COVID-19 protocols, our team has been excellent at being open-minded to change and continuing to come to work with a positive attitude.

I am so appreciative of the efforts of our staff. All of their hard work throughout the year has helped us gain new business opportunities and grow the partnerships of existing customers. Through it all, we were able to stay true to our core mission to provide unsurpassed satisfaction to all of our customers. I'd like to personally extend a thank you to the DeKALB staff for bringing energy and passion to the organization, buying into our process, allowing us to grow as professional individuals and as a business.

Our Customers – New & Old

To all of our customers, first and foremost, thank you for doing business with us. Without you, our business would not look the same. While this is true for any company, it resonates so much more this year as we have seen many have to scale back or close their doors.

This year required added patience as we all navigated through unscripted challenges. We cannot express enough how much we appreciate your loyalty, support and trust in DeKALB Molded Plastics to provide you with your structural foam needs. Thank you for believing in us, and we look forward to continuing to serve you as our on-going relationship continues to develop.

The DeKALB Community

Last and certainly not least, from our entire team at DeKALB Molded Plastics, we value the genuine relationship we have with our local community. From the day we first opened our doors, one of our core values has been to be an active member of our local community. To us, continuous improvement and care for our employees extend well past our walls and into our city. We dedicate our time to our community to help create a growing and supportive environment all around us.

We are grateful for the relationships that we have built within the area of Butler, IN. We are always happy to show our support as an active member of the community. While this year has had many canceled events, we were proud to still have the opportunity to give back through the annual United Way of DeKalb County Day of Caring event in September. However, one event that has been altered is our annual recognition dinner that honors members of the Butler Police Department, Butler Fire Department and locally stationed Parkview DeKalb EMTs. While the dinner is postponed, we will still be making a presentation of our support at an upcoming Butler City Council meeting next month.

I could go on about the many things I am indebted to, even in this time of challenge. Without the dedication of our staff, the support of our community and the confidence of our customers, DeKALB Molded Plastics would not be in business. For that, I am comforted, and I know the DeKALB teammates are too!

Thank you! Thank you! Thank you! – From all of us at DeKALB Molded Plastics

We wish you and your family a wonderful Thanksgiving!

 - Rick Walters

 

Community Focused – DeKALB’s Active Involvement

At DeKALB Molded Plastics, we are committed to our community, because being an active and supportive member of our local city is simply an extension of our core values.  Giving of our time and talent is our greatest contribution to our many partnerships, because when we support each other, incredible things happen, and everyone wins.

Our community has always been supportive of us, helping us be successful. In return of this support, we’re proud to be able to give back, supporting our neighbors and friends, helping to make things better. As a company, we are focused on Continuous Improvement, and we are proud to continue this philosophy from within our walls to everyone outside of them. Great employees create a great company, and in turn, with this attention, make a great community. This is why you will often see DeKALB employees and our logo present as a sponsor at numerous charitable events, including Butler DaysShop with a Cop, and multiple Butler 5K Run fundraisers.

United Way - Day of Caring

Each year one of the highlights of our community events is participating in the United Way of DeKalb County Day of Caring. DeKALB has participated in this volunteer opportunity for more than 20 years, lending a helping hand to local nonprofits and giving back to the great community that embraces our company. This is usually a one-day event where volunteers serve throughout the community, doing projects for those in need of assistance.

Open to all levels of employees, this event provides DeKALB Molded Plastic’s staff with the opportunity to go out and give back to the community by dedicating their time. At the end of the event, the dedication from our staff, and other community members that support this event, help to make a major impact throughout the county.

During the Day of Caring, some of the projects that are completed include repairing fences, painting projects, landscaping and making our area buildings more accessible for all by constructing access ramps. In addition, some skilled volunteers assist by doing minor home repairs. In 2020, even during a pandemic, the annual United Way Day of Caring in DeKalb County continues, as 24 outdoor projects are scheduled to be completed. Teams have already started work, which will take place over the next few weeks, unlike normal years, where all projects are finished within the same day.

