Rigid Packaging with Flexible Capabilities

Often, a product requires something more than what typical stock offerings provide. Something with a unique shape that will set your product apart from the competition. Maybe you need a special closure. Or perhaps you’re just looking to reduce expenses. Whatever your reason, we can provide a custom solution that works within your parameters and maximizes your returns.


Design

Simplicity is the ultimate sophistication

Simple and effective. It just makes sense. Gateway Plastics will learn about you and your particular market. We will then work collaboratively to design the package that will optimize your product's presence at retail. The process includes rough drafts of various ideas, final design, prototyping and appropriate material selection.

Design | Prototyping | Tooling


Production

We cover all steps in the process

The production phase is where your product really comes to life. Our equipment is state of the art and all work is done in-house to ensure quality and confidentiality, while minimizing cost and time to market.

Our high‑speed injection molding process enables us to produce a full range of packaging products. We also offer in‑mold labeling, a process that introduces a printed label into the injection mold so the package is actually molded around the label. This process creates superb, high‑resolution graphics that really make the packaging stand out. The in‑mold labeling process also reduces cost by creating an efficient, stream‑lined process without the need for secondary operations.

  • Press capability up to 1,000 tons and 10 pound shot size
  • Superior aesthetics
  • Eight on-site silos allow storage capacity for 1 million pounds of resin
  • In-house material blending

When sales are on the line, the last thing you want is product packaging that is flawed in any way. With quality testing before, during and after the entire production process, we go to great lengths to ensure that your finished product meets all specifications.

  • ISO 22000:2005 certification
  • First article and sampling capabilities
  • Fully-equipped lab for dimensional requirements
  • CMM and Optical Comparator on-site
  • Dimensional inspection
  • Torque and pull force testing
  • Color verification
  • Seal testing
  • Problem simulation lab
  • Destructive testing

With ever increasing demands put on companies to fill and cap jars at higher speeds and with more efficiency, bottle quality and consistency are of the utmost importance. With lines moving at several hundred jars per minute, small bottle variances can cause big downtime issues. For this reason Gateway Plastics uses the two step approach for manufacturing PET bottles. Two stage processing minimizes dimensional variability and provides the most reliable sealing lands for mating closures.

The first stage in making a quality bottle is injection molding precision preforms. Gateway molds preforms using tools, molding machines and automation from industry technology leaders. The preforms are robotically stacked in gaylords to maintain neck finish integrity during the 48 hour aging process. This aging process takes place in our HVAC controlled warehouse and ensures the PET material is fully stabilized before moving to the second stage or blowing process.

In step two of our bottle manufacturing process, GPI preforms are blown on linear machines providing bottles with uniform wall thickness and consistent neck finish quality for final fit‑up and sealing to our closures. Automated leak check machines ensure bottle integrity for customer fill lines, while laser etched date codes allow for product traceability. Finished bottles are robotically palletized, banded and stretch‑wrapped before being moved to Gateway’s HVAC controlled warehouse.


Post Production

Getting what you need, when you need it

Gateway Plastics offers automated operations, including assembly, packaging and shipping of product to help keep your costs down and project moving efficiently. We can also store your product-ready materials in our secure warehouse for delivery at a time and destination of your choosing.

Distribution and Warehousing

Extended shipping and receiving hours for effective material flow. Real-time warehouse management system with barcoding to ensure speed and accuracy. Secure, high-bay, high-density warehouse.