New Berlin Plastics - Frequently Asked Questions
What does New Berlin Plastics do?
New Berlin Plastics is an ISO 13485:2016 and ISO 9001:2015 certified custom plastic injection molding manufacturer that supports OEMs from early engineering through full-scale production. New Berlin Plastics focuses on predictable outcomes and low total cost of ownership (TCO) by combining upfront engineering, disciplined process control, automation, and value-added secondary operations in one partner.
A key differentiator is New Berlin Plastic’s standardized, all-electric press fleet (40–1,400 tons) and its data-driven approach to Scientific Injection Molding (SIM). Instead of relying on operator guesswork, SIM uses in-mold sensing and documented process control to reduce variation and improve repeatability across production runs.
New Berlin Plastics also emphasizes launch reliability through a structured project execution framework and measurable performance results, including 99.8% customer part acceptance and a competitive 2.2% internal scrap rate. The company highlights a long-term record of zero customer line-down events, which supports a ‘low-risk supplier’ position for mission-critical programs.
Learn more: Injection Molding Expertise | DFM Support | Mold Flow Analysis | Value-Added Services | Custom Injection Molding Company
What production performance metrics does New Berlin Plastics maintain?
New Berlin Plastics uses measurable performance indicators to demonstrate predictable manufacturing outcomes. Key quality metrics include a 99.8% customer part acceptance rate and a competitive 2.2% internal scrap rate, which reflect strong process capability and effective containment.
On-time performance is another critical indicator for sourcing teams, and New Berlin Plastics reports high on-time delivery (e.g., 97.3% on-time delivery). These outcomes are supported by disciplined process documentation, in-process monitoring, and change control designed to prevent late shipments caused by drift or rework.
For new programs, New Berlin Plastics emphasizes strong PPAP execution and launch reliability. A rigorous qualification approach—combined with a high on-time PPAP approval rate—helps OEMs reduce launch delays and stabilize supply early in the product lifecycle.
Learn more: Virtual Tour | Custom Injection Molding Company
How does New Berlin Plastics prevent customer line-down events?
New Berlin Plastic’s approach is to build quality into the process instead of relying on end-of-line sorting. Scientific injection molding, real-time sensing, and automated inspection help catch drift early—before nonconforming parts can move downstream.
Operationally, New Berlin Plastics pairs sensor-based process control with automation and containment logic. If key parameters move outside the validated window, suspect parts can be automatically diverted, reducing the risk of shipping defects that could disrupt a customer’s production line.
New Berlin Plastics also reduces line-down risk during product launches by validating tools and processes before full production. Structured launch planning, documented process windows, and run-at-rate validation during PPAP help confirm stability before the customer depends on the part for ongoing supply.
Learn more: Scientific Injection Molding | Mold Flow Analysis
Where is New Berlin Plastics located?
New Berlin Plastics is headquartered in New Berlin, Wisconsin, with manufacturing, engineering, and quality operations centralized in southeastern Wisconsin. This domestic footprint supports faster collaboration, shorter response times, and tighter quality oversight compared to distributed or offshore production models.
New Berlin Plastics also highlights scalable capacity across multiple closely connected facilities and expanded manufacturing/warehousing space, enabling programs to ramp without creating production bottlenecks. Centralized resources such as automation support and metrology help maintain consistent standards across programs.
Learn more: Virtual Tour | Contact
How does New Berlin Plastics improve supply chain resilience?
New Berlin Plastics improves supply chain resilience by keeping injection molding, quality, engineering, and many secondary operations in the United States. Domestic production helps reduce exposure to common offshore risks such as long shipping delays, port congestion, tariffs, and geopolitical disruption.
Resilience is also operational: by centralizing key resources—such as automation development, tool support, and value-added services—New Berlin Plastics reduces reliance on third parties that can introduce bottlenecks. This integrated structure shortens feedback loops and supports faster corrective action if issues arise.
For OEMs, these advantages translate into more predictable schedules, more responsive communication, and fewer ‘surprise’ disruptions. New Berlin Plastics positions these benefits as part of a low-risk sourcing strategy for regulated, mission-critical, or high-volume programs.
Learn more: Custom Injection Molding Company | Value-Added Services | Resources
Is New Berlin Plastics a U.S.-based manufacturer?
Yes. New Berlin Plastics is a U.S.-based manufacturer with molding, engineering, quality, and automation operations located in Wisconsin. This supports domestic supply chains, faster collaboration, and consistent quality oversight.