For DeKALB’s engineering manager, Chris Clear, who has participated in this event every year for the last twenty years, the most enjoyable part of this event is reflecting on the work DeKALB has helped to achieve, and the positive and lasting effect it has to this day for the community and the company.

“One of the projects that stands out is when I put in a garage door opener for a senior citizen, who I see from time to time, and when I do, she always comments on how thankful she is for our help,” said Clear. “I’m most proud of the reputation our staff has built with the United Way. Our team is known for taking on the difficult projects, and working until it is done, often being the last Day of Caring crew still working. We generate a better quality of life for the community when we give back, and it helps us when we help others.”

Diane Fogle, customer service representative at DeKALB, also shared a fond memory of volunteering at the Day of Caring and how DeKALB was able to help in going the extra mile to make a community member’s day.

“DeKALB has been proud of every project we have done over the years, but one that I will never forget is a landscaping project completed at an elderly women’s home,” said Fogle. “After meeting her, shared that she always wanted to be a queen for a day, like a homecoming queen, after hearing that, we declared her queen of the day and we presented her with a crown and a sash. This small act of kindness made a world of difference to her and had an impact on our team as there were tears of joy from everyone.”

Staying Active in the Community – The DeKALB Way

At DeKALB, caring for our employees includes caring for our community.  Our culture is centered on appreciating, thanking and cheering our employees for their contributions and support of their passions every day.  Our employees strive to make things better, to make a difference and make our community a great place to work, live and play.

As a thank you to all the first responders serving the Butler community, each year, we recognize and honor members of the Butler Police Department, Butler Fire Department, and locally stationed Parkview DeKalb EMTs with an appreciation dinner for all of the hard work that they do for us throughout the year.

To learn more about us and living the DeKALB Way, click here.

Employee Spotlight: Diane Fogle, Customer Service

DeKALB Molded Plastics is a partner that you can trust, working with you every step of the process, because we are committed to your solutions. All of this is made possible due to the talented individuals that make up DeKALB. Our Employee Spotlight series was developed as a way to introduce you to the impressive people that work here.

What is your name and title? How long have you worked with DeKALB?

Diane Fogle, Customer Service. I have been with DeKALB for 16 years!

Where are you from?

I was born and raised in Ohio.

How would you describe your current role?

It is ever-changing.  There are new challenges presented every day with opportunities to assist customers.

What does your typical day look like?

It is a mixture of fielding customer orders, scheduling, inventory control, production reporting, phone calls, emails, etc.

What drove you to apply for this position at DeKALB?

I was in an outside sales position and DeKALB was one of my clients. I had a working relationship with an Engineer at the time, and DeKALB had an issue with a paint process, and Chris knowing my background reached out for assistance.  Chris knew at the time I was wanting to change jobs because of all the traveling I was doing. DeKALB was looking for a paint supervisor at the time, I applied, and the rest is history.

What has been your favorite part of working at DeKALB?

Rick Walters - his sense of family and giving back to the community.

What is your favorite project that you’ve worked on at DeKALB?

5s—Finding a home for everything, and everything put away

What do you have a knack for?

Organizing and cleaning - fantastic stress relievers!

What’s the one problem you are best at solving for your clients?

Urgent production runs - that is not just me solving the issue, it is the DeKALB Molded Plastics team pulling together to make things happen in a short period of time.

What do your ideal clients say about you?

Professional, Knowledgeable, Friendly Accommodating

What are you most passionate about professionally?

Communication with our customers

Where can we find you when you’re not working?

With family and friends, poolside or on the golf course

What’s your favorite way to spend a weekend or a Sunday afternoon?

Attending live music concerts, golf course, poolside in the summer—I hibernate in the winter.

What would be impossible for you to give up?

My close ties with family and friends

Anything else you’d like to tell people about yourself?

For the people that know me well, they know that Zoe, my 16-year-old Yorkie, is my world

What is your dream job?

This would have to be something with cleaning or retirement

What are some of your hobbies?

Golf, concerts

Do you have any pets?

Yes, a 16-year-old Yorkie.

