ADVANCED PLASTICS
AN INJECTION OF QUALITY
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ADVANCED PLASTICS
180 Inside sustainability
I PROFILE
Founded in 1992 by three engineering partners with the goal of exploiting materials technologies and pushing the boundaries of what was possible with polymers, Advanced Plastics has since grown to become the largest privately-owned injection moulding business in the UK. Aided by its high-tech, high-efficiency sites across the UK, the company has steadily grown not only its production capabilities, but also its market share and its turnover. Group Sales Director Michael Hadfield spoke with Richard Hagan.
That would lead to the company’s successful penetration of the automotive sector only a year later in 1993. This major milestone would go on to define a substantial part of the company’s journey, with projects over the years being completed for the likes of Ford (parts for the Fiesta and Mondeo models) and flagship Jaguar vehicles.
Diversification and growth A further milestone was reached in 2006 when Advanced Plastics was sold to its original founder Rob Anderson and partner Chris Pearson (formerly Ford Business Unit manager of Nifco). The company rapidly diversified into the HVAC and filtration sectors, all whilst continuing to prove its ability to develop technically challenging
F
ollowing the company’s establish-
applications for its core automotive clients.
ment by engineers Peter Thompson,
Turnover, meanwhile, increased from
Glyn Barrick and Rob Anderson,
£2.75m in 2006 to £38m in 2023, while its
Advanced Plastics quickly found a niche with its ability to rapidly convert concepts into production jobs.
workforce grew to 317 staff. Today, Advanced Plastics boasts highly automated, world-class manufacturing
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ADVANCED PLASTICS
I PROFILE
facilities located in Hull, Fareham and
The company’s Hull facility is a partic-
Manchester. Across the three sites, the
ular highlight for its advanced Industry
company owns 70 injection moulding
4.0 technology. It features a fully inte-
machines ranging from 22 tonnes to 1,600
grated Enterprise Resource Planning
tonnes. The Hull facility boasts several
system, real-time monitoring of produc-
fast-cycling high efficiency, low energy
tion machines and six axis robotics on
all-electric machines that specialise in
each machine, while offering significant
high cavity, high volume mass production.
assembly automation.
The company continuously invests in the
However, according to Group Sales
latest and most efficient machinery,
Director Michael Hadfield, Advanced
delivering premium products from its
Plastics’ high-tech manufacturing capa-
three state-of-the-art facilities.
bilities are only half of the company’s secret to its success: “We recognise that
Specialised manufacturing
people are the key to our ability to con-
Across its machinery assets, Advanced
tinue achieving the quality and perfor-
Plastics is able to offer several speciality
mance demanded by our clients.
manufacturing services including Foam
Attracting talented individuals and
in Place (FIP) technology, within which it
developing them within the Advanced
produces over 500,000 sealed mouldings
Plastics way, immersing them within our
per year, and over moulding and 2k
core values of Partnership, Respect,
moulding, in terms of which it produces
Integrity and Commitment is critical to
several million parts per year.
our success.”
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Boiling up success
moulding machine, and the integration of
This combination of highly skilled and
all downstream manufacturing processes.
motivated staff and high-tech machinery
“This significant project was delivered
was put on full display during a significant
on time and within budget, clearly demon-
project involving the manufacture
strating our overall design, development and
of parts for a consumer product, as
manufacturing capability,” said Mr Hadfield.
Mr Hadfield explained: “Our team worked closely with the customer’s design team
The recycling revolution
to establish cost-effective solutions to
Amidst global concerns about plastic
meet the client’s design and performance
pollution and a general increased
criteria for a new high efficiency gas
emphasis on sustainable industry,
boiler that the client wished to produce.
Advanced Plastics has embraced
“The project scope included aesthetic
a number of sustainability programmes.
and end user interface elements of the
One of these is a major focus on the
boiler, fluid and flue gas carrying systems
use of recycled materials, especially
with chemical resistance, heat and
at its Fareham and Manchester
sealing performance requirements
factories. “Wherever possible, we
accounted for, as well as the integration
choose to use recycled resins and
of electronic components.
invariably that creates opportunities
“In addition to injection moulding, com-
for reduced cost and improved environ-
plementary manufacturing processes
mental impact,” Mr Hadfield explained.
had to be adopted including automated
He highlighted an example of how the
assembly, linear vibration welding, spin
company’s sustainability programme
welding, Ceracon FIP sealing, digital and
substantially benefits one of its larger
hot foil printing.”
customers: “A major worldwide telecommu-
The gas boiler project ultimately saw
nications customer traditionally used virgin
Advanced Plastics design and manufac-
polymer, reaching a peak of 800 tonnes in
ture 36 injection mould tools ranging in
2015. As of 2023, its use of virgin polymer
size from 250kg to 7,000kg, with the
has been switched for 90% post-industrial
largest running in a 1,500t injection
and post-consumer recycled materials,
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ADVANCED PLASTICS
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I PROFILE
all with the full knowledge and collabora-
ence, is developing a five-year business
tion of the customer’s technical and
plan with the stated goal of driving
commercial teams.”
Advanced Plastics to £50m turnover,
Meanwhile, Advanced Plastics has
which is set to be achieved organ-
become an industry leader in its ability
ically and through site growth and
to supply to customers the energy usage
strategic acquisitions.
data and carbon footprint information for
The company expects organic
its polymers, for use with Environmental
growth to be partially driven by further
Product Declarations (EPDs). The EPD doc-
diversification as well as continued
ument transparently communicates the
investment in the latest manufacturing
environmental performance or impact of
technology and automation, allowing
any product or material over its lifetime.
the company to continue to offer its
“Many of our customers readily embrace
customers the best and most competi-
this programme and supply the required data, increasing their market share and overall turnover,” Mr Hadfield said.
tive technical solutions. In conclusion, Mr Hadfield reflected on the company’s prospects: “Our team is very confident about our future;
New board and future plans
we believe that our business covers so
In September 2023, Advanced Plastics
many market sectors that we’re well
announced the appointment of a new
protected from major turbulence in
Board of Directors, with majority share-
individual ones. Our financial stability
holders Chris Pearson and Rob Anderson
remains a major strength and we look
becoming joint CEOs of the business.
forward to continuing to deliver excellent
The new board, with collectively over 150
projects on-time to customers all over
years’ worth of plastics industry experi-
the UK and Europe.”
n
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