Retrac Group, an engineering, design and manufacturing specialist, has positioned itself at the forefront of the revolution in developing lightweight applications for sustainable transport solutions. Having launched its Retrac Future range of sustainable composites to industry approval, Retrac Group CEO Dan Walmsley, CCO Tim Scott and Head of R&D Alan Purves outlined how the company is now set for expansion in its 50th year.
Profile by Andy Probert.The Retrac name may well be the original owner’s surname backwards; it is, however, fast-forwarding its engineering, design and manufacturing compe tencies in the sustainable bio-composites sphere at full throttle. The Group, which rests 50 years of excellence on its composites-metallics axis, is a leading supplier to blue-chip clients in the Formula One, automotive, aerospace, and motorsport sectors. Based at Swindon, in southwest England, Retrac supplies production components and mould tools, along with design, research and development services.
In alignment with the future transportation supply chain’s trends for sustainable lighter applications and a marked reduction in carbon emissions, the company has devised Retrac Future, a portfolio of sustainable and recycled composite materials.
“This range demonstrates to customers the breadth of what is possible with our various processes,” said Retrac Group CEO Dan Walmsley, “given the world is on the cusp of a lightweighting revolution.”
Exciting times ahead
It is just one of the many exciting elements Mr Walmsley and his team continue to evolve at the company.
Retrac’s half-a-century of business exploits notwithstanding, its paradigm shift to an Employee Ownership Trust (EOT) structure 18 months ago continues to see the company soar. Expansion and further innovation are also around the corner.
“The EOT has been bedding in for over a year,” said Mr Walmsley, “but through hard work from the team, we have not seen any slowdown in company performance. It offers exciting potential for years to come.”
While acknowledging that an EOT essentially places the future of the business into employees’ hands, Mr Walmsley said staff were more engaged than ever to ensure future success. Indeed, their workforce has risen from 115 to 170 personnel in less than a year to cope with an influx of new contracts and con -
tributed to Retrac posting a 45% uplift in turnover.
One such milestone under the new structure is the announcement that Retrac will expand its operations into a new facility, additional to its 50,000 sqft multi-axis machining facility.
Mr Walmsley said the expansion is solely to meet a specific contract to serve the needs of an automotive OEM in the Electric Vehicle (EV) sphere. “It’s an amazing opportunity for Retrac,” he confirmed. “The new facility will give us the adaptability to support all elements of the project, which will have a particular focus on sustainability.
“It is a high-level statement of intent from Retrac’s perspective, bringing additional people to the workforce and placing us firmly within the sustainability space.”
Retrac will focus on a specific component in the cab of a commercial vehicle, with the first production destined for 2023, according to Retrac Group’s CCO Tim Scott: “Sustainability is a key commercial consideration that we need to be involved in and evolving in, given the current market conditions – and certainly, if we want the business to be here in 10 to 20 years’ time.”
Retrac Future
The company has developed the Retrac Future range of bio-composite materials. The options, including natural fibres with a positive carbon impact, have been developed to offer greater access to high-performing sustainable materials. Emerging from an extensive R&D project by Retrac’s composites division, the range includes recycled carbon fibre and natural-fibre products suitable for multiple applications across lightweight structures.
Bio-content resin systems enhance the eco-friendly credentials of these composite
materials alongside an energy-efficient production process featuring bespoke compression moulding techniques.
“The options demonstrate what is possible with our various processes using sustainable and recycled materials,” explained Alan Purves, Head of R&D. “These developments have been built on the back of exceptional experience, vision and hard work in-house.
“We have invested in R&D to develop our manufacturing capability using numerous interesting materials. That gives us a great platform to offer clients tailored solutions for their specific requirements in sustainable composites.”
Bio-composites and their positive sustainability are quickly becoming game changers for the transport solutions sector according to Mr Purves: “Our advances are also contributing to starting a conversation with customers and their understanding of sustainability, the future for their applications and what they are trying to achieve. What Retrac offers is the art of the pos sible in today’s world.”
As part of this R&D effort, Retrac Group forged alliances with leading flax natural fibre specialist Bcomp and Composites Evolution, a UK-based prepreg manufacturer and supplier that launched the Evopreg ampliTex prepreg range. The prepregs combine the high-performance Evopreg epoxy resin systems with Bcomp’s ampliTex range of flax reinforcements.
Using Evopreg ampliTex alongside Bcomp’s powerRibs reinforcement system, Retrac produced a demonstrator bonnet panel for a race-bred supercar to form one of the new bio-composites range.
Two thermoplastic materials have been developed from woven carbon and woven glass, which can be manufactured in the company’s compression moulding press system. The 60-tonne bespoke electric servo press is used for product development and allows precise control of position and load at every part of the pressing cycle.
Innovations hub
“Making those major inroads in development reflects well on the business,” Mr Purves added, “and on the broader
UK manufacturing sector as a sustainable innovation hub. As globally sustainable transport solutions evolve, Retrac is determined to be central to that.”
Mr Walmsley agreed: “These materials now allow Retrac to positively influence customers’ decision-making, impact their success and futures.”
The new bio-composites range has invigorated the market and focus, with the Retrac Group fielding two to three calls of interest a month from new UK and overseas clients.
“Retrac Group is a relatively small company,” reflected Mr Scott, “but it is taking huge steps in innovation that has caught the attention of larger busi nesses who are approaching us, interested in what we are achieving. The new contract and our expansion is a result of Retrac Future’s innovation.”
Confirming its commitment to being an integral part of the future transportation supply chain, and keeping abreast of customers’ sustainability drives, Retrac Group is signed up to the UK Government’s SME Climate Commitment to halve its greenhouse gas emissions by 2030 and achieve Net Zero emissions by 2040.
“Retrac’s commitment to sustainability and bio-composites innovation demonstrates how far ahead it is in this space,” concluded Mr Walmsley. “It’s apt that we are celebrating our 50th anniversary with such breakthroughs and look forward to a greener 50 years of new materials, tech and innovation.” n