What’s your favorite movie?

Sweet Home Alabama

What are you most passionate about? 

Family

If you could learn how to do anything, what would it be?

A second language

What is your favorite meal?

Chicken and mashed potatoes

What would be your dream vacation, and why?

Somewhere definitely sunny and warm with a beach and golf course.  Very relaxing

What is your favorite color?

Purple

Want to join the successful team at DeKALB? Visit our Careers page to learn more.

Creating a Safe Work Environment

What does a true commitment to safety look like? At DeKALB Molded Plastics, safety is our number one priority, and we are dedicated to creating a safe work environment. From our employees to our guests, we want to guarantee that everyone who steps foot into our facility will leave in the same condition they came in. Our safety policy highlights much of this promise, but truly being dedicated to safety means remaining flexible, making adjustments to our policy as things change.

DeKALB’s Response to COVID-19

As the COVID-19 pandemic has forced many workplaces to alter their safety policies, DeKALB has made it our goal to quickly adapt, utilizing the latest CDC guidelines and recommendations, ensuring that we continue to keep our facility as safe as possible. Safety is the responsibility of everyone, and during this unprecedented time, it takes an increased focus to continue to maintain a safe work environment.

Some of the ways DeKALB is staying safe during COVID-19 include:

  • Additional cleaning of common areas, tools and workspace.
  • Face coverings worn at all times when working with other employees. Additionally, new employees are required to wear a mask at all times for their first 14 days.
  • All non-critical business meetings have been canceled or moved to a teleconference. The in-person meetings that do occur will limit the people involved, maintaining safe social distancing practices.
  • Hand sanitizer stations placed in various areas for use between washing hands, at start/end of the shift, and before/after breaks.
  • Limited the visitors in the building and those that do visit must complete and pass a health screening before being allowed to enter.
  • Maintaining social distancing of at least six feet. Throughout our facility, there are visual indicators to highlight proper distance for clocking in and in meetings.

Regardless of the number of safety guidelines and practices that are in place to maintain safety, we believe in constantly working together to promote safe practices throughout the workday.

Continuous Improvement - The DeKALB Way

One differentiating safety measure that DeKALB takes is through our card system. There are two types of cards in our system, green cards and blue cards. Both of these represent coaching, training, or acknowledgment opportunities. The blue cards are given out from peer-to-peer, and typically this is used to thank a team member for doing the right thing, helping a co-worker who may be struggling, or to provide training for a process. The peer review helps us to call out any potential unsafe practices or highlight a job well done. The green cards come from a member of our leadership team and are given to employees to recognize them for their contributions or to explain the importance of a particular job and how the process could be improved.

Nearly everyone has experienced the feeling of their stomach dropping and heart rate steadily rising as their manager is coming straight towards them. This scene typically means that you are in trouble, or you did something incorrectly. At DeKALB, we wanted to create a team-friendly, positive work environment that provides unique opportunities for anyone to take the time to appreciate the dedication and abilities an employee brings to our organization. These cards are effective because they can be a great motivating factor, and they not only help to improve our culture, but they offer the chance for us to coach our employees.

This system helps us continue to deliver the results that our customers expect and supports our on-going commitment to continuous improvement. The cards create an accountability system for all of our employees to do the right thing, keeping everyone safe, and knowledge-sharing opportunities, which help to cultivate a fun energy in the workplace. The goal of these cards is to have four positive interactions for every one negative. DeKALB employees did a great job and finished 2019 with a 3.5-to-1 ratio.

A Full Toolbox of Safety

DeKALB also holds weekly meetings that we call our ‘Safety Toolbox Talk’. These meetings provide the opportunity for supervisors to go over a different topic and refresh everyone on how to stay safe.

Topics that we discuss at these meetings include:

  • Driving a forklift safely
  • How to use a cut glove
  • Proper lifting technique
  • When to use a heat glove

These meetings are typically short and are meant to go over the basics, but have been effective with our staff, as they serve as friendly reminders for safety. The other benefit of these meetings is the opportunity to quickly address any updates or adjustments to safety policies, or how we can improve, pointing to examples that may have been brought up through our card system.

