INNOVATIVE PLASTIC PACKAGING FOR TOMORROW . . .TODAY

P.O.Box 2775, 22-36 Green St., Paterson, NJ 07509

Phone: 1 (973) 523-3030

Fax: 1 (973) 523-0643

Thank you for the opportunity to service your

disposable plastic needs !

Douglas Stephen Plastics, Inc.

Douglas Stephen Plastics, Inc. is an independently owned and operated company based in Paterson, NJ. Our company was originally established over 50 years ago with an understanding of the distributor and end-user marketplace but also a clear vision of the type of disposable products that were missing from the industry. In fact, our founder was a distributor sales rep himself thereby giving him an understanding of the many challenges that companies face in the ever-changing Food Service industry. 

About us overview

Ultimately, the mission of our company still remains ... "to make quality products that meet our customers needs, filling niche markets and designing custom products from an ever-Increasing varlety of raw materials." 

We appreciate your interest in the Douglas Stephen Plastics product line and look forward to the opportunity of servicing your disposable plastic needs in the future.

Experience. Quality. Reliability.

MATERIAL GUIDE

POLYSTYRENE (PS)

  • Wide Temperature Perfonnance (20°F to 170°F)

  • Maximum Hot Fill: 185°F

  • Great for Room temperature & Chilled Food         displays

• High Clarity

• No odor & taste transfer to or from food products

• Low cost, high yield material

• Rigid material, great for stacking

• Excellent value for merchandising displays

POLYETHYLENE TEREPHTHALAYE (PETE)

  • • Wide Temperature Performance (0°F to 160°F)
  • • Maximum Hot Fill: 140°F
  • • Great for Freezer, Cold Case & Room durability application

• High Clarity with toughness & strong impact resistance

• Excellent for low temperature performance

• Great performance with challenging foods (e.g. acidic,    fat, grease or oil content)

• Excellent barrier characteristics for extended shelf life

POLYPROPYLENE (PP)

  • Excellent Temperature Performance (-10°F to 240°F)
  • • Maximum Hot Fill: 260°F
  • • Microwavable (food temperatures up to 230°F)

• Great for merchandising hot or chilled prepared food

• Great performance with challenging foods (e.g. acidic,fat,   grease or oil content)

• Excellent for Ready to Heat products (freezer/refrigerator to the microwave)


HOW DO WE DO IT ?

BASICS OF INJECTION MOLDING

One of the most common methods of shaping plastic resin is a process called injection molding. Injection molding is accomplished by large machines called injection molding machines.

Resin is fed to the machine through the hopper. Colorants are usually fed to the machine directly after the hopper. The resins enter the injection barrel by gravity though the feedthroat. Upon entrance into the barrel, the resin is heated to the appropriate melting temperatura.

The resin is injected into the mold by a reciprocating screw or a ram injector. The reciprocating screw apparatus is shown above. The reciprocating screw offers the advantage of being able to inject a smaller percentage of the total shot (amount of melted resin in the barrel). The ram injector must typically inject at least 20% of the total shot while a screw injector can inject as little as 5% of the total shot. Essentially, the screw injector is better suited for producing smaller parts.


The mold is the part of the machine that receives the plastic and shapes it appropriately. The mold is cooled constantly to a temperature that allows the resin to solidify and be cool to the touch. The mold plates are held together by hydraulic or mechanical force. The clamping force is defined as the injection preasure multiplied by the total cavity projected area. Typically molds are over designed depending on the resin to be used. Each resin has a calculated shrinkage value associated within.

BASICS OF VACUUM FORMING

Vacuum forming is a plastic thermoforming process that involves forming thermoplastic sheets into three-dlmenslonal shapes through the application of heat and pressure. In general terms, vacuum forming refers to all sheet forming methods, including drape forming, which is one of the most popular. Basically during vacuum forming processes, plastic material is heated until it becomes pliable, and then it is placed over a mold and drawn in by a vacuum until it takes on the desired shape. Vacuum thermoforming is a great method for producing plastic parts that have sharp details and fit nicely to specific products.

During the vacuum forming process, a sheet of heated plastic material is placed over a male or female mold. The meld then moves towards the sheet and presses against It to create a seal. Next, the application of a vacuum draws out the air between the mold and the sheet so that the plastic conforms to the mold exactly. Thls ls accomplished through venting holes In the mold that are joined to vacuum lines. The mold also has a water cooling system integrated into it that brings the temperature of the plastic to the set temperature needed. When the curing temperature is reached and the piece is formed, air blows back into the mold and separates the new part from the mold.


Vacuum forming produces plastic parts for various industries, such as the food, cosmetic, medical, electronics, entertainment, household products, toys, athletic equipment, appliance, automotive, office supplies and clothing industries. One of the most important industries that thermoforming serves, however, is packaging. Products like blister packs, inserts, trays and clamshells are used to house other products and are Important for both preservation of the items they hold and the aesthetic designs they can provide. Consumer product manufacturers often use vacuum formlng to produce plastlc trays and glasses.


The greatest advantage to vacuum forming is that it involves less parts and tooling than injection molding, and therefore is more cost-effective. It is an economical choice that can be used for small and medium production runs, with low cost tool modifications. There is great design flexibility available, from a variety of prototypes to custom made designs that can be used to cover almost any product. Most manufacturers also offer a wide variety of trim and other decoration options that can prove quite a visual advantage. Time of production is generally short, which frees up time to do more detail-oriented aspect of production. Sharp, precise detail is available for many products, which makes vacuum formed plastics an attractive alternative to other molding processes.


Company history and timeline

FROM THE BEGINNING

Douglas Stephen Plastics led the industry by developing and manufacturing some of the first disposable, injection-molded plastic catering items ever produced. Thermoforming equipment was later added to produce a number of new products. 

TODAY

Douglas Stephen Plastics continues to be an industry leader. Our Sales and Marketing efforts now extends throughout the United States through a network of distributors and broker organizations and with multi-site production capability. We have dramatically expanded our product offering to an even broader line of both injection-molded and thermoformed products. A clear example of this expansion is our Ultimate Cater Service that includes Stakmates Trays and Embassy Trays & Bowls. The DSP product line is well respected and in use throughout the Foodservice, Hospitality, Catering, Supermarket and Food Processing market segments.

MISSION

Ultimately, the mission of our company still remains…"to make quality products that meet our customers needs, filling niche markets and designing custom products from an ever-increasing variety of raw materials" 



We appreciate your interest in the Douglas Stephen Plastics product line.