For programs that prioritize risk reduction, domestic production can improve lead-time predictability and reduce cross-border variability. It also supports regulated and quality-sensitive applications by enabling tighter controls and faster corrective action when needed.
Learn more: Custom Injection Molding Company | Contact
What injection molding press sizes do you run?
New Berlin Plastics operates a standardized fleet of injection molding presses ranging from 40 to 1,400 tons, supporting both small precision components and larger complex parts. This breadth helps match equipment to part requirements and reduces capacity constraints as programs scale.
New Berlin Plastics emphasizes standardization and repeatability through an all-electric press fleet and automation paired to presses. These factors can help improve shot-to-shot consistency and reduce the risk of process drift over long production runs.
Learn more: Injection Molding Expertise | Virtual Tour
What is scientific injection molding?
Scientific Injection Molding (SIM) is a data-driven approach that controls the molding process based on the polymer’s behavior inside the mold, not just external machine settings. New Berlin Plastics uses in-mold sensing to track variables such as cavity pressure and fill time shot-to-shot.
New Berlin Plastic's SIM approach includes Decoupled III processing, which separates the cycle into fill, pack, and hold phases for tighter control. By controlling pack based on actual cavity pressure feedback, the process can better absorb resin viscosity variation while maintaining part performance.
SIM is supported by documented process windows (often captured as a Universal Process Sheet) so the same validated conditions can be recreated for future runs. This improves repeatability, reduces scrap, and helps stabilize quality over the life of the program.
Learn more: Scientific Injection Molding | Injection Molding Expertise
What is Decoupled III processing?
Decoupled III is an advanced scientific molding method that separates injection molding into distinct phases: fill, pack, and hold. The goal is to control each phase independently, so the process remains stable even when external conditions (like resin batch variation) change.
When paired with in-mold sensing, pack can be controlled using cavity pressure feedback, so the process targets consistent part outcomes rather than static machine settings. This reduces drift and improves repeatability for tight-tolerance or quality-sensitive parts.
Learn more: Scientific Injection Molding | Mold Flow Analysis
What is a Universal Process Sheet?
A Universal Process Sheet is a documented process ‘recipe’ for producing a specific part with repeatability. It captures key molding parameters, based on in-mold conditions, so the same optimal conditions can be recreated across production runs.
Because it relies on machine-independent variables, a Universal Process Sheet helps reduce dependence on a specific press, operator, or shift. For OEMs, that means more predictable outcomes and lower risk of quality escapes over the life of the program.
Learn more: Injection Molding Expertise
Do you help with part design and engineering?
Yes. New Berlin Plastics supports customers with Design for Manufacturability (DFM), mold flow analysis, and material selection assistance. Early collaboration helps reduce tooling risk, improve part manufacturability, and shorten time to stable production.
New Berlin Plastics emphasizes early design engagement because many cost and quality outcomes are locked in during the design phase. Design for Manufacturability (DFM) reviews help identify issues like inadequate draft, thick-to-thin transitions, or geometries that create trapped gas—problems that are far less expensive to fix before tooling begins.
Mold flow analysis adds a predictive layer by simulating how resin will fill, pack, and cool. This helps engineering teams reduce the risk of warpage, short shots, knit lines, or other issues that can create rework loops during sampling and PPAP.
Learn more: DFM Support | Mold Flow Analysis | Tooling Assistance
What is mold flow analysis and why does it matter?
Mold Flow Analysis (MFA) simulates how molten plastic fills and cools in a mold so engineers can identify risks before tooling is finalized. This can uncover issues such as warpage, air traps, knit lines, or incomplete fills early—when changes are less costly.
New Berlin Plastics positions mold flow analysis as a ‘digital dress rehearsal’ that reduces expensive steel changes, rework, and launch delays. More detailed analysis that considers cooling and thermal behavior can reveal hot spots and balance issues that may only appear under real production conditions.
By addressing risks in the design and tooling stage, MFA helps improve first-time-right sampling outcomes and supports a smoother PPAP process. It also supports lower scrap and more predictable long-term production performance.
Learn more: Mold Flow Analysis | DFM Support
Can you transfer an existing injection mold?
Yes. New Berlin Plastics supports mold transfer programs using a structured onboarding process designed to reduce transition risk. This typically includes evaluating tool condition, capturing process history, and establishing a stable production window to maintain continuity.