Why Safety is at the Forefront

With our safety policies in place, our card system and our flexibility to adjust to a pandemic, there is a clear expectation at DeKALB - we care about the safety of each of our employees. We want to always make it understood that safety is not an individual responsibility, but it is the duty of every employee at DeKALB Molded Plastics. Our policy reminds our team to observe all safety rules, follow safe work practices, and immediately report injuries or unsafe conditions. When we all join in together, a safer environment is created, which results in a happier and more productive staff. A dedication to safety really is a win-win for everyone.

Employee Spotlight: Jessica Roby, Intern

DeKALB Molded Plastics is a partner that you can trust, working with you every step of the process, because we are committed to your solutions. All of this is made possible due to the talented individuals that make up DeKALB. Our Employee Spotlight series was developed as a way to introduce you to the impressive people that work here.

Where are you from?

I am from Butler, IN.

What drove you to apply for this position at DeKALB? 

I met Marcia, DeKALB's HR manager, at a job fair. She was well represented, spoke highly of DeKALB and showed a lot of enthusiasm for me to be a part of the team.

What has been your favorite part of working at DeKALB?

My favorite part about working at DeKALB is the friendly nature of the employees. Everyone here is nice and welcoming.

What are your plans after high school? 

I will be attending Indiana Tech after high school.

Do you have any advice to give to underclassman?

Even though you are trying to keep your grades up and have a great future, have fun with it. You only get one high school career, make the most of it.

What is your dream job?

My dream job would either be a medical manager or HR manager. Both of these are what I am going to school for.

What are some of your hobbies? 

My biggest hobbies are cheering and creating new things.

Do you have any pets?

I have two dogs, one is a 5-month-old puppy, Gunner, and my other dog, Zakari, is a German Shepard.

What’s your favorite movie?

My favorite movie is "The Last Song"!

What are you most passionate about?

I am most passionate about making a difference. I want to make the most out of everything and make a difference in the lives of myself and others.

If you could learn how to do anything, what would it be?

I would love to learn how to understand people who don’t like to show the emotional state of being and how to help people communicate. Both of these would help me with my future career.

What is your favorite meal?

My favorite meal is steak with mashed potatoes, green bean casserole and rolls.

What would be your dream vacation, and why?

My dream vacation would be visiting Hawaii because you’re surrounded by the ocean. The ocean is extremely beautiful; I could only imagine being surrounded by water on all four sides.

Want to join the successful team at DeKALB? Visit our Careers page to learn more.

Dedicated to Continuous Improvement, Dedicated to Quality

With over 40 years of experience in structural foam molding, DeKALB Molded Plastics is proud of the world-class quality reputation we have built. At DeKALB, our mission is to provide unsurpassed customer satisfaction with the products and services that we provide. To achieve this, we have placed a heavy emphasis on continuous improvement, taking a comprehensive look at every detail of our process, understanding there are always ways to advance our capabilities. Our team has established clearly defined standards that help control all process variables, ensuring that every product that leaves our facility meets our standards before they exceed yours.

Standard Process, Custom to You

Being an ISO 9001:2015 company, we take great pride in creating quality parts that our customers can count on. DeKALB Molded Plastics has a standard process for every part that we mold, with established procedures inside of the practice as a whole. Our meticulous quality checks include processes for:

  • Material
  • Melt Flow Analysis
  • Colorants
  • Specifications of the material
  • Value-added inspections
  • Visual inspections
  • Weight tracking

In addition to our standard processes, we also have the flexibility to implement additional verifications and inspections, as required by our customers. Some of our additional quality process capabilities include the ability to complete gage R&R studies, understanding how the measurement determines repeatability and reproducibility, flatness checks to discover how well the part maintains its shape, verification of size and some capability studies. For customers with higher-level requirements or those in the medical industry, DeKALB offers a production part approval process or PPAP submission to ensure that part specifications are met.

