Blue Star Plastics

About Blue Star Plastics

Blue Star Plastics operates from Lexington, Kentucky, where it was established in 1984 as a family-owned business. The company began with a focus on zero-defects production and on-time delivery, positioning itself as a full-service plastic injection molder and contract assembly provider for customers seeking a reliable outsourcing partner. The facility runs injection molding presses ranging from 40 to 600 tons, equipped with robotic part handling and on-the-press color feeders, operating 24 hours a day, five days a week. An in-house tool room supports mold maintenance and quick reaction, while an IQMS ERP system links purchasing, production, quality, shipping, and accounting for real-time monitoring. The company processes both engineering and commodity resins — including PP, PE, ABS, PC, POM, PA, and elastomers — producing parts from a single gram up to two-foot square dimensions. Value-added assembly services cover pad printing, screw and clip installation, tape and felt application, and multi-component assembly, supported by automation, poka-yoke error-proofing, flexible work cells, and a 5-Gate APQP launch system. Blue Star Plastics primarily serves the automotive sector, supplying interior trim components with color-matched, grained, and decorated finishes, as well as exterior and under-the-hood parts requiring engineered resins and tight tolerances. The customer base also extends to consumer and industrial markets, where quick-to-market timelines and aesthetic appeal are critical. The company states its founding purpose was to make clients more profitable by delivering a competitive advantage: faster time to market, better product quality, and budget adherence through zero-defects production and on-time delivery.

Equipment

• 40-600 ton injection molding presses
• On-the-press color feeders
• Robotic part handling systems
• In-house tool room

Company details

Location

Lexington, Kentucky

Company type

Manufacturer

Founded

1984

Ownership

Family-owned

Languages

English, Spanish

Production volume

Parts from a single gram to two-foot square in size

Certifications

ISO 9001:2015, IATF 16949 compliant processes

Listed under

• Plastics & Packaging Manufacturers in Kentucky

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