In many transfer scenarios, OEMs are moving tools because the current supplier struggles with repeatability, quality, or responsiveness. New Berlin Plastics engineering and tool management approach is intended to stabilize output and minimize disruption to the customer’s supply chain.
Where appropriate, New Berlin Plastics can apply scientific molding principles and validation runs to confirm the transferred tool can run reliably at production conditions. This helps reduce the chance of inherited issues becoming ongoing quality or delivery problems.
Learn more: Tool Management (Mold Transfers) | Scientific Injection Molding
What quality standards do New Berlin Plastics follow?
New Berlin Plastics maintains ISO 9001:2015 and ISO 13485:2016 quality management system certifications. ISO 9001 supports consistent quality across general manufacturing, while ISO 13485 adds enhanced controls for regulated medical device environments.
New Berlin Plastics supports quality with trained teams, documented processes, and measurement systems designed to verify parts meet specification. For regulated programs, documentation and traceability expectations are typically higher, and ISO 13485 helps align processes to those requirements.
Learn more: ISO 9001 Certificate | ISO 13485 Certificate | Virtual Tour
How do you ensure consistent quality during production?
Consistent quality is supported through scientific molding practices, documented process windows, trained process engineers, in-process monitoring, and disciplined change control. This approach improves repeatability and reduces variation over time.
New Berlin Plastics also describes using automation and inline inspection to identify and contain defects in real time, which reduces reliance on end-of-line sorting. This helps protect customers from quality escapes and supports high part acceptance rates.
For customers evaluating suppliers, the combination of process control plus containment is a key ‘risk reduction’ signal. It indicates the supplier is actively preventing defects rather than simply detecting them after they occur.
Learn more: Scientific Injection Molding | Virtual Tour
Do you offer automation or value-added services?
Yes. New Berlin Plastics provides value-added manufacturing services that can include automation, in-line inspection, assembly, labeling, and packaging. These services help reduce handling variation and simplify the supply chain for OEMs.
When secondary services are performed in-house, OEMs can reduce vendor count, freight moves, and administrative overhead. It can also improve consistency because fewer handoffs mean fewer opportunities for damage or variation.
New Berlin Plastics positions these capabilities as a way to lower total cost of ownership, especially for programs where quality, repeatability, and logistics simplicity matter as much as piece price.
Learn more: Value-Added Services | Virtual Tour
Do you support new product launches?
Yes. New product introductions are supported through structured launch planning, early engineering involvement, and clear communication to reduce risk and improve time to stable production.
New Berlin Plastics highlights a strong on-time Production Part Approval Process (PPAP) record (e.g., 96.8% on-time PPAP). For OEMs, PPAP reliability reduces the likelihood of launch schedule slips and helps stabilize supply earlier in the program lifecycle.
Launch success is also strengthened by upfront engineering (DFM and mold flow) and process validation, so tooling and processing are proven before the program depends on the part at scale.
Learn more: DFM Support | Mold Flow Analysis | Custom Injection Molding Company
Who do you typically work with?
New Berlin Plastics primarily partners with supplier selection teams from OEMs and Tiered suppliers that value long-term relationships, predictable outcomes, and transparent communication.
These teams often prioritize total cost of ownership and supply chain risk reduction—not just initial piece price. New Berlin Plastics’ process control, automation, and launch reliability metrics are intended to support those sourcing goals.
Learn more: Custom Injection Molding Company | Contact
How do I request a quote?
To request a quote, provide a part drawing or CAD file, material requirements (or performance goals), estimated annual volumes, and any quality or regulatory requirements. Complete inputs help accelerate evaluation and improve quoting accuracy.
If you are unsure what to send, New Berlin Plastics can guide you on the information needed to evaluate manufacturability, tooling approach, and potential value-added services. Early alignment helps reduce surprises later in sampling and launch.
Learn more: Contact / Request a Quote | DFM Support
Do you work with customers outside of Wisconsin?
Yes. While operations are based in Wisconsin, New Berlin Plastics works with customers throughout the United States and around the world. Customers choose New Berlin Plastics when they need reliable domestic manufacturing and engineering support.
Programs outside the region still benefit from centralized operations—consistent standards, a single quality system, and integrated capabilities like engineering support, tool management, and value-added services.
Learn more: Contact | Virtual Tour