What Makes Us Different

Some companies may pass on parts that require too many part inspections, while others do not have the capabilities to do part testing. Being committed to your solutions means that we are dedicated to finding a way to offer a complete custom molding solution, every time.

As part of our growing capabilities to ensure quality, we offer some product testing including:

  • Adhesion testing & plastic welding parts
  • Build up test
  • Falling dart test
  • Other various tests, as requested by the customer

As a custom molder, one of our greatest strengths is our flexibility. We regularly have customers ask us to do specific inspections and verifications for their products. At DeKALB, our customers set the standards for the quality checks and verifications that are completed on their parts through individual runs or set of runs. Far from simply molding a part and shipping it, what separates us from our competition is the number of quality checks we perform, our ability to produce parts in color, and our willingness to do as many inspections as needed by our customers.

Continuous Improvement in Action

Continuous improvement is a way of life at DeKALB, as we constantly strive to advance our company, never being satisfied with where we are. Our culture of continuous improvement means we are always looking at how we can improve our processes, quality, safety and how we can expand our capabilities.

Recently, DeKALB has experienced exciting growth with our expansion in automation and continued additions to our quality measures to support a high grade of aesthetics. At the end of 2019, DeKALB added a new robot, adding to our automation capabilities. Currently, the new robot is being used for multiple customers and will continue to be utilized more.

As DeKalb continues to expand capabilities to suit the needs of our customers, our team recently began working with new programs that require more analysis, including some hot stamping applications for multiple parts, as well as adding labels more accurately. These parts have labels that require very precise placement and have several requirements and standards related to their placement. Our team has added additional quality control measures, helping to improve our ability to meet these needs. Both of these examples are areas that highlight how DeKALB is growing and showcases how we continue to find ways to live out our culture of continuous improvement.

Future of Quality at DeKALB

We are excited to expand our abilities in electronic data collection and use lessons learned to improve our sampling and manufacturing capabilities. As we continue to grow, we maintain our commitment to delivering excellence, ensuring that our products and services are best-in-class, and understanding that each of us is responsible for the quality of everything we do.

Let’s start your next project together; contact us today!

Structural Foam Molding, It’s What We Do

As a custom structural foam molder specializing in large, multi-nozzle plastic products, DeKALB Molded Plastics has more than 40 years of experience serving our customers as a trusted business partner. We believe in structural foam because, at DeKALB Molded Plastics, we are structural foam!

The Basics of Structural Foam

A simple question that is often asked to us is, “what are the characteristics of structural foam?” Since structural foam is not a material but rather a manufacturing process, it’s not easy to answer this question. What is structural foam? Structural foam plastic molding is an injection molding process that utilizes a foaming agent and/or nitrogen gas that mixes with the base resin in the polymer melt before being injected into the mold.

What Materials are used in the Structural Foam Process?

As the case with most plastic manufacturing processes, polymers are used. There are two main categories of polymers, thermoplastics and thermosets. The main difference between the two is thermosets cannot be recycled, while thermoplastics can. At DeKALB, we primarily work with thermoplastics and can mold almost all of them. Under the thermoplastics umbrella lies three general groups of resins - commodity, engineered and performance. DeKALB Molded Plastics mainly focuses on commodity resins, but we mold many engineered resins as well. True to our commitment to providing unrivaled customer satisfaction, we have the flexibility and experience to work with all three types. In addition to the resins that we work with, DeKALB is also equipped to add additivities including talc, glass-fiber, impact modifiers and, in some cases, crumb rubber.

Structural foam has great recyclability, as parts molded in this process can be made from virgin material or recycled material. From there, the part, whether originally from virgin material or recycled material, can continue to be recycled, and subsequently, remolded again and again.

What Does DeKALB Molded Plastics Do?

Simply put, we mold big, heavy-duty thermoplastic parts. Generally, the guidelines for the parts that we produce weigh between 3 and 150 pounds, dimensionally parts are a 1’ x 1’ square, up to 4’ x 8’, similar to a sheet of plywood, and 30” deep. The thickness of the parts produced ranges from 3/16” to 3/8+” (4.7mm to 10mm).

We have the capabilities to go slightly outside of those boundaries getting close to 6 feet by 6 feet or just under 36 square feet. As always, depending on the application, there are some instances where we can go larger. As for the thickness of the part, we can go thicker or thinner, though when making a part thicker, it is usually more cost-effective to add strength with ribbing rather than thicker sections of plastic. Additionally, when making a part thinner than 3/16”, there are more considerations to make and pay attention to during the process.

DeKALB has a long and proud history of producing custom molded products for multiple market segments. Some examples of the products that we mold include:

  • Yellow barrels – (Seen on highways)
  • Pallets
  • Flooring
  • Underground enclosures

Can You Paint Structural Foam Parts?

From the color of your kitchen to the shoes that you wear, being able to customize something to get exactly what you want is important, and the same is true for the parts that we make. Providing custom solutions, in exactly the color you need, is just one of the ways DeKALB effectively serves our customers. Structural foam parts can be painted, and there are two ways to go about creating parts in a certain color. The part can be molded in color with colorants mixed in or color can be added during secondary operations. To meet your exact specifications, we either add colorant into the foam-resin mix or our in-house paint shop can meet the specific color requested.

We Are Structural Foam

Do you have questions about structural foam? Visit our structural foam FAQ’s.

When you work with us, you work with a partner that is committed to your solutions, providing the answers to your structural foam needs. With a wide range of capabilities in plastic processing and an experienced team of engineers, operators and quality technicians, DeKALB Molded Plastics is up to the challenge. Ready to discover what DeKALB can do for you? Contact us today!

DeKALB Molded Plastics Committed to Safety

At DeKALB Molded Plastics, we strive to ensure that everyone who enters our facility is entering a safe work environment. As a team planning our 2020 goals, we decided we’re not willing to give up on anyone’s safety. It doesn’t matter if you’re an employee, a customer, a vendor, or a truck driver, our goal remains the same – ZERO! At DeKALB, safety is everyone’s responsibility. We are conscientious not only about our safety but the safety of others around us.

The benefits of maintaining a safe work environment are many, but first and foremost, safety is about the dedication and execution of protecting those within your building. We at DeKALB, want to send our teammates home in the same condition they arrived in.

DeKALB’s strategic focus on a safe work environment boosts employee morale, which in turn, increases productivity, efficiency and profit margins. When our teammates feel like they have a good, safe work environment, they feel like they can make a difference. There are fewer staff absences, less staff turnover and improves the quality of work.

Regardless of the number of safety guidelines and practices that are in place, we believe they won’t do any good if our teammates are not aware and invested in following those guidelines. We at DeKALB embrace the fact that the safest work environment occurs when employees, at all levels of the organization, work together to communicate and adhere to the safety standards defined. Our safety program has been successful because it encourages employees to report unsafe situations and behaviors, promoting safe practices throughout the workday.

Equipment maintenance is important at DeKALB. When equipment is not properly maintained, the work environment can become a hazard, even beyond the risk of malfunctions. Our teammates have been trained and are prepared to know what to look for when a machine is not operating correctly. Our staff is on the lookout for warning signs like vibrations, alarms, leaks and unusual noises. When our equipment is being maintained, we make sure safeguards are in place. Additionally, our staff is cautiously responsible for moving materials in multiple conditions: raw, in-process and finished goods. Inappropriate handling of material can be dangerous, resulting in overexertion and exhaustion, running the risk of equipment failure. Our team values how important it is to physically lift objects the right way, which reduces the risk for strains and sprains or even broken bones.

At DeKALB Molded Plastics, we take safety seriously. When an employee grows complacent with safety, it can become a huge liability to the team member’s wellbeing and the company. We believe that most workplace accidents can be prevented simply by being alert. Heavy machinery and forklifts can especially be dangerous, and that’s why we require our team to be constantly vigilant and consistently aware of their surroundings.

At the end of the day, we deliver high-quality structural foam components that are used in many of today’s medical and material handling end products. Our high standards for quality are paralleled by our high standards for safety within our building and for our team members.